Master cylinders

Adjusted cylinders for pedal alignment. Installed rudder pedals and checked for full travel. Masters are clear of pedals.

Measured brake line lengths, hopefully get some ordered tomorrow.

Tips: 4.6 hours

Primed elevator tips, vertical stabilizer tip, and rudder tip.

Tail: 4.3 hours

Primed horizontal and vertical stabilizer tips. Final sanded elevator and rudder tips.

Fabricated elevator trim tab hinge pin. Drilled trim spar for hinge pin retainer.

Fiberglass/headset holders: 4.9 hours

Sanded fiberglass tips and masked for primer.

Installed headset holders. Moved pen holder to left side.

Fiberglass: 2.3 hours

Applied three epoxy skim coats to all tail surface tips.

Riveted remaining upper horizontal stabilizer inboard flange holes. Installed fairing nutplates on bottom flanges.

Vertical stabilizer: 3.3 hours

Riveted remaining holes in bottom of vertical stabilizer flange. Installed platenuts on flange for empennage fairing attchment.

Sanded vertical stab and rudder fiberglass tips.

Rudder tip and stops: 5.4 hours

The rudder tip was rubbing the vertical stab tip so I spent the am sanding for clearance. The gap needs to be increased. I will do that after final install.

Trimmed rudder stops to 31° of travel. Trimmed empennage fairing to clear rudder horns.

Began running tail LED wirng.

Various: 2.8 hours

Applied proseal to elevator and rudder tips. Sanded skim coat and added micro to the aft seat top low spots.

Wiring: 3.9 hours

Torqued rudder rod bearing jam nuts and rerouted various wires. Cut transponder coax to length, installed BNC connector, and installed transponder antenna to fuselage.

Vertical stabilizer alignment 15.6 hours

I decided to revisit my alignment. After I thought I had achieved good alignment when I went to install the rudder I had to back out the middle and top rod bearings to the point where I did not have enough thread engagement. I followed the directions exactly. The issue is that the hinges when aligned with a straight edge are off because the hinge lenght must not be exact. So now I have to redo my attach plate as I drilled my holes about an 1/8 inch off, not a task I am looking forward to. I will have to fabricate an new attach plate from sheet for it to work.
Three days work 1/25/17-1/27/17. Fabricated and installed new attach plate. It took me three attempts but the third plate worked. I ended up drilling the holes about 1/8″closer to the attach bolts, that’s all the room I had. The only other option would have been to replace the forward spar.

Bending angle to attach plate.

The shorter one on the right is the new plate.

Not much room between the rivet heads and the spar bars.

Just enough room for the nuts to clear the web edge.

Good rudder horn parallel gap and rod bearings now within 1.5 turns from spec.