Stephen Larew

personal website — updated sporadically

Rudder Skeleton

Work entries: E41, E44-E57 Performer: Stephen Larew Location: San Diego apartment garage Methods: Construction Manual, Construction Standards, and Photo Assembly Guides

Rudder skeleton parts laying out on the work surface.
Rudder skeleton parts were first laid out to get a sense of how they fit together.
Cut angles at ends of the rudder spar doublers.
Bottom corners of the 65-T-4-5 rudder spar doublers were trimmed to form a 33˚ angle.
A cleco holds the 65-T-4-4 vertical tail spar and 65-T-4-5 rudder spar doublers together.
Holes were drilled and my first cleco set in the 65-T-4-4 vertical tail spar and 65-T-4-5 rudder spar doublers.
Both rudder spar doublers are drilled and fastened to the vertical rudder spar with clecos.
Moving along the spar, more holes were drilled along the vertical rudder spar and doublers.
A burr emerges from a freshly drilled hole in the vertical rudder spar.
My first burr emergin in a spiral form from a hole I drilled. I cleaned up the burr and refined my drilling technique.
Ribs affixed to the rudder spar.
Next I moved on to drilling the rudder ribs and fastened them onto the spar.
Cortec application on the doublers and spar.
Once all parts were finished with fabrication, I strategically applied cortec (for corrosion control) where metal will meet metal.
Leading and trailing edge skins fastened to the skeleton with clecos.
Now it is starting to look like a rudder. Both leading and trailing skins are fitted to the skeleton with clecos.