Stephan's Sonex #1627 Builder's Log

I decided to finish up the elevators this weekend. I updrilled all of the holes to final size and also cleaned up the overlap on the elevator root assembly. I had cut the elevator skins according to the size and angles required, but the control horn assembly that was provided by Sonex caused the skins to overlap by almost 5-7mm, with the overlap being more pronounced near the tips. I filed down the excess so that the elevator skins were flush with the edge of the root assembly ribs. 

All that remains now is to debur, polish and prime the ribs and to rivet the bottom portion of the elevator. The top portion will have to remain cleco-ed until the MD-RA inspection is complete.

I worked on polishing of the rear spar for the horizontal stabilizer and deburring of the spar channels. The rear spar had a lot of relatively deep cuts and stratches, presumably made while the spar was being fabricated. I used red Scotchbrite pads to smooth the surface and then used grey Scotchbrite pads to further polish it. I then cleaned with Paint Thinner and then sprayed with self-etching primer. I cleco-ed everything back together and riveted the whole rear spar assembly.

I worked on up-drilling the entire horizontal stabilizer and elevator assembly. 

I worked on installing the left hinge on the horizontal stabilizer today. I again used the elevator as a guide and added the end-stop to ensure everything is flush with the edge of the stabilizer.

I did not have a piece of hinge left that spanned the entire required length so I made it out of two pieces instead. I had previously confirmed with Kerry at Sonex that this was acceptable, and he indicated that as long as the hinge pin spanned the entire length, it wasn't a problem.

I positioned the elevator with the hinge pieces in place and drilled and cleco-ed everything together.