Elevator twist... ??
I saw a similar problem in an orphaned -7A that I acquired. Suspect that the factory bend in the elevator skin was just slightly off. Or maybe Builder One biased the fold in the process of closing the skin. With the elevators attached to the HS and aligned flush at the counterweights, the inboard trailing edge of one elevator was about 20 mm lower than the other. This was visually quite noticeable in the shop. I suspect that it would have flown okay. After much consultation, laserplaning, and noodling, we drilled out all the perimeter (spar) rivets on the bottom side of one of the elevators including the spar and leading edge roll wrap, slid the skin on that side just a skooch to the right wrt/ the elevator spar, clamped it at the spar, and checked with the laser plane again and again. Eventually drilled all the open -3 holes up to -4, countersunk, and riveted with -4 rivets. Came out surpisingly true. Wasn't as much work as it sounds like. Added a few new rivet holes in strategic locations, some of the rivets were pulled rivets out of conveninece. Caught it before the tips were attached.
So, when you see a -7A with #4 rivets on the bottom surface of one elevator, that's me. But look how good the trailing edges line up! Extra work? Yes. I'd do it again.
- Roger Kellogg