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  #1  
Old 04-22-2018, 04:16 AM
StressedOut StressedOut is offline
 
Join Date: Jun 2017
Location: Fullerton, CA
Posts: 113
Default Disaster! Iím seriously depressed.

All that was left on my rudder was the riveting of the trailing edge and rolling the leading edge. I used Proseal on the wedge instead of tape, so after it cured I was clearing the holes of excess Proseal and discovered that almost all of the TE holes were double drilled (binocular).

Thinking back I know exactly where this happened. I used a rectangular steel tube to cleco the TE against. I match drilled holes using the TE as a guide. It served its purpose well. I had a perfectly straight TE. I just didnít use enough care in the match drilling the tube.

The holes look to be about 15 to 20 percent oblong. I think Iím going to buy new parts and rebuild the rudder. Iím not comfortable with such a defect. The cost is about $320 plus shipping. This is a hard lesson to learn. Itís not the cost that bothers me as much as the 40 or so hours I have to spend rebuilding the rudder.
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Art Jackson
RV-14A Kit#140433
Completed: Vertical Stab/Horizontal Stab
Scrapped: Rudder
Working on: Empennage (Elevator)
Construction log - mykitlog.com/ajackson
Dues paid on 10 October 2018
Member of EAA Chapter 92 (KCNO)
Pet peeve: "Lose" is the opposite of "find". "Loose" means "not tight".
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  #2  
Old 04-22-2018, 04:24 AM
YellowJacket RV9 YellowJacket RV9 is offline
 
Join Date: Oct 2012
Location: Clearwater, FL / KZPH
Posts: 1,138
Default

I rebuilt what in hindsight would have been a totally airworthy horizontal stabilizer, due to some newbie cosmetic mistakes. I know it stings, but in the long run the extra time and effort will be a rounding error compared to your total build.

One suggestion to feel better is to hold off on building a new one until later. Just move to the next project until you feel better or actually need to mount the rudder.

Chris
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RV-9A - Done(ish) 4/5/16! Flying 4/7/16
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  #3  
Old 04-22-2018, 05:46 AM
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DanH DanH is offline
 
Join Date: Oct 2005
Location: 08A
Posts: 7,848
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Quote:
Originally Posted by StressedOut View Post
I think I’m going to buy new parts and rebuild the rudder. I’m not comfortable with such a defect. The cost is about $320 plus shipping. This is a hard lesson to learn. It’s not the cost that bothers me as much as the 40 or so hours I have to spend rebuilding the rudder.
It's not a disaster. It is education and recreation. Shrug it off. And bravo to you for not accepting defects. The best time to adopt that habit is right where you are now, building the tail.

News flash....the best builders throw away a lot of parts.
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RV-8 SS
Barrett IO-390
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  #4  
Old 04-22-2018, 06:00 AM
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M McGraw M McGraw is offline
 
Join Date: Dec 2012
Location: Greenback, TN
Posts: 403
Default Bad part

Your experience is normal! I spent about a month making custom wheel pants, they were beautiful, but I missed centering the hole for the tire and it just looked bad, bad, bad.

I kept them under my work bench for a year as a reminder that sometimes you just start over and end up with a better plane.

I find Makers Mark is an appropriate builders tool. 😊
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RV-14. #140039 Complete
Flight hours: 200+
2018 Dues Paid
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  #5  
Old 04-22-2018, 07:13 AM
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bkervaski bkervaski is offline
 
Join Date: Mar 2017
Location: Birmingham, Alabama
Posts: 771
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Many of us experienced the rudder twice! I feel your pain ... I was down to the last few rivets and made an aweful cosmetic mistake ... the second one will go a lot faster and will be better quality ... the first one was just practice
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  #6  
Old 04-22-2018, 07:18 AM
BillL BillL is offline
 
Join Date: Sep 2007
Location: Central IL
Posts: 4,447
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Quote:
Originally Posted by bkervaski View Post
Many of us experienced the rudder twice! I feel your pain ... I was down to the last few rivets and made an aweful cosmetic mistake ... the second one will go a lot faster and will be better quality ... the first one was just practice
Yep - Like Dan sez - - educational.

Besides, it would have cost you 3 kts too.
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RV-7
1st Flight 1-27-18
Phase II 8-3-18
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  #7  
Old 04-22-2018, 07:46 AM
mturnerb mturnerb is offline
 
Join Date: Apr 2015
Location: Ponte Vedra, FL
Posts: 722
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I built 3 elevators - 2 left and one right. Did re-use the trim tab!
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https://turnerb14a.blogspot.com/
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  #8  
Old 04-22-2018, 07:47 AM
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bkervaski bkervaski is offline
 
Join Date: Mar 2017
Location: Birmingham, Alabama
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Quote:
Did re-use the trim tab!
I built 5 trim tabs. Vans thought I was a crazy person, my girlfriend and co-builder (now fiance, somehow) thought the same.

The re-do's seemed to calm down towards the end of the empennage.
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Last edited by bkervaski : 04-22-2018 at 07:49 AM.
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  #9  
Old 04-22-2018, 07:57 AM
painless painless is offline
 
Join Date: Jan 2005
Location: Peshtigo, Wisconsin
Posts: 725
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You now have some wall art for your man cave.

Press on.
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RV6A N782P
Peshtigo, WI
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  #10  
Old 04-22-2018, 07:58 AM
Tom023 Tom023 is offline
 
Join Date: Jul 2011
Location: Cypress, TX
Posts: 243
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Quote:
Originally Posted by YellowJacket RV9 View Post
I rebuilt what in hindsight would have been a totally airworthy horizontal stabilizer, due to some newbie cosmetic mistakes. I know it stings, but in the long run the extra time and effort will be a rounding error compared to your total build
Chris
+1. And I thought I was the only one. I built my second one almost two years later because the mistake was visible and bugged me the entire time. Adding insult to injury, the replacement spar was misdrilled so I needed a third at $125 shipping alone! Now itís perfect and I get satisfaction every time I look at it. Just part of the building process.
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Wings, empennage, fuselage and finish slow builds completed. Avionics and engine installed.
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