Vertical Stabilizer

Construction of the Vertical Stabilizer (VS) is similar to that for the Horizontal, except it is easier, and perhaps should be done first.

1. Reading the Plans, building the skeleton

Did I tell you how important it is to read and re-read the plans? The VS plans below show the skeleton with one half of the skin applied. In the large image you will see details like rivet call-outs (e.g. AN470AD4-4 all VS-708 to VS 702 rivets). This simply means Universal "round head" rivets (AN470) of width (4) 4/32" and length (-4) of 4/16". Fortunately Van labels these supplied components well. Basically if you are riveting a number of sheet components together you need a longer rivet, and you must end up with the correct protruding lengthm (1.5 x diameter) to give a good manufactured head dimension. The correct call-outs guarantee this. All the skeleton components must have their rough edges smoothed with the Scotchbrite wheel. Then they are clecoed together and match-drilled to final size. The skins are added and remaining holes are also match-drilled. Then all is disassembled, and every hole is deburred and dimpled if required. Some holes are not dimpled and some are, so it pays to be careful and double check here. Flush rivets are used on the forward surface of the rear spar to give a flat surface where it will abut against the furelage. The rear spar reinforcing plate and rudder bearing attach flanges are also added, drilled and deburred.

2. Finishing rear spar, priming and riveting

The rear spar reinforcing plate needs two large holes (2" diameter), and five smaller holes (1 1/4" diameter) made to reduce weight - see the drawing for details and dimensions. I used holesaws for this, using slow drill speed, very light pressure and heaps of kerosine to lubricate. It was messy as the hole-saws tend to bind. It would have been better with a good fly-cutter. As with the HS, everything was then treated with primer/sealer, including a light coat to the inside skin surfaces. The rear spar is reveted together, flush rivets being used where it will mate with the fuselage. The skins are then riveted to the front skeleton (without rear spar at first). Once your technical counsellor has checked your work, you can button-up this assembly and move on. My last image shows the rear spar fastened with clecoes, ready to be checked and finished.

Vertical Stabiliser complete May 24th, 2004