Man…I am flying through this second rudder. The first one seemed to take much longer. I’m starting to get the hang of the rhythm though. Drill, de-burr, dimple, prime, rivet. Today, I clecoed on the skins and final drilled the remaining holes with the exception of the AEX wedge and trailing edge. On the last rudder I think part of the problem with my rivets in the trailing edge were because the holes had become ever so slightly enlarge do to the number of times I ran a drill through each hole. The instructions tell you to cleco it all together and then final drill…then later on you have to use the holes in the trailing edge as a guide to create the aluminum angle so you end up running a drill through the same holes twice. This time I will just use the AEX wedge as a guide for drilling the aluminum angle. (I screwed up the aluminum angle before because I was going to try a trick where you use a squeezer to set the rivets in the trailing edge…which I ended up not doing anyway. The trick involves enlarging the every other hole on the aluminum angle to get the squeezer to fit. So I needed to redo the aluminum angle for sealing the trailing edge). This time I am also using a chuck reamer to final drill the holes. This leaves less of a burr and nicer holes.

