Rudder Spar Test Fit

After the rudder’s left and right spar caps are matched drilled to the rudder spar and the hinge bracket is Clecoed onto the assembly. The rudder horn is also matched drilled to the rudder spar and Clecoed in place. Next the spar assembly is test fit to the vertical stabilizer. This step is to determine the overall fit and also as a means of denoting the type of washers needed to achieve proper spacing. There are regular washers and also washers that are half as thick that can be used … the test fitting is a means to note the order and size of the washers required.

The rudder’s lower attachment bracket at the rudder horn.

The rudder’s upper attachment bracket.

Easy way to hold washers being inserted into tight places. Tape on the edge of the washer or use a tool made out of banding material similar to the one shown.

Builder note:
The washers on either side of the bearings on the vertical stabilizer can be tricky to get in place without dropping them. An easy way to place washers into tight places is to fold a piece of tape along the washer’s sides to prevent the washer from dropping while aligning it so a bolt can pass through the washer. If you want to go high tech, a simple but effective tool can be made out of crate banding material. Cut out a notch to accommodate the size of washer being held. Both ways work well but the tool made out of the banding material will hold the washer tighter if you get the notch made correctly.