2-1/2 hours .Took a break last night as I was very tired from staying up too late on Sunday night (playing hockey). So tonight I wanted to make sure I spent at least some time in the shop. De-bured the remake rudder horn rib (T13-04 and 05) and bent them to shape. Since this was the second time I made these two parts I paid closer attention to a couple of things. 1) I made sure I had spacer pieces of scrap aluminum at the back end and the sides of the brake to insure the top nose piece was flat when clamped. (I noticed this the last time I bent them that the really small pieces were not held well in the brake so I have been using these small shim pieces on most bends since then). 2) I made sure that I bent the parts in a cirular manner around the perimeter. What I mean by this is that starting on either long side as the first bend, I bent the next side as the shortest sid and finally bent the last side. With each side that was already bent, I made sure it hung off the end of the brake so it did not collide with the nose. The first time I made these parts I bent the middle side last and ended up kind of messing up the first side that was previously bent and had to straighten it out with a hand brake.
The results of this second effort to make these parts was very impressive. Even though the first time I made the parts I thought they turned out really well (I remade them becasue one of the parts was laid out and cut slightly in error and one of the tabs was a bit short and they are such small parts it was easy to remake them). These parts lined up nearly perfectly with the rudder horn.
As can be seen in the photo, we (Tim) drew the part with the bend lines in CAD and plotted it and then we glued it to the sheet aluminum with 3M 77 glue. The part was then cut out and bent following the site lines that were laid out.
Anyway, the rest of the night was spent deburing and bending a couple of the elevator ribs that get mounted to the elevator horn and finally bending two of the six straight ribs for the horizontal stabilizer (T04-01).
