Help With Tail Surface Gussets

[tonyp51qa]

Hello,
I'm in need of help. I need suggestions on how to install the gussets on the tail surfaces. Do I put them on flat, then drill, debur and rivet? When done on all the gussets flip over, bend the aluminum gussets around and repeat the install? Or do I wrap the gussets around, hold them down, then drill, debur and rivet? Suggestions are welcomed. Thank You!!
Tony

[Kamcoman77]

After cutting gussets to shape, bend them over a tube one size smaller than the tube they will be riveted to. Because of springback, the gussets won't fit tightly unless you do this before drilling & riveting. I put the gussets in place & marked the holes on one side then drilled a couple of holes in each gusset & tube, added clecos & then pulled the gusset tight and drilled the other side & clecoed. Once a couple of clecos are in place on both sides it is easy to drill all the holes through the gussets & tubes. Cleco as you go so nothing pulls out of place. Remove all the clecos & de-burr the tubing & gussets. Do not forget to place the hinges on the appropriate tubes before the next step. Re-install the gussets with a few clecos. Now you are ready to rivet.

[tonyp51qa]

Thank You. I did not know to wrap/bend the gussets around a smaller tube. I'll give it a try first thing in the morning!!!
Tony

[DA Miller]

Tony, if you haven't made your ribs yet you might consider making them wider than 1/4".  That 1/4" flange is hard to work with using 1/8" rivets.  5/16" or even 3/8" might be better. Check out Chuck from Indiana's build.  He and many others added a rib to the vert stab to prevent distortion when shrinking the fabric.  Do a search on tailfeathers;  there's a lot of hints therein.

[tonyp51qa]

Thanks! Are you talking about the ribs on the elevator? I'm using tubing on all control surfaces. Not using the 0.020 formed ribs.
Tony

[Kamcoman77]

T.C. Please show us some photos when you get one of your pieces riveted. You are the first builder I've heard of that used tubing for all the empennage ribs. Others may really like the idea. I used 5/8" x 0.035 6061 tubing for my bottom V.stab rib.

[DA Miller]

Yes and I too would like to see some pics ala Kam's request.