After a brief interruption for a wedding (Ellen’s and mine!), it was back to the rudder. This weekend’s tasks were to countersink the trailing edge wedge, prepare a piece of angle stock to hold the trailing edge straight, and finally, debur and dimple the skins.

Countersinking the rudder wedge

The first step in countersinking the TE wedge was drilling the holes to final size. I borrowed a technique for this from my friend Jim Piavis, match-drilling and clecoing the wedge to a flat surface – in this case, the hollow-core door I use as a work surface. Match-drilling into the door leaves a nice, accurate hole for the coutersink pilot. That, in turn, helps keep the countersink from chattering and chewing up the hole.

Dave’s pudgy hand. Note the wedding ring!

Here’s the end result. The process worked, and the wedge looks good. Another test-fit of the skins and wedge was encouraging. Next step – match drilling one rudder skin to a piece of aluminum angle per Vans’ instructions. I fastened the angle to one edge of the work surface for some added stability. Once assembled and prosealed, the trailing edge will be held straight when clecoed to the angle.

Drilling the wedge

The end result will look something like this…except with both rudder skins clecoed to the angle.

The wedge of doom