reskinning a rudder

6896 · Post by **6896** » Tue Dec 18, 2018 12:07 pm

More aileron photos

6896 · Post by **6896** » Tue Dec 18, 2018 1:18 pm

Aileron skin rolling from one end of spar to other

6896 · Post by **6896** » Tue Dec 18, 2018 2:07 pm

Also, if you need to replace your rudder hinge block as I did, attached is some information about where to get the block and bushing.

6896 · Post by **6896** » Tue Dec 18, 2018 3:02 pm

Also, I had to redo my rudder NAV light wiring. I chose to upgrade the A2064 Grimes receptacle as Cessna had done in later models by adding a ground tang captured under the knurled nut rather than rely on getting the ground through the shell of Grime receptacle, then through the rudder skin, then rudder hinges back to the fuselage. I am running a separate ground wire through the rudder and back into the fuselage for attachment to a rear bulkhead. I will use two Molex type pin disconnects between the rudder and fuselage wrapped in shrink tube so I don't have to cut the wires. Photos that I have seen show the rudder NAV light wire running out the grommet in the rudder spar then around the fuselage gap between the vertical fin and rudder, then back into another grommet hole in the left fuselage skin just beneath the horizontal stabilizer. Because I am enclosing my NAV light wires in abrasion resistant braid, I enlarged the grommet hole in the rudder spar using a counterbore with a pilot and aluminum backup block clamped to the rudder spar. This worked out well. Forum is not allowing photo uploads at this time, but when it does, I will add to this post.

6896 · Post by **6896** » Tue Dec 18, 2018 3:03 pm

Photos

6896 · Post by **6896** » Tue Dec 18, 2018 3:06 pm

Rudder NaV light with ground tang and AMP spade PIDG connector

6896 · Post by **6896** » Tue Dec 18, 2018 3:09 pm

Rudder NAV light with positive and negative ground wires in braid with silicone wrapping tape to protect against moisture.

6896 · Post by **6896** » Tue Dec 18, 2018 3:54 pm

Rudder NAV light with Tygon transflex tube, silicone wrap, and abrasion resistant sheathing under shrink tube. Shrink tube squeezes abrasion resistant
sheathing over transflex Tygon tube. You can see the pattern of the sheathing under the shrink tube.

6896 · Post by **6896** » Tue Dec 18, 2018 3:57 pm

Also, I opened up the grommet hole for the rudder NAV tail light using a counterbore and pilot. In my rudder, there is an angle reinforcement behind the grommet hole so I put an aluminum stop block with the pilot hole diameter in it between the angle reinforcement and spar. The counterbore cut a nice hole through the thin skin spar. Counterbore and pilot obtained from Brown Aircraft Tools.