Horizontal Stab, Elevator Fairings, Tail Cone, Elevator Trim

The Sportsman has been in the hangar for a couple months... progress has been slooooow.  But finally starting to pick up some speed.

There is so much to do... almost an overwhelming amount.  So I finally decided to focus on the tail.

Elevator fairings:

Initially I fitted the elevator fairings.  Followed the manual, got everything trimmed and drilled.  And THEN I mounted the elevator and tried to align the horizontal stab portion of the fairing.  Well.... they HS portion is not long enough... or more accurately the elevator portion is too wide!

The problem... I already drilled the holes.  However, I only drilled them with #40 bits (not #19 as specified in the manual).  I had to cut 0.75" off each side in order to get them to align, and then carefully mark and redrill the holes.  

Then I figured I would just do EVERYTHING on the tail.  So onto the tailcone.

I had to cut a slot in the bottom for the tailwheel cable lock (not a steerable tailwheel - but a fully castering, lockable, not steerable tailwheel).  The slot has weakened the tailcone... so planning on 2 additional fasteners at the bottom in addition to the standard 4.  I still need to make the slot slightly longer, and put a grommet on the cable.

While I had everything apart, I put in the elevator pushrod and temporarily connected it.  Man, the elevator is HEAVY without any counterweights.

Then reassembly to start on the rudder base fairing.

That sucker is going to need a lot of trimming.

PROBLEM... my lower rudder hinge is not in the right spot for my rudder.  The lower rudder hinge and vertical stab spar was installed by another builder.  I will need to offset my hinge 0.2" to port.  Will have to get a new bracket machined...  Need to disassemble to do so.

Time for a lot of fasteners!