Drilling Rudder Panel For Hinge Assembly

Using a jig to drill hinge holes

Jig ensures perfectly aligned holes for the hinge

Hinges temporarily installed

Covering sharp edges & protrusions with anti-chaf tape

Rudder panel gussets and rivet heads all taped over

Applying Poly Tak adhesive to the rudder panel

Covering and trimming the rudder panel with Poly-Fiber fabric

Cementing the fabric covering to the rudder frame

Calibrating iron to tauten fabric by heat shrinking.

Ironing fabric on leading edge of rudder panel to tauten and remove wrinkles.

Trimming excess fabric off leading edge.

Trimming excess fabric off remaining open edge of rudder panel cover.

Trimming to achieve a minimum of 1.5 inch overlap of fabric on the rudder panel leading edge.

Preparing to glue remaining fabric lip to rudder panel leading edge by applying Poly Tak adhesive.

Gluing remaining fabric lip to rudder panel leading edge.

Applying topcoat of adhesive to fabric overlap covering the rudder panel leading edge.

Ironing fabric on rudder panel leading edge to remove wrinkles.

Ironing rudder panel cover to tauten fabric. First pass was at 250 degrees (F).

Ironing rudder panel cover to tauten fabric. Second pass was at 300 degrees (F). Third pass was at 350 degrees (F).

Applying Poly Tak adhesive to entire perimeter of rudder panel after completing the tautening process.

Allowing adhesive on rudder panel perimeter to dry.

Jayne holding the finished rudder panel - ready for painting.

All tail panels now covered