These rudders aren’t really rudders in the traditional sense. They’re actually vertically oriented ailerons that can only be deflected in one direction. End result is that to get them back in the neutral position, a spring is used. The spring is embedded in the winglet. A one inch diameter hole is drilled into the back of the winglet five inches deep. To keep the hole from damaging the navigation antenna, it’s important to keep the drill laterally aligned. It’s also important to keep the drill aligned vertically so that it’s perpendicular to the leading edge of the rudder.

So a line is placed on the side of the winglet.

Closeup

Then a hole saw drill is chucked into the drill. Malcolm will make sure the drill is aligned laterally. I will watch from the side tell Malcolm whether he’s high or low. Once the hole is drilled, the spring sleeve is sanded, the hole is coated with an epoxy/cabo mix and the sleeve is inserted.

Here’s Malcolm drilling into the winglet. While he’s drilling, I’m saying “up” and “down” so he can keep the drill on line.

This is the rudder return spring epoxied in position.

Once this was done, the bottom of the rudder and aileron ends need to be covered with a layer of lightweight fiberglass.

This is the inside surface of the right aileron with a layer of fiberglass and peel-ply.