Tail Surfaces Layout and Jigging for Welding

[fairchild1934]

Thanks Gerald--- thats what I had a sheet of and used-----
Here it is --- about ready to tack-----

IMG_20251003_032428.jpg

[geraldmorrissey]

Building flight hardware out of raw stock sure is fun. Nice job.

[fairchild1934]

Im a bit out of practice on this thin sheet----- hope I dont get shaky !

[BTAZ]

here is what I did to try to get the holes for the trim shaft in near as perfect alignment as possible. I cant think of how to do it any better. I can measure front-to-back between the TE and the shaft and make that constant--- and between the table and the shaft for the up-down. Anyone have any better tips for locating the holes in the ribs ?
here is a pic----- Tim

IMG_20250923_004422.jpg

I'm probably late but when I did mine on my LSA I just used a full length tube passed it through and welded it to the ribs. Then I just cut out the section in between the ribs. I faintly remember(going on 10 years now) I mounted both the horizontal stabilizers to the fuselage and ran the "bearing tube" all the way from one side to the other so I knew the trim torque tube would be in alignment all the way from left to right.

[fairchild1934]

would all most like some kind of flex joint between them inside the tail........ anyone done that ? maybe something with a r disk made out of rubber belting in the center ?
but I dont know if there will be room for something like that......

[geraldmorrissey]

When it comes to control surfaces, I build per print.

[SpruceForest]

would all most like some kind of flex joint between them inside the tail........ anyone done that ? maybe something with a r disk made out of rubber belting in the center ?
but I dont know if there will be room for something like that......

What is the statement of the problem you are trying to solve, and can it be addressed within the confines of the existing, proven design (e.g., by adjusting your construction techniques versus a design change... such as getting the tail feathers on the airplane and rigged to final locations before tack and weld of horns)?

In any engineering task, an accurate, complete problem statement comes first. Two surprisingly common outcomes: the perceived problem evaporates once we attempt to accurately define it (i.e., we thought there was a design issue, but upon further examination now understand intent, method, our own mental error, etc.), or we solve the wrong darned problem. DAMHIKT.

Even experienced engineering teams get this stuff wrong, which is why good engineering practice is to do exactly what you are doing with your question.