Step 2.   Make 6 trim tab ribs.  And while you're at it, cut the ribs for the elevators too. 

02/03/07  -  30 minutes

Step 3.   Mark where the trim tab foam ribs go, then remove the plastic as you did for the elevators, leaving bare aluminum to mark the foam rib locations.  Then scuff the aluminum with the same sandpaper, 150 grit.  Clean thoroughly after scuffing.  At this time, peel off the rest of the plastic.  I left mine on and it proved difficult to get out once you've bent the tabs.  Also, at this time, after you've cleaned the scuffed area, cover with the masking tape.  Again, it's easier to do it now.  (Can you see the mistake in the picture?  It has since been corrected.)    

02/10/07  -  1 hour

Step 4.   Bruce lent me his break, which is real simple to make.  Just two 2x8's, one shorter than the other, hinged.  See chapter 5 for instructions and a picture.  Set the skins in the break and GENTLY and A LITTLE AT A TIME apply pressure to bend to final shape.  You know its final when a steel rule sits flat all the way across the width.  The bend should be flat against the rule.  If it bends away from the rule, you need to bend it further.  Sneak up on the final bend so you don't over bend.  

Once bent, cleco the E-920 spar back into place and, using a trim tab block, check for both the correct amount of bend and for any waviness (ballooning, puckering according to the plans) in the skin.  Bruce had trouble with the latter and had to do his skins over.  He explained all the above to me, so I was lucky and mine came out okay.   

02/10/07  -  1 hour

Step 5.   Time to close up the ends.  Bend the two tabs on each end of each skin, similar to what you did for the tabs on the elevator skins.  Take your time and they'll bend just fine.  Make sure that the wedges are clamped tight and that you have the inside one held with carpet tape.  This, you'll discover, is necessary.  Begin bending with your fingers, then move to using a block of wood, then finish them off with a rivet gun set low.  Make sure that the one without the holes is bent first. 

02/11/07  -  2 hours