Step 1.   Make the hinges.  Begin by cutting two 35" lengths.  I used the Dremel.  

03/31/07  -  30 minutes

Step 2.   Measure and drill the first holes in the hinge.  Use the spring loaded punch to make the initial hole, then take a tiny drill bit to make a pilot hole that you then use with a #40 mounted in your drill press.  If you don't make the pilot hole, the #40 can wander.  

04/14/07  -  30 minutes

Step 3.   Cleco the hole just made to the elevator and adjust the hinge until it all lines up with the edge of the spar and skin.  It lines up quickly and easily.  Use the large C-clecos to hold the hinge in place.   Then, using a sharp #40 drill bit, match drill a hole at the other end and in the middle.  This sets the hinge, but before doing so, make sure you have the flex in the hinge worked out. 

04/14/07  -  1 hour

Step 4.   Attach the trim tabs to the hinge in the same manner as you did the eleators above.  I took the hinge off the elevator for the first one.  Worked okay.  It shows to leave the hinge on the elevator.  No trouble with the second one, either, so it's okay to do so.  (How's that for logic!)

04/14/07  -  1 hour

Steps 5 & 6.   Mark the inboard edge of the hinge for final cutting to size. 

Take the hinge off and remove the pin.  Using the band saw, cut the hinge 1 mm outside the mark so you can use the scotch brite wheel to smooth out the cut to the cut line.  Don't cut the hinge pin at this point.   

04/14/07  -  30 minutes

Step 7 & 8.   Clean and prime the hinges.  Then rivet them to the elevator and trim tab.  The pneumatic squeezer works very well for this chore. 

Put everything back together and spend the next ten minutes moving the trim tab up and down.  Note the euphoria when you notice that this is the first moving part on the plane! 

04/15/07  -  2 hours