Modify rudder control horn?

[Eric Page]

Well, that didn't go well. Ten minutes into the effort, my rudder fell over and shattered the Hysol/SuperFil cap. So, I get to re-live that couple of days' worth of work.

Rudder Cap Damage.jpg

Here's what I came up with for extending the rudder horn -- just a cardboard template at this point. It's 6-1/2" x 1-1/2" with a ~5/8" radius notch to clear the vertical tube and its weld bead. The holes for bolting it to the existing horn can be match drilled from underneath, and the new holes are marked 1-3/16" from the fabric surface, as @airlina measured on a factory Series 7 at OSH.

Rudder Horn Template 1.jpg Rudder Horn Template 2.jpg

The existing horn measures 0.115" thick including powder coat, so I presume it's made from 0.100" material. Spruce sells 0.100" x 1-1/2" x 36" strips of 4130 for $6.50.

[airlina]

Well, that didn't go well. Ten minutes into the effort, my rudder fell over and shattered the Hysol/SuperFil cap. So, I get to re-live that couple of days' worth of work.

Rudder Cap Damage.jpg

Here's what I came up with for extending the rudder horn -- just a cardboard template at this point. It's 6-1/2" x 1-1/2" with a ~5/8" radius notch to clear the vertical tube and its weld bead. The holes for bolting it to the existing horn can be match drilled from underneath, and the new holes are marked 1-3/16" from the fabric surface, as @airlina measured on a factory Series 7 at OSH.

Rudder Horn Template 1.jpg Rudder Horn Template 2.jpg

The existing horn measures 0.115" thick including powder coat, so I presume it's made from 0.100" material. Spruce sells 0.100" x 1-1/2" x 36" strips of 4130 for $6.50.

Eric , the mockup looks great, should work well to get your cables clear of the rudder leading edge and rudder authority will be dampened some. sorry bout the rudder crash and burn, better notify the NTSB. Bruce N199CL

[Jerrytex]

Curious to know what the one's that didn't modify the the shorter horns are doing to protect the lead edge fabric? I didn't know about this mod and I am not going to tear off into the rudder and have to do more fabric work. Is there some material to make a guard or something?

[alexM]

Curious to know what the one's that didn't modify the the shorter horns are doing to protect the lead edge fabric? I didn't know about this mod and I am not going to tear off into the rudder and have to do more fabric work. Is there some material to make a guard or something?

In post #3 Arlina shows where he used some stainless steel strips.

I'm on the fence about this one. I have fully rigged my rudder but nothing is covered, so I could do something without major surgery if needed. I'm surprised I didn't notice the riding condition when I rigged it (I do have the "speedster" tail). The down side is that I actually prefer a sensitive rudder on a tail dragger, and lengthening those horns means the rudder pedals will need a more dramatic poke to keep the tail of the plane behind the front - always the favored orientation.

[airlina]

In post #3 Arlina shows where he used some stainless steel strips.

I'm on the fence about this one. I have fully rigged my rudder but nothing is covered, so I could do something without major surgery if needed. I'm surprised I didn't notice the riding condition when I rigged it (I do have the "speedster" tail). The down side is that I actually prefer a sensitive rudder on a tail dragger, and lengthening those horns means the rudder pedals will need a more dramatic poke to keep the tail of the plane behind the front - always the favored orientation.

Alex, No such thing as a dramatic poke required with the Series 5 stock rudder horns or lengthened in my humble opinion , I've got a tad over a 1000 hrs in mine now and I still think the rudder control is overly sensitive and could be toned down to a more subtle feel. On hard surfaces the weight of my toe is all thats required for a directional change and by lengthening the horn I feel like goldilock that the rudder feel might be just right. I you get a chance to fly a 5 with the stock setup it might help you decide. (whatever you do don't wear boots, even in the winter I wear light shoes and throw a pair of boots in the back) Bruce N199CL

[Dave S]

Curious to know what the one's that didn't modify the the shorter horns are doing to protect the lead edge fabric? I didn't know about this mod and I am not going to tear off into the rudder and have to do more fabric work. Is there some material to make a guard or something?

Jerry,

I fabricated a poly plastic wear shield in the same place on the rudder where the other person used SS. The material was cut from a plastic container of iced tea which had the same curvature as the rudder area requiring protection from the link. Sorry I don't have a photo but the shields have been there since 2008 when the plane was built and still fine. I used a couple very small SS screws to hold it in place. Some might think the choice of materials was somewhat mickey mouse, however, it had all the right characteristics.

[Jerrytex]

Oh I do see the stainless now. Thanks.

I'd probably do the extension if my fabric wasn't on already. However, the thought of doing more fabric work right now is enough to make me start drinking bottles of tea to get the material I need to make Dave's modification work!

Thanks.

[Kitfox Pilot]

Well, that didn't go well. Ten minutes into the effort, my rudder fell over and shattered the Hysol/SuperFil cap. So, I get to re-live that couple of days' worth of work.

Rudder Cap Damage.jpg

Well Eric the bright side is, I always say I could do that better and faster the next time....
Your on the next time. Haha
Just have to laugh at deals like that even though its not funny at the time. I've been there. Harlan

[Eric Page]

Just have to laugh at deals like that even though its not funny at the time. I've been there. Harlan

Yeah, I may have uttered some things that my dear mother would not be proud of!