February 22 and 23rd, 2001
Well, I suppose you could say the adventure started here. My girlfriend Melissa and I went to the factory in Mexico, Missouri to take part in the rudder building session they have there. I figured if I was going to build this plane, I should probably have some idea of what's entailed and whether I'd really enjoy this type of work or not. My original intention was to fly one of my flying club's planes down for the two day session, but weather was looking rather bleak, so I decided against it. Good thing too. About an hour before we got into Missouri, we drove into a blizzard. A trip that was to take only about 5 1/2 hours ended up 8 hours. If I'd decided to fly in, it wouldn't have happened.
The people at the factory were outstanding in accomodation and the session went quite well. At first I was very apprehensive about the work I was doing ("Hmmm.. am I really doing this right?), but as I progressed my confidence bagan to creep up from "I'm dead... I'm SO dead", to "I might make it out of here with a part".
Upon arrival , we were shown around the factory (it sure isn't all that big, for all the parts they put out) and got to poke and prod the aircraft they had in the shop (a completed 601XL, an in progress 601XL, a 701 and an 801). Strangely absent was the 601HDS. Also unusual were the number of 701 builders in this months shop. Of the 8 builders there, only 2 of us were building a 601.
After the formalities it was time to go to work on the rudders. We all split off to our tables to begin deciphering the plans for this thing we were making. After some head scratching and questions, I finally went ahead and started work. After some sessions of "measure, measure, check plans, measure, mark, check the mark, erase the mark, remeasure, mark again, clamp, measure, ask the guy next to me if that looked right, drill, measure" the work started to progress rapidly. By the end of the shortened day of building, I had the skeleton built up and the rear skin partially drilled.
The next day we got back to it at 9:00 am and I found that I was easily able to pick up where I left off. I finished the skinning of the rudder and had a completed part by around 12:30. The two days we were there, the weather only improved marginally so I wasn't able to take a flight in the 601XL (apparently the HDS is out of annual), but I did get to visit the HDS in the hanger across the field. I got to sit in it and get a feel for the airplane, and determined that yes, it fit well and no I am NOT going to build a tail-dragger. Climbing into a 601 is a challange. Climbing into a 601 that's sitting nose high is an exercise requiring significant upper body strength. Though I'm not THAT out of shape, I'd just as soon not be worn out before I crank the engine!
Jumping into the future, here are some pictures of the completed rudder. Unfortunately I did not get an opportunity to take any shots down at the factory. These shots were taken while I was shuffling the shop around...
This is the completed rudder assembly, minus the bearings that will attach it to the fuselage and the rudder cables. Those will be added later when I can precisely align them to the rear fuse.
And this is another view of the profile. The hand you see to your left is that of my friend Michael Kelter. He'll be working alot with me on this project. Anyway, the hand gives you some reference of the size of the rudder. The 601HDS has a "flying rudder", which means basically that the entirety of the vertical stabilizer is the rudder. I can't wait to do crosswind work in this beast! You'll also notice that there's significant "divoting" along the rivet lines. It seems the air riveter I used at the workshop had better pull then I though, so I pressed a bit too hard on it. It really looks worse then it is, and this deformation isn't going to significantly effect the aircraft. Once it's painted, you wouldn't really notice unless you're looking for it.