- Joined
- Jan 12, 2017
- Messages
- 717
For my Flying Flea HM293 project I am working on the rudder horn and hinges. Per plans the upper hinge is integrated with the horn and (as far as I can tell) fabricated from 5 plates of 0.080, each welded to the others at their seams. (See pic). This gives me the heebie-jeebies. The Flea is a 2-axis aircraft, so the rudder is big (proportionally) and loosing rudder control would be catastrophic.
Instead, I plan to fabricate the horn using thinner sheets, 2 on each side of the rudder, matching where they project from the rudder, and bent rather than welded along the seams. On top of the upper side of this part I will bolt a single folded bracket, to which the hinge tubes will be welded (not shown in these pics).
What's the best way to fuse the mirrored sides of this horn together?
I can edge weld the outer perimeter (not the seam where they meet, that would weaken the part and defeat my purpose) , but given the odds of some melt back in places, the result is not likely to be very clean. To limit melt back, I could braze the perimeter (and even the seam, I suppose). I could use short bolts, but that would be ugly and create drag. I suppose I could rivet them together - does it ever make sense to rivet steel? I suppose I could even epoxy them together, as I imagine they are nearly as strong acting independently as they are as a unit.
Thoughts? Thanks
Instead, I plan to fabricate the horn using thinner sheets, 2 on each side of the rudder, matching where they project from the rudder, and bent rather than welded along the seams. On top of the upper side of this part I will bolt a single folded bracket, to which the hinge tubes will be welded (not shown in these pics).
What's the best way to fuse the mirrored sides of this horn together?
I can edge weld the outer perimeter (not the seam where they meet, that would weaken the part and defeat my purpose) , but given the odds of some melt back in places, the result is not likely to be very clean. To limit melt back, I could braze the perimeter (and even the seam, I suppose). I could use short bolts, but that would be ugly and create drag. I suppose I could rivet them together - does it ever make sense to rivet steel? I suppose I could even epoxy them together, as I imagine they are nearly as strong acting independently as they are as a unit.
Thoughts? Thanks
Last edited:
