I started the day by noticing the trim detail for the E-714 counterweight on the right elevator (DWG-5).  Van's instructions didn't make any mention of trimming this under the right elevator construction instructions so I was a little confused.  I read ahead, and they do mention balancing the elevator after everything is put together.  After some thought, I decided to trim just under the minimum called out by the print (leaving the counterweight heavy).  Van's instructions state later to reduce weight by drilling a series of holes in the counterweight.  By leaving it heavy, maybe I won't have to drill out so much later to get the elevator balanced that if I didn't touch it at all.

Trimming the lead counterweight turned out to be a major pain in the A_S.  I tried the band saw with the metal blade in it.  DIDN'T WORK!!  The counterweight grabbed the saw blade and ripped it right off the pulley wheels on the band saw.  Then I tried a hacksaw to rough cut.  DIDN'T WORK VERY WELL EITHER.  The lead just plugged the hacksaw blade and then it wouldn't cut.  After struggling with this, I got it pretty close and then used a vixen file to take it down the rest of the way and smooth it out.  I used a Dremel grinding wheel then to radius the trimmed out area.  It didn't look to bad when I got done.  It took a sweat, and about 1.5 hours to trim that dang thing out.  Good thing that this was only required on the right elevator counterweight.

The rest of the day was just drilling, deburring, and dimpling stiffeners and elevator skins.  I did have a little trouble getting the aft most hole dimpled.  I tried the C-Frame with just me holding it since Tami is at her folks.  I was not able to hold it square on the C-Frame and it distorted the skin.  I figured it out after the 2nd hole, but they are on the top side (DANG).  I then used the close quarter dimple dies and they turned out to work pretty good on the elevator skins.  I went down stairs and got some nails (4D, a.k.a. 4 penny) from out stock in the basement.  I was snapping the shafts supplied with the dimple dies after about 2-3 holes.  the nails worked good and when they snapped, I had a whole box of spares.

I was out in the garage over 12 hours, but only seemed to get in about 9 hours of productive work in.  Gotta make my own meals now that Tami is gone for the week.