The bellhorns took a couple more days to finish. Most of yesterday was sanding and shaping and making nice. I spent a while drilling out the holes for the rivets after having glued the end pieces to the larger aluminium. Then more cleaning up.

Next it was alodine for the 2024 T3 aluminium and the green zinc phosphate for the 4130 end pieces. Thats not the really nasty stuff but still worth a face mask and outdoor spray.

I riveted it together today after checking my books for rivet lengths and a few more practices with the hand squeezer on scraps. No rivet was harmed in the operation, just squished a little and it worked out well. These look so pretty and no one will see them after they get embedded in the rudder.

Next I was back on the winglet and squared up the A block insert. A bellhorn glassed in place with foam pocket filler is the next step, then the outside layups.

Bellhorns ready for coating

Completed bellhorns

Starting on the A block shaping