Molex connector, elevator attachment and fairing

Since last I've spent much time on fairings and to attachment of the elevator to the horizontal stabilizer. It would have been much more fun to get started on the aft fuselage, but my workshop space is limited. So I want to complete as much as possible on the elevator, HS, VS and rudder and then store them away.

Micro Molex

The trim motor is supplied with micro Molex connector and they have to be crimped. I was sure I knew how to do this (had even seen then video from Stein Air), but I mixed up the "standard" size molex and the micro procedure.
I bought some new ones from RS-Components. The Molex part number is 43030-0007 (female) and 43031-0007. I also bought the extraction tool with part number 11-03-0043.

Broken terminals.

The crimp tool from Stein Air.

The finished servo motor with the Molex connector crimped.

I had to function test - it works😀

Fairings

First the flanges had to be adjusted. The Dremel cutter
works very well for this.

And the small Dremel for the curves.

The fairing is to narrow out of the box, so I put
a paint roller inside to match drill it properly.

There was a gap in the front part. I decided to fill it with epoxy.

I put on a thick mix of epoxy/microfiber and a sheet
of peel ply.

This is the result. The surface was then wet sanded to fit the
counter balance skin. 

The result after sanding and a few round with spray filling.

I also put a layer of epoxy to fill the small
misalignment on the sides. The peel ply leaves
a nice finish, and reduce the sanding work a lot.
BUT! I used a thin aluminums tape to protect the
aluminum on the elevator, and that was not a good idea.
It was extremely difficult to get it off afterwards😒

I used a spray filler and wet sanding paper
to get a smooth finish. I guess one
could continue forever with this kind of work😵

 

Here I've prepared the layup for the horizontal stabilizer tip fairing.

The tail light bracket has to bonded and riveted
onto the lower rudder fairing.

The HS tip fairing must be adjusted slightly
out before gluing the back plate.

Match drilling the rudder fairing

I bought this small kit from West System, together with microfiber
filler and peel ply. Also a bottle of cleaning liquid (855) has
been useful.

 Attaching the elevator to the stabilizer

The weight installed.

I made this tool from a wood block to easily adjust the
hinge rods to correct depth.

Left elevator on.

Section 11-03 match drilling elevator horn.

Both elevators on and secured. I only needed one thin washer
on the right side.

I made the drill guide block(11-02 step ) on the
3D printer.

All together.