Rudders
Rudders
Beginning 6" from the top and bottom of the rudder and rudder well, measure and mark two hinge center positions on the outboard side. Place third hinge between the two. They are all 4" hinges. Figure 2-50 shows the hinge locations. The rudders will hinge at the outboard surface of the winglet (the flat side). Remove 1-1/4" foam from the winglet rudder wells and rudders.
Rudder Hinge Installation 
Sand all edges straight. Cut six 4" long pieces of hinge for your rudder hinges. Cut each hinge pin about 1/8" shorter or grind to a point and peen the end of each hinge closed to trap the hinge pin in. This will make sure 
that you do not loose your hinge pins. Install the hinges on the rudder along the marks that you placed. Drill through the hinges and skin and countersink the outer skin for 1/8" flush head pop rivets. Make sure to keep the hinge pins in line so you do not have any binding. Use the straight edge of the rudder to do this. Detach hinges, clean off the epoxy and sand thehinges and mounting areas for bonding. Apply Structural Adhesive to the hinges and mounting areas on the rudder and pop rivet the hinges to the rudder. Use 5 rivets (BSC-4-4), staggered on each hinge. Let cure. Cut 1/8" notches in the rudder well to accept the hinges as you did for the ailerons. 
You will have to file the trailing edges of this notches in order to allow the hinge to sit flush with the outside skin. Remove the rudders and drill two 1/8" holes per hinge notch. The holes should be 1 inch from the ends and 1/2" forward of the trailing edge of the notch. Reinstall the rudders and use a straight edge to put pressure on the hinge from the back. Mark the hinges through the holes in the rudder well.
Remove the rudder and drill one hole out on each hinge to 1/8". Reinstall the rudders with 1/8"clecos in the holes you drilled. Check the rudders for proper operation. When satisfied with you rudder installation drill the remaining holes in the rudder out to 3/16". Remove the rudder and install MS21047-3 nutplates with AAC-3-4 rivet on the Remove 3/4" of foam from the bottom of the rudder. Place your rudder horn on the bottom of your rudder. Line up the flat side of the rudderhorn with the outside skin of the rudder. Make sure that the rudder cable attach hole is 5" forward of the hinge point. Place the rudder on the winglet so the hinges fit in the notches. Leave the hinges out and line them up on the outside of the winglet so you can mark and drill the holes onto the winglet. Drill the holes on the wignlet for the hinges. Place the hinges on the inside of the winglet. Attach the Seal the top of the rudder and winglet with micro-glass and 2 bid fiberglass. Sand and fill 
holes you just drilled as you did with the aileron hinges. Reinstall the rudder with AN526-1032R8 screws and drill the remaining holes. Remove rudder and install nutplates on the remaining screw holes.
Mark the trailing edge of the horn on the rudder. Slurry the foam and install the hardpoint making sure that it is flush with the rear line you drew for the horn. You also want to make sure that the marks you drew for 
the screw locations are somewhat centered on the hardpoint. Cover with 3 bid. Let cure.
rudder to the winglet with screws.Check the rudder for clearance. The rudder should move smoothly 3.75". 
The inner edge of the rudder and wing forms the rudder stop. The sand the needed material on the rudder and wing so that when the rudder touches the stop it is in the nuetral possition. 
the countersunk holes on the rudder with frosting. Sand while attached to the winglet so the surface
areas will line up then prime.