The rest of this weekend was spent deburring and dimpling the rudder parts. Here's a shot of my solution for how to dimple the aftmost holes in R-903… pop rivet dimple dies with the nail inserted from the outside, and washers to take up the gap:
The lead brick is attached to the counterweight rib with #10 screws. Dimple dies for a screw that big can be expensive, so some builders use their #8 dies and mash the screw in there to expand the dimple. That sounded like an opportunity for a stress riser and an eventual crack to me, so I found some cheap #10 dimple dies on eBay and used them to make the proper dimple. No big deal. The lead then is countersunk to fit the dimple – it's soft enough that I was able to use my deburring tool to do it.
