So we have something a little substantial to look at for the D VII today. I got one side of the rudder tacked up.
First I had to prepare the spar. The bottom gets flared as you can, and that bottom hinge as a result only gets one retaining collar. I just used a ball pean hammer and a dolley in the vise to flare the end of that tube. Work slow and in stages so you don't mangle the tubing.
Then I had to load all the hardware onto the spar; four hinges, 3 collars, and a control horn. Then the top of the spar gets squished down to the thickness of the outer edge tubing.
I included a picture of the bending fixture I set up on the press.
I shot a general pic of the welding jig
I created on the work table using cleats and shims to hold everything in place while I tacked it all up. I now have to flip it over and tack the riblets on the other side, final weld, clean it up, and get some primer on. Enjoy