Summary of Contents for Silence Aircraft Twister Kit
- Page 1 Revision 1. 6 Aircraft Assembly Manual Twister Kit Revision 1.6 Silence-Aircraft GmbH, Kapellenweg 54a, 33415, Verl Germany...
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Page 2: Table Of Contents
Revision 1. 6 Table of Contents 0. Using this Manual 1. General Specifications Materials and Tools Fiber Composite Basics Safety 2. Wings Flaps 2.1.1 Installing the Hinge Pin for the Flap and the Aileron 2.1.2 Installing the Connecting Pins 2.1.3 Installing the Counterweight 2.1.4 Laminating the Seams and Ribs... -
Page 3: Fuselage
Revision 1. 6 Installing the flap mechanism and the supports for the wing torque tube Installing the landing-gear struts, wheels and fairings Installing the landing-gear actuator Installing an undercarriage warning system PFA MOD 329/007 Installing the horizontal stabilizer with securing wire Installing the ribs in the rudder assembly Mounting the wings Installing the fuselage base... - Page 4 Revision 1. 6 Installing the Cooling Air Ducts Installing the Air-Intake Casing Installing the Crankcase Ventilation with Separator Mounting the Propeller and the Spinner Assembling the Throttle and Brake Assembly Installing the Control Cables on the Engine 5.10 Installing the Tank and Fuel System Incorporating PFA MOD 329/002 5.11 Installing the Cowling 6.
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Page 5: Using This Manual
Revision 1. 6 0 Using this Manual Note: This manual was translated from a German original. Measurements The design of the Twister is based on the metric system. All US conversions given in the text are for guidance only. All dimensions in the figures are in millimeters (mm) unless otherwise stated. -
Page 6: General
Revision 1. 6 Part Numbers The part numbers refer to the bill of materials, which is delivered as a separate document. Printing the Manual The layout of this manual is adjusted for letter size paper. Abbreviations cotton flock microballoons fiber-reinforced plastic fiber composite unidirectional General guide line for the installation of bolts. -
Page 7: Specifications
Revision 1. 6 1.1 Specifications The Twister kit consists of structural components made from honeycomb fiber glass composites, with spars and additional reinforcements made of carbon fiber reinforced plastic. For extra safety, an aramid honeycomb monocoque (cockpit cell) is used. - Page 8 General Revision 1. 6 Strength The Twister is certified for the following load factors: +6 / -4g at 400 kg (882 lb) take-off weight at 209 km/h (113 kt/130 mph) maneuvering speed Do not exceed these load factors. Especially, avoid wide rudder movements at speeds above 209 km/h (113 kt/130 mph).
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Page 9: Materials And Tools
General Revision 1. 6 1.2 Materials and Tools The Twister is primarily built from fiber composites. The structural honeycomb sandwich components are vacuum molded by the manufacturer. The builder has to carry out the following tasks: Laminating joint tapes Adjusting and installing the ribs into the structural components Sanding and filling the surfaces Mechanical assembly Wiring/laying the wire harnesses... - Page 10 General Revision 1. 6 The following table lists all fiber composites used in the Twister . Materials printed in blue have to be applied by the builder. Twister List of Fiber Composites Used In the Fabrics Interglas Fabric Description Weave type Finish width 1000mm...
- Page 11 General Revision 1. 6 Resin / Hardener Scheufler L285 + H286 Cyanoacrylate glue ("super glue"), medium viscosity Fillers Cotton flock Thixotropic agent (Cabosil or equivalent) Glass bubbles 0.12g/cm³ (119.86oz/cu ft) Micro balloons Support Materials Description Thickness Density Aramid honeycomb, 3.2mm (0.13") cell 48kg/m³...
- Page 12 General Revision 1. 6 Tools To build the Twister you need the following tools: Paint brush Scissors Power drill Pop rivet pliers Set of wrenches and screwdrivers Torque wrench General Torques for Screw/Bolt Connections (Bolts/screws slightly greased) 23Nm 46Nm Twist drill set, 1-12mm (.040"-0.50") Long nose pliers, long type Caliper gauge Set of files...
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Page 13: Fiber Composite Basics
General Revision 1. 6 1.3 Fiber Composite Basics Plastics in General For thousands of years human existence depended on natural materials. Clothing, tools, and utensils were made from leather, metal, stone, clay and other substances provided by nature. Most manmade materials like porcelain, glass, and metal alloys were discovered more or less by accident. - Page 14 General Revision 1. 6 4. The Paradox of Composite Materials When taken as a whole, a composite can withstand stresses that would break the weaker component, whereas the composite’s stronger component can exhibit a greater percentage of its theoretical strength than when loaded singly (G. Slayter). Fiber Composites The principle of combining different materials to form a composite with enhanced properties is just as common in nature as in lightweight engineering.
- Page 15 General Revision 1. 6 Manual lamination using a foam roller Simply speaking, fiber composites can be compared with reinforced concrete, where a brittle, shape- giving material (concrete) is reinforced by steel. The fibers are embedded in a liquid mass of reactive resin and fixed in place when the resin hardens in the mold.
- Page 16 General Revision 1. 6 A high dynamic strength is particularly needed for components which are subject to frequent bending cycles (e.g. struts in aircraft construction). Even after several tens of thousands load reversals, epoxy resins suffer only the smallest decrease in strength and therefore have the highest dynamic strength.
- Page 17 General Revision 1. 6 Polymerization does not start until a certain time after the reactive agents have been added. Thereafter the resin compound solidifies relatively quickly. This involves heat generation and a rapid increase in viscosity, but no release of volatile products. Once started, the curing process cannot be stopped or reversed.
- Page 18 General Revision 1. 6 Manual lamination: carbon- aramid fabric being impregnated with epoxy resin Glued Bonds Cyanoacrylate-based glues (super glue) and epoxy resin show superior adhesion on various materials and are used to bond plastics, metals, wood, glass, concrete, ceramics, etc. The strength of a glued bond is determined by the following glue properties: the strength of the adhesive (cohesion)
- Page 19 General Revision 1. 6 Degreasing is one of the most important prerequisites for proper wetting, so it should be carried out regardless of whether the surface will be treated further. Suitable solvents are, among others, various alcohols and acetone. Although they were frequently used in the past, do not use chlorinated hydrocarbons (CHC), such as chloroform, methylene chloride, TRI, carbon tetrachloride, etc., unless it is absolutely necessary.
- Page 20 General Revision 1. 6 To check for proper degreasing you can pour a few drops of distilled water on the surface: Water collects into droplets Water forms a film a) Poorly degreased: b) Well degreased: Part to be bonded Manual Lamination Manual lamination (hand lay-up) is the oldest, simplest and most common method.
- Page 21 General Revision 1. 6 Cotton Resin Mix (CF) As reinforcing fibers, cotton flock is mixed into the resin. The amount of cotton flock used depends on the desired viscosity of the cotton resin mix. Usually the amount of cotton flock is increased until the cotton resin mix stops flowing.
- Page 22 General Revision 1. 6 Processing Epoxy Resins Process cold-curing epoxy resin systems at room temperature (20-25°C [68-77°F]). By choosing the right temperature you can decisively influence both the processing properties of the resin as well as the properties of the cured molded materials. In general, changes in processing temperature have the following effects: Increasing the temperature: ð...
- Page 23 General Revision 1. 6 Even if the mixing ratio is absolutely correct, some molecules which have not found a reaction partner will still be left behind, as in any chemical reaction. However, for optimum strength it is necessary to achieve the highest possible degree of cross-linking. In addition to adhering precisely to the required mixing ratio, you can achieve almost 100% cross-linking by controlled heating (annealing).
- Page 24 General Revision 1. 6 Health complaints therefore arise in the time between the mixing of resin and hardener and the setting of the mixture. In this context, a distinction is made between skin irritation and allergies: Skin Irritation In the case of acute skin irritation red patches develop, e.g. on the back of the hands, the fingers and in parts of the face and neck.
- Page 25 General Revision 1. 6 Also avoid inhaling the sanding dust of epoxy resins. Wherever possible, do not transport open containers with chemicals over long distances. Mix resin and hardener near the processing site. ð Do not eat, drink or smoke while working. After finishing work and before using the toilet, wash your hands thoroughly.
- Page 26 General Revision 1. 6 Danger Notices On Chemicals Containers Danger Notices Danger Notices R 34: Causes chemical burns. R 36/38: Irritates the eyes and skin. R20/21/22: Harmful to health if R 43: Skin contact can cause inhaled, swallowed, or allowed sensitization.
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