Veloce 400 Manual
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Veloce 400 Manual

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VELOCE
Manufacturing
Manual – 400

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Summary of Contents for Veloce 400

  • Page 1 VELOCE Manufacturing Manual – 400...

  • Page 2: Table Of Contents

    Summary General Information 1 Getting Started 3 Wing 4 Wing mounting template 4 Wing top coating preparation 5 Rear spar preparation 7 Experimental Fit 7 Main spar 8 Fuel Tank Preparation 8 Fuel output 10 3.6.1 Fuel vent lines 11 3.6.2 3.6.3 Tank breather 11...
  • Page 3 Trailing edge strengthening 22 3.16 Hinges Installation 23 3.17 3.18 Aileron horn 23 Wing tips Installation 24 3.19 Horizontal empennage 25 Assembly Preparation 26 Horizontal stabilizer spar 28 4.1.1 Elevator spar 20 4.1.2 4.1.3 Ribs preparation and positioning 30 trim-tab hinge region preparation 32 4.1.4 Component lamination 33 Spars lamination 33...
  • Page 4 Temporary fit of the fuselage top 47 Firewall 48 Front face of the firewall 49 5.4.1 5.4.2 Engine mount reinforcements 50 Lamination of the firewall lower reinforcements 51 5.4.2.1 Lamination of the firewall's top reinforcements 52 5.4.2.2 Front seat reinforcement 53 Installation of the rear seat backrest 56 126 Station cave 57 185 Station Cave 58...
  • Page 5 Gluing -86 5.17.4 Luggage compartment cover 86 5.18 Elevator scale 88 5.19 Installation of the wing attachment eyelets 89 5.20 Wing-fuselage junction 90 5.21 EngineCowl 91 5.22 5.23 Internal finishes 91 Fuselage - Translations (includes mechanics) ..........92 Mounting the stick linkage 92 Flap mountingBracket 93 Rudder cable route 94 Installation of the aileron horn 95...
  • Page 6 Mounting the hinges 141 Aileron142 Preparation for Spar assembly142 Initial assembly of the lower half 143 Gluing Preparation 143 Preparation for the aileron control arm 144 Installation of top coating 145 Gluing the top coating 145 8.5.1 Closing of the external face 146 Assembly of the Aileron Components 147 Balance 147 Rudder 148...

  • Page 7: General Information

    General Information Congratulations on selecting the Veloce 400 as your personal aircraft build kit. If you've built any other composite aircraft before, you'll be pleasantly surprised at the simplicity and ease with which this project will progress. If this is your first build on a project, please pay particular attention to all phases of instruction and you will also be guided to a satisfactory completion of this excellent aircraft.

  • Page 8: Getting Started

    Chapter 2 - Getting Started INITIAL INSTRUCTIONS IT IS OF VITAL IMPORTANCE TO READ THIS CHAPTER BEFORE BEGINNING CONSTRUCTION. All references relating to BID tape laminations refer to bidirectional glass fabric laminations. This fabric is cut and laminated at +/- 45º if not specified. The small radii on the edges using MICRO (micro glass spheres) or FLOX pastes are approximately 1/8 inches which can be made by sliding the indicator over the joints.

  • Page 9: Wing

    Chapter 3 - Wing Wing Wing Assembling Template The first step in assembling the wing is to fabricate an assembly template similar to the photo shown below. The upper contour of the airfoil should be traced from the full- size template provided and carefully cut into the plywood or MDF (you will build the wing sections from top to bottom on this frame).

  • Page 10: Wing Top Coating Preparation

    Chapter 3 - Wing pipes, foundation shoes and holes in the ground). Make a mirror template on the newly constructed one and attach this to the side so that the wing is constructed in one piece. It is recommended that the wing template be made stronger than suggested in the basic instructions.

  • Page 11: Rear Spar Preparation

    Chapter 3 - Wing Rear spar preparation The rear spars are identical and interchangeable, however note that there are hard points on the edges which will be located in the center of the wing. Select a rear spar for the wing section you are building. Cut any extra corner material and remove all peel ply and other non-structural manufacturing materials.

  • Page 12: Experimental Fit

    Chapter 3 - Wing Experimental fit Select the ribs for the assembly (there are no ribs on the right or left side, so just select the required number of parts). Again, remove all peel ply and sand the corners for personal safety when handling.

  • Page 13: Main Spar

    Chapter 3 - Wing Clecos or small metal screws can be used to correctly position the parts before and during gluing and will be useful for re-installing the parts precisely in place with the gluing materials for final assembly. Main spar Select the main spar, remove the peel ply etc, prepare in the same way as for the rear spar.
  • Page 14 Chapter 3 - Wing With the help of the leading edge of the front ribs, position and mark the location of the tank closing spar, fasten it with clecos or screws with superb thread. Note that there is an extra front rib added to support the aileron drive arm mounting point and that the front channel inner closure ends at the end of the tank bay.

  • Page 15: Fuel Output

    Chapter 3 - Wing anti-slosh valve. Drilling holes and other preparations are most successfully done on local components prior to gluing. 3.6.1 fuel output The fuel outlet uses a “finger” filter located in the lower back corner of the first rib. It may be easier to install this filter on the loose rib before sticking it in place.

  • Page 16: Fuel Vent Lines

    Chapter 3 - Wing 3.6.2 Fuel Vent Lines Fuel tanks must be vented, allowing the entry or exit of air equivalent to the fuel flow. The upper rear corner of the outermost rib of the tank bays is the preferred location for locating this vent.

  • Page 17: Anti-Slosh Valve

    Chapter 3 - Wing 3.6.4 Anti-slosh valve The anti-slosh valve system is installed in the lower section of the second outer rib. This rudimentary check valve will keep the internal tank relatively full during agitation due to inclement weather or maneuvering. This valve is a flap configuration which is attached to the second rib.

  • Page 18: Fuel Cap

    Chapter 3 - Wing fuel cap The fuel cap will be installed in the highest corner of the fuel tank area. Locate the desired position and hold the cap against the inside surface of the liner and draw around the perimeter. Cut the inner liner to the edges of the mark, clean the core material without damaging the outer liner.

  • Page 19: Tank Bridge

    Chapter 3 - Wing After curing remove the outer coating from inside the cap and finish. tank bridge Take the pipe sections for the bridge and laminate them with two BID layers. Allow healing. Drill 2 holes of 1 ½” with center to 7/8” the top and bottom edges and the 1” from the trailing edge of the ribs of the BL 118 and BL 125 .

  • Page 20: Rigid Point For Aileron Horn

    Chapter 3 - Wing Rigid point for aileron horn The BL 125 rib is where the aileron horn will be mounted. The rigid point for this mount can be installed more easily before gluing the ribs to the wing. Take the aluminum rigid points provided, demarcate their position on the outer shell of the tank (this rigid point is centered on the rib and with the front face aligned with its internal flange, see figure).

  • Page 21: Tank Closing Lamination

    Chapter 3 - Wing Mix a wet FLOX paste and spread over the spots. Remember that the bonding must be done from the secondary spar to the front. Remember to ensure that the bonding areas are clean and free of any debris, grease or oils which could interfere with the bonding process.
  • Page 22 Chapter 3 - Wing all areas that will be wet with fuel and clean off any loose oils, greases or debris. It is necessary to prepare the tank for the fuel, waterproofing the tank with resin suitable for this. Mix this resin with hardener and laminate 2 layers of BID internally with the tank resin leaving no gaps (non-waterproof parts) reinforcing and waterproofing the tank.

  • Page 23: 3.12 - Fuel Test

    Chapter 3 - Wing 3.12 fuel proof After the tank closing lamination has cured, remove the wing from the jig and place it in the flight position (reverse position) and fill the tanks with water. Check for any leaks or porosity, if any, empty the tank, wait for the product to dry and proceed with the appropriate repairs immediately.

  • Page 24: Undercoating Preparation

    Chapter 3 - Wing 3.15 Preparation of the undercoat 3.15.1 Fuel drain valve It will be necessary to install a fuel drain valve in the lower section of the fuel tank to drain the fuel and check for water accumulation. Locate the place to mount this drain as far inward as possible and close to the spar.

  • Page 25: Aileron Horn Inspection Panel

    Chapter 3 - Wing 3.15.2 Aileron Horn Inspection Panel The aileron horn inspection panel must be made before gluing the wing casing in place. This will be installed between the BL-118 and BL-125. Demarcate the area in the lower cladding close to these ribs and 6 inches long, transmit the marking to the outer cladding with the aid of a square.

  • Page 26: Undercoating Lamination

    Chapter 3 - Wing 3.15.4 Bottom coating lamination The largest portion of the undercoat glue line is very critical. A fit test that conveys the impression of the surface is good practice for this. Locate all areas of the bottom liner which will be glued in the assembly and sand these areas and test fit on the top surface to verify the contact of the parts.

  • Page 27: Trailing Edge Strengthening

    Chapter 3 - Wing 3.16 Strengthening of the trailing edge The trailing edge of the wing covers must now be hardened and reinforced for flap and aileron mounting forces. Look under the edges and see if any curls can be seen. If any significant distortion is observed, secure the edge to something rigid and straight.

  • Page 28: Hinges Installation

    Chapter 3 - Wing 3.17 Installation of hinges When the flap and ailerons are complete, the hinges must be fitted and the anchor nuts installed to install and remove flaps and ailerons to their respective sections on the wing. Carefully snap and align the respective control surfaces, cleaning the mounting surface for secure, level mounting.

  • Page 29: Wing Tips Installation

    Chapter 3 - Wing 3.19 Wing tip installation Wing tip installation can be extended to close to the final assembly process for storage and handling reasons, but this is the obvious place to describe the process in the manual. The wing tips are removable fixing it with approximately 16 screws downgraded, anchor nuts.

  • Page 30: Horizontal Empennage

    Chapter 4 - Horizontal empennage Horizontal empennage Inspect the top and bottom precast liner of the horizontal stabilizer. Note that each liner consists of the horizontal stabilizer and elevator liners which were factory molded into one piece. Identify the top of the stabilizer on the factory labels ( C104T ) and the top of the elevator ( C104ET ).

  • Page 31: Assembly Preparation

    Chapter 4 - Horizontal empennage Assembly preparation Using the templates provided in the drawings ( TR4-H2 ) make the ½ inch plywood jig components. Prepare a table or flat surface for mounting with a length of at least 120 inches long. Locate the center and draw perpendicular lines forward at point BL-0 and BL-57 left and right.
  • Page 32 Chapter 4 - Horizontal empennage Measure 1 ½ inches in front of the elevator cut line and draw a cut line parallel to the cut line for positioning the back face of the spar. Similarly draw a straight line 1 ½ inches behind the cut line for positioning the front face of the elevator spar.

  • Page 33: Horizontal Stabilizer Spar

    Chapter 4 - Horizontal empennage After marking the position of the spar and ribs it is a good time to prepare the cladding areas for gluing. Take a piece of 80 sandpaper and roughen the areas around the spar and ribs on the top and bottom liners. A gentle sanding is all that is needed to give the resin a good bonding surface.

  • Page 34: Elevator Spar

    Chapter 4 - Horizontal empennage 4.1.2 Elevator Spar Measure 1.5 inches behind the elevator cut line and draw a line from BL-57 L to BL-57 R. This line will locate the front face of the elevator spar. Separate the two outer parts of the elevator spar and remove the back shell and core from the central area where the phenolic material will be placed.

  • Page 35: Ribs Preparation And Positioning

    Chapter 4 - Horizontal empennage 4.1.3 Preparation and positioning of ribs Locate the 3/8 prepreg panel ribbed BL-5 R and L, BL-30 R and L and BL 57 R and L cut with a fine tooth saw . Cut slightly larger and sand to final size controlling fit with liner.
  • Page 36 Chapter 4 - Horizontal empennage Cut the elevator ribs from the 3/8prepreg panel using the templates provided. Note that the bottom of the spar is angled such that each piece should be marked so the spar can be mounted correctly. Positioning is carried out by the top edge of the spar, this is up in the assembly.

  • Page 37: Trim-Tab Hinge Region Preparation

    Chapter 4 - Horizontal empennage Above can be seen all ribs and spars positioned as specified. Below we have the detailing of the BL-5 L rib of the elevator. 4.1.4 Preparation of the trim tab hinge region draw a distant line 4 inches from the trailing edge to the right of the centerline between BL-0 and BL-30 inside the casing.

  • Page 38: Component Lamination

    Chapter 4 - Horizontal empennage Component lamination 4.2.1 Spar lamination 4.2.1.1 elevator spar Apply a strip of 4x20 inches of prelam of 3 layers on the rear surface of the spar from BL-10 L to BL-10 R covering the spar completely and overlapping the liner by at least one inch of extension in the area of the phenolic insert and overlapping the outer sections of the spar.
  • Page 39 Chapter 4 - Horizontal empennage Fit the ribs and spars to the horizontal empennage coating with an FLOX paste to hold them in place (positioning described in item 4.1.3 ). Cut two (2) pieces of 10” fiberglass mat along the length of the fabric and prepare 2 layers of prelam.

  • Page 40: Trim-Trab Hinge Preparation

    Chapter 4 - Horizontal empennage 4.2.3 Trim-tab hinge area lamination Using the folder from FLOX also make a small strip on the inner panel beside the small added spars (opposite the hinge line). Cover these areas with the 2-layer prelam Mounting and installing the top cladding Position the horizontal stabilizer top casing on the ribs and spars by carefully sanding the ribs for a good fit using the top casing as a guide.
  • Page 41 Chapter 4 - Horizontal empennage Mix a good amount of FLOX and fill in the corners of the ribs allowing this paste to accumulate up to ¼ inches above of the ribs. In the same way, place the paste on top of the trim tab cutter spars and the elevator spar, taking care not to overfill this area.

  • Page 42: Elevator And Stabilizer Cutting Sections

    Chapter 4 - Horizontal empennage After curing, remove the clecos or screws, sand the holes and fill with a MICRO paste. Do not overfill, your intention is to fill only the hole. Cutting the Elevator and Stabilizer Sections Find the marked lines that will break the stabilizer and elevator on the outside of each casing.

  • Page 43: Surfaces Closing Lamination

    Chapter 4 - Horizontal empennage Cut the hinges to a length of 4 3/8”, remove a small part of the pin and bend the ends of the hinge if it is not ready. Take the supplied aluminum horn for the trim tab. Open a slit in the center of the lower trim tab casing just enough to pass the trim tab tab.

  • Page 44: Elevators Hinge

    Chapter 4 - Horizontal empennage Elevator hinge The elevator hinges are mounted on the top casing since this is a straight line. The back line of the bottom cladding has an angle and the result of a geometric error could cause the parts not to bond together.

  • Page 45: Assembly Of The Elevator Control Horn

    Chapter 4 - Horizontal empennage The next step is to install the four hinges in their respective positions on the stabilizer top casing. Place the hinges on the trailing edge of the top casing with their pins centered over the slotted corner. Mark hole locations. Countersink the hinge holes to meet the geometric conditions of the screws provided.

  • Page 46: Mass Balance

    Chapter 4 - Horizontal empennage NOTE: Leave space for the elevator horny closing rib. Position and adjust the counterweight closing rib. Make sure that, in the final assembly, it remains parallel to the stabilizer rib and does not interfere with the movement of the elevator.

  • Page 47: Trim-Tab Actuation Servo

    Chapter 4 - Horizontal empennage Place the stabilizer in the corner of the bench or on the stabilizer itself and release the elevator rotation. The elevator should rotate about 20 degrees under its own weight. Place a lead cup where the lead will settle (near the finish foam of the counterweight tip) until the elevator surface evens out.
  • Page 48 Chapter 4 - Horizontal empennage trim tab actuation as well as its actuation arm positioning. Cut the bottom cladding as shown in the figure below. Dig the core and place a MICRO paste for finishing. Roll out triangles below rectangle corners with anchor nuts to attach the servo cover. Make a slit in the line to exit the actuator arm.

  • Page 49: Fuselage

    Chapter 5 - Fuselage Fuselage Observation: Spar Preparation If you have not completed the spar preparation steps outlined in the section 3.10 of this assembly manual, it might be a good idea to do it now. The assembled center section will be required in the fuselage assembly process. The spar assembly operation requires a large clean area to properly align the joints.

  • Page 50: Leveling And Fixing

    Chapter 5 - Fuselage inferior is 1.25 inches above the notch. The factory longitudinal notch is located on the line of -1.25 level. the flattened edge 1.25 inches above is located in level 0 line . Flatten this edge with some care as this edge will be used for reference during the leveling procedure.

  • Page 51: Wedge Rods

    Chapter 5 - Fuselage For the proper leveling of the surface, use levels (it can be a transparent hose with water inside). In this way, level the reference line on the same horizontal plane. If necessary, use shims to fulfill the leveling. Right now, straightness and lack of twist is more important than alignment this time, however, always working with the parts aligned and level gives a better result.

  • Page 52: Temporary Fit Of The Fuselage Top

    Chapter 5 - Fuselage Waist distance from station 0 External width of the fuselage 43 3/8 44 1/2 45 3/16 45 5/16 45 1/16 43 7/8 39 1/2 32 11/16 25 9/16 Temporary fitting of the top of the fuselage The upper section of the fuselage will be temporarily installed.

  • Page 53: Firewall

    Chapter 5 - Fuselage Fire Wall change_photo The fire wall will be fabricated from a ¼ inch thick piece of plywood included in the kit parts. This piece of plywood must have the external lines and component locations (such as engine cradle) marked at the factory. Light planing may be required to fit the fuselage.

  • Page 54: Front Face Of The Firewall

    Chapter 5 - Fuselage FLOX paste and pass over the edges of the firewall where they will make contact with the underside of the fuselage. Reposition the fire wall in place with the help of the drilled holes, fix this with screws through these holes. 5.4.1 Front face of the firewall All previously cured BID coats that will be glued in later steps should be roughened...

  • Page 55: Engine Mount Reinforcements

    Chapter 5 - Fuselage 5.4.2 Engine strut boosters Engine support points will be marked on the fire wall plywood panel. It will be helpful to drill small guide holes through the fire wall to denote the location of the engine stud pins.

  • Page 56: Lamination Of The Firewall Lower Reinforcements

    Chapter 5 - Fuselage 5.4.2.1 Lamination of lower firewall reinforcements Clean and rub with a coarse sandpaper all areas that will be covered with layers BID glued around the reinforcements. Make paper patterns approximately the shape and sizes shown in the attached drawing. Try to optimize the pattern to provide complete coverage over the firewall screw areas.

  • Page 57: Lamination Of The Firewall's Top Reinforcements

    Chapter 5 - Fuselage The lower engine mounting areas have only one plywood per hole. Cover the area between these reinforcements with a total of 8 layers in IDB pre-lam (this is one of the tail end mounting areas). The area of the fire wall next to it (bolt hole side) will receive 8 layers folding the overlap at the screw mounting points.

  • Page 58: Front Seat Reinforcement

    Chapter 5 - Fuselage excess overhanging the edge of the plywood stiffeners or sand these edges to shape after curing. Front seat reinforcement Cut the front seat reinforcement from the supplied two-layer prepreg panel material. Review the sketch below, locate and install rigid points for positioning the control. The installation of rigid points is more easily done right after the cutout of the prepreg panel.
  • Page 59 Chapter 5 - Fuselage Make sure the fold line marked on the panel is 4 inches below the top edge. Correct if necessary and cut the front panel cladding in this line with a little space to each side. Remove the core material from this strip helping to bend the flange of this reinforcement. Heat the back cladding at the crease location, pass a FLOX paste on the spot and fold 90th the flange.
  • Page 60 Chapter 5 - Fuselage THE front face of this reinforcement will be located in the station 31 , check placement before gluing. Dig the core from the edges of this panel and pass a FLOX paste in this cavity protruding from the edges, position the panel at the bottom of the fuselage designated for it, place the FLOX paste on the joints to be glued (to form a small radius) and glue the reinforcement with 2 layers of IDB on both sides of this panel.

  • Page 61: Installation Of The Rear Seat Backrest

    Chapter 5 - Fuselage Rear Seat Backrest Installation Cut the rear seat back panel from the two-layer prepreg panel provided in the kit using the proper pattern and install it in position behind the center section of the rear spar. Add a hard point of 3 inches square of plywood of 1/4 inch thick for the elevator scale at the location shown in the figure.

  • Page 62: 126 Station Cave

    Chapter 5 - Fuselage FLOX paste in the excavated site and reposition the panel in place. Use the FLOX to form a small radius on the edges where the panel will be glued. Glue backrest assembly in place with 2 layers of BID in 2 inches in width on the front and back face. Final bonding of the upper surface of the flange should be postponed until the final assembly of the top of the fuselage, as these layers overlap in this assembly.

  • Page 63: Station Cave

    Chapter 5 - Fuselage preg that has the outline of that part drawn on the panel at the factory. Carefully cut this part once the cave of station 185 is outlined in the center of the cut of this part . use a fine toothed saber or similar blade tool for this operation.
  • Page 64 Chapter 5 - Fuselage This cave will also require a hard point for mounting the rudder winch. Cut a 3-inch square of ¼” thick plywood and cut the same size cladding on the back face of the cave, as shown in the figure. Insert the plywood with a MICRO folder , cover the back face with 4 layers of BID large enough for a complete overlap around the patch and extending outwards to the edge of the frame (the front 4-layer reinforcement will be glued when the frame is permanently installed) as shown in the figure (this rigid point will support the...
  • Page 65 Chapter 5 - Fuselage Front floor assembly The floor panel itself is to be installed with the outer edges touching the back of the fire wall and with the edges touching the surface of the fuselage. make sure there is 1.5 inches free between the upper surface of the floor panel and the hole positions for the lower engine mounting screws.
  • Page 66 Chapter 5 - Fuselage with a spacing of 1 ½ inch between the marked line and the center line ( 3 inches between the 2 marked lines). After curing the lamination, drill the holes indicated in the detail in the figure above with a 3/16 drill.
  • Page 67 Chapter 5 - Fuselage prepare one FLOX paste and pass over the lower edges of the supports, position these over the proper places and with the paste create a small radius on the edges for the lamination. Glue in place with a BID tape in 2 layers in 2 inches width. After these brackets are cured, cut out the 2 inch edges left in the center section of the top panel and prepare the separate top sections and rear closure sections in the same way as the brackets, test them for fit as well, and make any necessary adjustments.

  • Page 68: Reinforcement Of The Main Train Box

    Chapter 5 - Fuselage 5.10 Reinforcement of the main train box Cut out the front reinforcement from the rear seat of the pre-marked panel provided. The front face of this panel will be located at 3 inches from the front face from the landing gear box and perpendicular (90°) from the upper face of the landing gear box.
  • Page 69 Chapter 5 - Fuselage series of 4 layers at the front of the gusset) in the area for the train mounting bolts, overlapping the sides of the fuselage wall and the faces of the seat gusset as shown in the figure.

  • Page 70: Reinforcement Of The Nose Gear Assembly

    Chapter 5 - Fuselage 5.11 Beke Mount Reinforcers The tail wheel will be supported in two places: on the engine mount (upper part) and on the fire wall (lower part). For this it is necessary to install reinforcements in the fire wall.

  • Page 71: Vertical And Horizontal Stabilizers

    Chapter 5 - Fuselage As seen in the figure above, position the internal plywood reinforcements. Align them vertically, sand them if necessary for a good fit in place, and mark their respective positions. prepare one FLOX paste and pass over the edges of the reinforcement to be glued.
  • Page 72 Chapter 5 - Fuselage to transfer the exact cutout location of these pieces. Carefully align the front edge of the two halves of the tail with the rear edges of the upper fuselage molding and drill a few holes (every 10 centimeters for a proper joint) to position small metal clecos or screws (either near the upper or lower fuselage ) to secure and align these parts.
  • Page 73 Chapter 5 - Fuselage collage or painting will be carried out). Remove the halves of the tail, and cut these carefully marked pieces to size using a saber saw or similar tool. This cutout is slightly larger than the socket to allow leveling of the stabilizer from side to side, and to determine the projected incidence value.

  • Page 74: Installation Of The Horizontal Stabilizer

    Chapter 5 - Fuselage 5.12.2 Installing the horizontal stabilizer Prepare both the horizontal stabilizer and the fuselage surfaces adjacent to the cutout for gluing (clean and roughen the surfaces to be glued with BID tape as described in the procedures section). Optionally, you can use small pieces of plywood to fix the stabilizer in the desired location, which includes setting the hinge line at the station 203 centering and leveling from side to side, and setting the incidence of 0º...

  • Page 75: Bonding Of The Station Cave

    Chapter 5 - Fuselage outside, so that the cave of station 185 must be removed and adjusted after these steps. apply 4 layers of BID inside the fuselage and stabilizer junction with a minimum of 2 inches overlap on both surfaces (inside of the tail cone). The two inner bottom sides must be glued together, as well as the right inner top side.

  • Page 76: Gluing Of The Vertical Stabilizer's Rib And Spar

    Chapter 5 - Fuselage 5.12.4 Gluing the vertical stabilizer rib and spar Cut the rib and spar of the vertical stabilizer from the supplied two-layer prepreg panel, also cut the upper part of the frame. station 185 . Their drawings are pre-marked on it.

  • Page 77: Installation Of The Left Rear Fuselage

    Chapter 5 - Fuselage Keep surfaces secured with staples and allow to cure. Temporarily position the left rear fuselage in place by taking a tentative alignment. Work on the frame, spar and rib of the vertical stabilizer, sanding them so that they fit into the cladding without the need for tightening.
  • Page 78 Chapter 5 - Fuselage After bonding the cap-strips, remove the left side, remove all used plastic and sand the external faces where they will be glued on the left coating. Remove the tape from the inside of the left rear fuselage and prepare these same places for gluing, clean and roughen.

  • Page 79: Bonding Of The 126 Station Cave

    Chapter 5 - Fuselage After gluing, clean and roughen the outer surfaces near the horizontal (top and bottom surface) and vertical (left side) stabilizer junction in preparation for gluing. Scale the width of the layers to be laminated by applying BID tapes in 2 layers of 4 inches width, 2 layers of 5 inches wide and more two layers of 6 inches wide (6 layers total) to improve smoothing in these areas for the final aircraft finish.
  • Page 80 Chapter 5 - Fuselage Make a chamfer (this should be about 30 degrees and must be done by removing the backing of the closing panel and the core in order to achieve the angle) on this new edge so that there is no stress concentration in the closing lamination of the same. Lamination a 2-ply 2-inch-wide BID tape around this section as illustrated below.

  • Page 81: Wing Attachment Reinforcements

    Chapter 5 - Fuselage 5.13 Wing Attachment Reinforcers NOTE: WING ASSEMBLY MUST BE PREPARED BEFORE THIS STEP, REFERENCE IN THE WING ASSEMBLY SECTION AND COMPLETE THE REQUIRED ASSEMBLY (It is possible to perform the operation with the wing mounted up to the section 3.10 , however it is recommended to assemble it to the section 3.16 ).

  • Page 82: Placement And Installation Of The Rear Spar

    Chapter 5 - Fuselage After curing, remove the spar from its location, note that the final dimensions of the lamination are marked on the lower side. With a band saw or hand saw, cut along these markings. After completing the process described above, the secondary spar must have its final dimensions and have a channel of ¼''...
  • Page 83 Chapter 5 - Fuselage Another important alignment is the positioning of the wing in relation to the fuselage. Take a reference to the centerline of the aircraft near the vertical stabilizer spar. Measure the distance between this point and two respective points on each wing so that this distance becomes the same.

  • Page 84: Control Console

    Chapter 5 - Fuselage Cut out this spot on both sides. Make 2 lines running through the interior of the fuselage demarcating the position of the spar. Peel off the liner and core between the lines in the region near the cutouts. This operation is carried out to make the lower face of the secondary spar as close as possible to the central casing.
  • Page 85 Chapter 5 - Fuselage front seat to the rear most part of the rear seat and is squeezed between the seat areas on either side. The sides of the console are made from 2 pieces of 2-layer prepreg panel. The contours for these sides are marked in the appropriate section of the panel.

  • Page 86: Assembly Of The Front Seat Back Section

    Chapter 5 - Fuselage Remove the panels and place a MICRO paste over the previously excavated core. Reposition panel in place, test fit. Take advantage of the MICRO paste and make a small radius at the glue places. Laminate these with 2-ply BID tape 2 inches wide (1 inch overlay on each surface).

  • Page 87: Assembly Of The Seat Bottom

    Chapter 5 - Fuselage 5.16 Bottom seat assembly 5.16.1 front seats Cut the front seat back panels from the supplied laminate panel. Take a minimum 3-inch gusset, cut out 12 layers of 4.5 x 4.5” BID for each gusset (there will be 4 gussets for a total of 48 layers).

  • Page 88: Rear Seats

    Chapter 5 - Fuselage 5.16.2 the rear seats The placement of the lower rear seat is also somewhat controlled by the height of the front-mounted panel (reinforcement at the top of the landing gear box), and the location of the rear seat backrest. Place the rear seat against the rear backrest, lower until the lower part of the seat touches the undercarriage reinforcement, mark this inclination for gluing the seat backs.

  • Page 89: Door Buffer Reinforcerment

    Chapter 5 - Fuselage Mark out 100mm in front of the trailing edge of the design for cutting. Cut the “triangular” part through both facings. Outline ½ inch around the design and cut out the inner paneling of the panel and remove the core. Laminate 3 layers of BID on the rectangular part from the inside.

  • Page 90: Alignment

    Chapter 5 - Fuselage position is given by the damper fastener. Make a chamfer around the edges of about 30 degrees as shown below: Prepare a MICRO paste, pass the bottom of the rigid stitch and laminate in place with 3 layers of BID with a 1 inch edge exceeding the dimensions of this reinforcement. 5.17.3 Alignment Level the lower fuselage.

  • Page 91: Gluing -86

    Chapter 5 - Fuselage 5.17 Gluing Preparation for gluing: clean and roughen gluing sections. Make a wet FLOX paste and spread it at the junction with the firewall, the side junction and the junction with the rear fuselage. Realign in place with the help of the clecos, remove the excess from this paste.
  • Page 92 Chapter 5 - Fuselage Laminate the inner contour of this rim with a BID tape of 6 layers 3 inches. If desired, replace 3 inner layers of BID with 3 layers of carbon. Finishing the lid, fitting it into this rim (Do the same finish performed on the BL- 126 frame lid referenced in the section 5.12.6 ).

  • Page 93: Elevator Scale

    Chapter 5 - Fuselage 5.19 elevator scale The desired routing of the elevator push-pull rod and the extreme length of this rod assembly suggests the value of mounting two push-pull rods, with an elbow located behind the seat assembly. This set will stabilize the long push-pull rod, and allow the path to be split into two sections with a good stabilization point near the middle of the span.

  • Page 94: Installation Of The Wing Attachment Eyelets

    Chapter 5 - Fuselage Use the attached figure as a guide, and fabricate the middle elevator lever from a piece of section aluminum provided. Use the rod rod ends to establish the number of washers to provide a good fit on the channel sections. Insert the bushings into the end pivot of the gear lever, and use the mount, with the mounting angles (part KS-3) to help drill the mounting holes (4) for this mount.

  • Page 95: Wing-Fuselage Junction

    Chapter 5 - Fuselage Mark the position of the eyelet centered on the phenolic reinforcement included in the wing spar box and drill a guide hole. After the guide hole, use a hole saw. two inches and drill a hole through the spar box together with the spar. With the wing still in place, make sure the phenolic and rear wing spar are centered.

  • Page 96: Enginecowl

    Chapter 5 - Fuselage 5.22 Engine Cowl After positioning the engine and beke, fit the upper and lower cover of the cowl with clecos provisionally and fit the fuselage leveling with it and aligning it with the engine shaft. 5.23 INTERNAL FINISHES The position of the panel is defined by the fit provided by the front side finishing columns.

  • Page 97: Fuselage - Translations (Includes Mechanics)

    Chapter 6 - Fuselage - Translations (includes mechanics) |||FUSELAGE translations (include mechanics) Assembling the yoke linkage The yoke linkage mounting process is initiated by temporarily installing the yoke mounting brackets (KS-29) to the proper position of the crossover control (KS-30). Position the control cross over the mount against the rear face of the front seat front brace, with the pivot line on the WL -11.5, and the yoke mount centered on the fuselage (careful - elevator actuation rod is not centered on mounting the control cross).

  • Page 98: Flap Mountingbracket

    Chapter 6 - Fuselage - Translations (includes mechanics) Flap Mounting Bracket This is a good time to install the flap actuation arm and lever level selector joint assembly (KS-26). Use the flap sector stamps to demarcate the vertical location for this arm.

  • Page 99: Rudder Cable Route

    Chapter 6 - Fuselage - Translations (includes mechanics) Temporarily screw these bottom mounting holes using a 1/4-inch spacer between the flap selector assembly and the inner console wall. Using the flap selector as a template, drill the hole in the console sidewall for the flap selector’s rear top screw. Make sure any of these mounting holes have a rigid point previously installed.

  • Page 100: Installation Of The Aileron Horn

    Chapter 6 - Fuselage - Translations (includes mechanics) The rudder cables will be routed within these sections of the tunnel at a later stage. The cables will be routed inside a plastic tube, close to each side of the tunnel walls. Be aware! of this requirement in installing and routing other things within the tunnel sections.
  • Page 101 Chapter 6 - Fuselage - Translations (includes mechanics) Mark the location of the hole in the seat front gusset. Insert a 2 inch square rigid point in this position (if this was not done at an earlier time), and drill a 1/4 inch hole. Space the KS-3 arm with the horn link and two washers and mark the mounting holes in the fuselage wall.

  • Page 102: Installation Of The Elevator Push/Pull Polen

    Chapter 6 - Fuselage - Translations (includes mechanics) Elevator push/pull rod installation When the horizontal stabilizer glue is secure, remove just enough material behind the horizontal to allow free elevator travel mounting. On the right side use the elevator and mark the side of the fuselage with the angle of the section across the range, along the stroke of the elevator to cut.
  • Page 103 Chapter 6 - Fuselage - Translations (includes mechanics) with a push/pull actuation stick. This cleans the aircraft’s aerodynamics, eliminating external cables in the rudder actuation. This horn is manufactured from a 1 inch section of “U” aluminum section from the channel provided in the kit.

  • Page 104: Flap Torque Tube Installation Actuation

    Chapter 6 - Fuselage - Translations (includes mechanics) cut holes in the same cave to allow movement of the horn and allow installation of the push-pull tube of the horn. rudder Check operation and fill edge of holes with dry MICRO. The most correct geometry will be ensured if the rudder cables are crossed ahead of this horn, and the...

  • Page 105: Cruiser Flap Pivot Hangers Actuation

    Chapter 6 - Fuselage - Translations (includes mechanics) Dremel on the fuselage side, to allow the tube to protrude through the fuselage surface and operate freely. Repeat this step on the opposite side. CRUISER FLAP PIVOT HANGERS ACTION The location called to mount the flap actuation having assemblies on the rear spar will result in some interference with...
  • Page 106 Chapter 6 - Fuselage - Translations (includes mechanics) exchanged when reassembled. Withdraw your right arm to prepare for the next steps. Sliding the torque tube through the mounting bracket and fuselage hole on the left side. Sliding the actuation flap of the inlet lever arm, and the remaining end mounting bracket inner tube long torque, and pass the tube end through the other fuselage wall, and the...

  • Page 107: Routing Rudder Cable And Installation

    Chapter 6 - Fuselage - Translations (includes mechanics) countersunk screws, installed as before, and the second mounting screw for the center bracket is another #10-32 hex head.. Select the push-rod actuator tab mount (part CS-24) from the included parts, and trim the open tube end such that the nominal length of the assembly will hold the vertical tube actuating arm torque on the retracted tab (forward ) lever position .
  • Page 108 Chapter 6 - Fuselage - Translations (includes mechanics) The rudder cables will be routed against the walls of this section of the tunnel to minimize friction and avoid interference or conflict with any other function of the tunnel. To achieve this, the cables will run inside rigid nylon tubes attached to these WALLS The front of the nylon tube will be held directly by the appropriate means, while...
  • Page 109 Chapter 6 - Fuselage - Translations (includes mechanics) The image above shows one side of the rear tunnel control assembly. t is suggested that this tunnel be constructed in two sections, and a floor; be provided in the section between the rear of the front seat and the front of the rear seat. The function of this floor is to ensure that the control funtions be placed against the incursion of any loose objects that could jam the controls.
  • Page 110 Chapter 6 - Fuselage - Translations (includes mechanics) CONTROL TUNNEL - luggage area. FIGURE - Tunnel of protection for the baggage area. 6.9 - ROUTING RUDDER CABLE AND Page 105 INSTALLATION...
  • Page 111 Chapter 6 - Fuselage - Translations (includes mechanics) The area established behind the back seat to the baggage bulkhead just installed will be the baggage area, and it is particularly desirable to avoid objects carried in this area interfering with control components passing through this area. The main components of concern in this area are the push-pull elevator tube assembly, and the associated horn at the back of the seat, and the rudder cables, which should be exiting the rear seat at the edges of the console assembly.

  • Page 112: Installation Main Gear

    Chapter 6 - Fuselage - Translations (includes mechanics) 6.10 INSTALLATION main gear The main gear must be prepared for installation by locating and drilling for the two roll pins that prevent lateral movements of the main gear. The location for these pins is on the rear edge of the center gear section located vertically over the section centerline and 15.75 centimeters on either side of the gear/planes centerline (LBL and RBL 15.75).
  • Page 113 Chapter 6 - Fuselage - Translations (includes mechanics) FIGURE - Main gear assembly operation The mounting bolts will be located 16.5 inches each side of the aircraft’s centerline (RBL and LBL 16.5), and are 5.5 inches center to center (forward and aft) centered in the molded recess..

  • Page 114: Line Installation Brake

    Chapter 6 - Fuselage - Translations (includes mechanics) misalignment noted. If significant shimming is required, build the mounting surface in the box area of local mounting gear with 3 inch BID pre-lam width. Lightly torque the screws holding the equipment in place and correct any positioning before BID cure. Wipe off excess resin or glass before it becomes fully cured.

  • Page 115: Rudder Pedals

    Chapter 6 - Fuselage - Translations (includes mechanics) This is probably a good time to install the brake lines from the main wheel gear assembly to the master cylinders in the rudder pedal area. Pre measure the proposed routing for the brake lines and cut suitable lengths of the supplied hard nylon tubing for the hydraulic lines (leave a little excess length for possible future cutting and reassembling operations).
  • Page 116 Chapter 6 - Fuselage - Translations (includes mechanics) The mounting pins of the two blocks on the left (pilot side) will also mount the arms for the brake cylinder. Manufacture these 1/8 inch thick aluminum angle arms provided in the kit.
  • Page 117 Chapter 6 - Fuselage - Translations (includes mechanics) to the right side. Study the action of these links very carefully before making any revisions. A U shaped cutout of at least one inch square must be placed on both the front and rear panels of the floor mount.

  • Page 118: Extras

    Chapter 6 - Fuselage - Translations (includes mechanics) cutouts allow the passage of fuel, brake, and other lines or wires between the spar area and the fire wall area. Attach the end panels to the floor mount with a two-inch width of two-ply BID at the corners, and adjust the frame mount fit to the interior surface of the fuselage (close these openings to prevent screws or nuts from going under the floor in most parts.
  • Page 119 Chapter 6 - Fuselage - Translations (includes mechanics) countersunk with countertop sink or Tinnerman washers, walnuts and elastic stop on the inside. Check the required course, and trim any areas of interference. Check rod length actuation for proper rudder position with rudder pedals centered. Verify that this stick and rudder can be recycled through its full course, without interruption or undue rubbing on any structure, and that the rudder travels in the correct direction with the control activation.
  • Page 120 Chapter 6 - Fuselage - Translations (includes mechanics) Prepare two 1.5 by 4 1/4 inch pieces of plywood. Drill a 3-16 hole through the center of the bottom and a washer glue on the top surface centered in this hole. drill a 1/4 inch hole and install the #10 TEE nut in the center of the other plywood section..
  • Page 121 Chapter 6 - Fuselage - Translations (includes mechanics) inside and outside). Adjust the position to the center of the window in the open area of the door opening, using the hinge areas as a guide. ). WINDOW INSTALLATION Select the proper formed window panel, panel A is to the left side. Position the window pane over the window opening, and roughly mark the frame outline over the protective covering.
  • Page 122 Chapter 6 - Fuselage - Translations (includes mechanics) Plastic both the window and the window frame with the adhesive. Carefully position the window in the opening and tape in place until the adhesive cures. Squeeze out any excess adhesive, and wipe off excess and smooth a bead around the edge of the joint. before adhesive cure ..
  • Page 123 Chapter 6 - Fuselage - Translations (includes mechanics) thread UNF 05/16. Cut off the tops of these screws and round the ends of a bullet like rounded tip. It would probably be advisable to “mock up” the system on a board with its dimensions marked as a perimeter.
  • Page 124 Chapter 6 - Fuselage - Translations (includes mechanics) With very careful adjustment to the plunger lengths, and a tapered metal striker plate. a system lock slam can be artificial. However, the increased plunger insertion depth with this current system gives more peace of mind. Test the position of the assembly, and mark the location for the hole where the latch pin of the latch plunger will have to protrude out through the molding of the inner door skin.
  • Page 125 Chapter 6 - Fuselage - Translations (includes mechanics) ends extending from about 1/2 inch of an inch beyond the pillows. Select the door hinges from the hardware provided, fitting the short duration of the hinge to the fuselage in the pad area on the fuselage molding.
  • Page 126 Chapter 6 - Fuselage - Translations (includes mechanics) INSTALLATION OF LATCH BOARDS The lock plate for the door security system for this aircraft is probably best accomplished by gluing a short section of piping to the front and aft door frames. Use about 1 inch long section, or a perforated piece of steel to make a hard locking surface enemy of the locking pin.
  • Page 127 Chapter 6 - Fuselage - Translations (includes mechanics) DOOR OPENING REINFORCEMENTS. To ad rigidity and strength around the bottom corner of the door openings, an added lamination of glass ply reinforcement is recommended. While this is not a flight safety item, these added tarps will reduce cabin shake during engine starting and idle.
  • Page 128 Chapter 6 - Fuselage - Translations (includes mechanics) with the self tapping screws provided. A bit of FLOX “shims” under these brackets can provide a more secure mounting. FIGURE - Installation of strut air in the doors. REAR WINDOWS The rear windows are inserted in much the same way as for the windows in the doors.
  • Page 129 Chapter 6 - Fuselage - Translations (includes mechanics) When the window adhesive cures, remove the staples, and prepare the inner edge of the window for gluing. Use the same procedures for peeling back the protective cover and mask. James Bond on the inner side of the window with a prewetted monolayer BID tape. Make sure this tape covers the holes that were drilled for fixing and filling the outer surface with relatively dry MICRO.
  • Page 130 Chapter 6 - Fuselage - Translations (includes mechanics) manual, so that a standardized layout must be used to ensure the safe operation of the aircraft. . Position of the dashboard is a bit of a personal preference, making sure the clearance is just right for the knees, and enough space is provided behind the dashboard for instrument installation and maintenance.
  • Page 131 Chapter 6 - Fuselage - Translations (includes mechanics) Windscreen The windshield should be one of the last things installed in the fuselage as it will restrict many operations in the cockpit area. Make sure you have planned the rest of your final assembly before securing the plastic in place.
  • Page 132 Chapter 6 - Fuselage - Translations (includes mechanics) FIGURE - Seat belt attachments (REAR are similar) The hard-to-front attachment points of the built-in seatbelt back are located in the lower rear corner of the control sides of the console tunnel. Drill a 1/4 inch hole through the center of this rigid point, and another 1/4 inch hole vertically down through the bottom of the fuselage, into the control tunnel area about an interior half inch of the wall, through the reinforcement BID layer 12 applied in a previous step.
  • Page 133 Chapter 6 - Fuselage - Translations (includes mechanics) flat head machine 1 inch apart to hold a 1/8 inch aluminum strip for belt attachment. fully retracted FIGURE ATTACH TO SEAT’S SHOULDER STRAPS The rear seat seatbelt attach locations are hard points reinforced on the rear seat where lower rear edge attaches to the fuselage at four points as shown.
  • Page 134 Chapter 6 - Fuselage - Translations (includes mechanics) Seat articulation at the rear to keep them in place, but also allow storage or inspection access. FUND REAR SEAT ASSEMBLY The rear seat bottom can be manufactured similarly to the front seat, as single panels on each side of the control tunnel.
  • Page 135 Chapter 6 - Fuselage - Translations (includes mechanics) While many of our builders are opting for remote electrical trim systems (MAC or similar) the standard cut pitch control for this aircraft is implemented using a Bowden wire cable back to a movable guide on the elevator, and the hardware to implement this system.
  • Page 136 Chapter 6 - Fuselage - Translations (includes mechanics) the wire positioned as desired. It’s a good idea to apply a small drop of glue to the strands, and tighten the second “jam” nut in place. Make sure enough of the center wire is exposed from the Bowden housing to ensure full guide fit.
  • Page 137 Chapter 6 - Fuselage - Translations (includes mechanics) FIGURE - Trim Activation Lever - Suggested Assembly Connect the free end of the Bowden center wire to the smaller hole in the lever using a “terminal assembly” as before on the rear control horn. Orient the assembly such that the screw head is towards the tunnel wall.
  • Page 138 Chapter 6 - Fuselage - Translations (includes mechanics) The control console cover is a molded set equipped with the kit. Clean the edges and check adequate space for the control levers that protrude from this cover. Installation is done simply by setting the cover in place, and the seats will sit on the flanges holding it in place.
  • Page 139 Chapter 6 - Fuselage - Translations (includes mechanics) area washer inside the shell surface, and a self-locking nut on the outside of the fairing. An area washer here would support structural ad d but probably not needed. Excess rod trim for a sheer looking job with minimal air resistance. Supported on both sides in this way, the fairing should almost be secure enough to hold up.
  • Page 140 Chapter 6 - Fuselage - Translations (includes mechanics) locate a bolt to attach as far forward as practical on the flat surface on the side of the “fork” (the nose wheel fork has a material separator pointing forward for this end). A “fix”...

  • Page 141: Flap

    Chapter 7 - Flap FIAP Identify the main portions of the kit’s flap parts, and prepare them by removing all peel ply and other debris. The primary components of the flap are the top linings ( C20TR & C20TL ) and lower ( C20BR &C20BL ) for each side, and the rib patterns marked on the 2-ply laminated panel supplied with the kit.

  • Page 142: Spar

    Chapter 7 - Flap 7.1.1 Boom The spar for the flap must be cut from a section of the prepreg panel provided. Cut 89 inches long and 3.5 inches wide, which should be slightly wider in width to be ground into the top surface later to position the top coat.
  • Page 143 Chapter 7 - Flap Adjust the spar and ribs into their respective positions. After satisfactory adjustment, dig the lower edge of them. Make a dry MICRO paste and spread over the hollow edges and under the plywood rib. Laminate the inner surface of the spar and the ribs with 2-ply 2-inch-wide BID tape.

  • Page 144: Flap Actuation Rail

    Chapter 7 - Flap Flap actuation rail See figure for location of rail section and drill 2 holes using flap drive rail as template. The lower corner of the flap rail should be aligned with the lower edge of the rib, with about 1/16 inches of clearance to allow for small adjustments, and the leading edge located 6 inches behind the hinge line.
  • Page 145 Chapter 7 - Flap inside the top coat and sand two inches wide along these lines. If you are satisfied with the fit of the top liner, drill two small holes through both liners near the trailing edge to position the liners during gluing. Excavate the upper core of the spar and ribs.

  • Page 146: Mounting The Hinges

    Chapter 7 - Flap have been balanced to ensure synchronization between the flaps on both sides, before sticking in place at the end. Assembling the hinges Locate the hinges, and locally trim the flap corners approximately 1/16 inches to fit the hinge slightly within the flap surface.

  • Page 147: Preparation For Spar Assembly142

    Chapter 8 - Aileron Aileron The processes for aileron assembly are similar to flap assembly. One of the primary differences between these is the fact that the hinge will be placed on the top surface rather than the bottom as in the case of flap mounting. Ailerons will be mounted DOWN UP. Locate the aileron liners in the kit.

  • Page 148: Initial Assembly Of The Lower Half

    Chapter 8 - Aileron In each flat panel spar section measure from one corner two inches and mark with a vertical line, find another line 4 inches besides this ( 6 inches of the lip). Place the sections on a flat table and cut the liner in this section of 4 inches , also remove the core from it Mix a small amount of MICRO paste and glue the plywood into the opening made, fill any gaps between each end.

  • Page 149: Preparation For The Aileron Control Arm

    Chapter 8 - Aileron Adjust the spar and ribs into their respective positions. After satisfactory adjustment, dig the lower edge of them. Make a dry MICRO paste and spread over the hollow edges. Laminate the inner surface of the spar and the ribs with 2-ply 2-inch-wide BID tape.

  • Page 150: Installation Of Top Coating

    Chapter 8 - Aileron Position the aileron in the correct position on the wing, observe and mark the location of the actuator arm (KS-4) which should be centered on BL 119.5 (The aileron inner edge reference is BL 114 ). This should position the actuation arm to align with the actuation rod location on the wing.

  • Page 151: Closing Of The External Face

    Chapter 8 - Aileron Carefully lower the top liner into place. Align the pins to hold the liner in position and place weights securely over the areas being glued. Wipe off any excess adhesive for future lamination. Closing the outer face Prepare outer surfaces for final closing glue.

  • Page 152: Assembly Of The Aileron Components

    Chapter 8 - Aileron Aileron Component Assembly Remove the glass burrs from the mounting holes for mounting the aileron actuating arm (or drill with a 3/16 bit – do not damage the thread of the locknuts). Install the aileron control arm. In the hinge areas, cut a recess about 1/16 for the hinge cradle.

  • Page 153: Rudder

    Chapter 9 - Rudder 9 Rudder The four-seat aircraft rudder is mounted similar to the elevator or aileron mounting procedures. As with other assemblies, we start by locating and identifying the component parts. The right and left sides should be easily identified by viewing their respective location on the aircraft.

  • Page 154: Assembly Of The Right Side

    Chapter 9 - Rudder 8.10 Right side mount Initial assembly will start with the right side panel. Temporarily secure the panel (outside down) to a flat surface with sergeants. Note that the front counterbalance section should not be contained in the flat position, but the centerline of this front rib should line up with the centerlines of the rear ribs.

  • Page 155: Final Gluing Of Half Of The Right Side150

    Chapter 9 - Rudder 8.11 Final gluing of half on the right side Dig the bottom edge of the ribs and spar, fill with a dry MICRO paste. Laminate with 2-ply BID tape 2 inches wide on the back side for the entire length of the spar. Glue the back and front ribs in place and laminate with 2-ply 2 inch wide BID tape (front rib lamination is inside only).

  • Page 156: Fitting Test

    Chapter 9 - Rudder 8.12 Fitting test: Test the fit of the rudder half against the tail of the fuselage to determine if any thickness correction is needed for the leading edge of the rudder. Sand the top surfaces (50 sandpaper) of the spar and ribs if necessary for a better fit. The rudder thickness should not be so great as to allow interference with the fuselage structure with its movement.

  • Page 157: Final Closing - Gluing

    Chapter 9 - Rudder 8.14 Final closing - Bonding Test the fit of the left casing, noting any interference or other conflicts. When the fit is satisfactory, drill two small holes (about 1/16 inches or less) near the trailing edge of the top and bottom liner to aid in pin placement during gluing.
  • Page 158 Chapter 9 - Rudder After curing, cut the front edge flush with the molded part and cut this corner back 1/16 inch into the 9 inch each hinge location. Test the fit of the hinge location to the rudder hinge line on the fuselage and drill the mounting holes for both sides of both hinges, coordinating both parts.

  • Page 159: Balancing

    Chapter 9 - Rudder Remove the corners where they are exposed and fill with a very dry MICRO paste so as not to run off forming the finishing rays of the piece. Place the pieces in place and allow them to cure. Laminate exposed faces with 2 coats of BID. Allow healing. Trim the spare and finishing material from the part with 100 sandpaper.
  • Page 160 Chapter 9 - Rudder Wet lead with epoxy and MICRO and pour through hole. Position the rudder so the counterweight is down and allow for healing. Take the cut-out piece for the hole, fill with MICRO and fit this into the hole and laminate with a 2-ply BID tape overlapping 1 inch from the edges of the hole.

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