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Sequoia Aircraft Corporation F.8L Falco, Construction Manual

The Sequoia Aircraft Corporation F.8L Falco Construction Manual is a comprehensive guide for building your own aircraft. This detailed manual provides step-by-step instructions and diagrams to help you successfully assemble your Falco. Download the free manual from manualshive.com and start constructing your dream airplane today.

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F.8L Falco Construction Manual

A–2

Revision 4, March 1, 2002

Craftsman Wood Service Co, 1735 W. Cortland Ct., Addison Illinois 60101.  Large supplier of
wood veneers.  Carries over 4000 items including books and tools.  (800) 543-9367

The Xylophile’s Co, 138 East Loudon Avenue, Lexington, Kentucky 40505.  Telephone: (800)
354-9083 or (606) 254-9823.  Mail order machinery and tools—Makita, Hitachi, Inca, Elektra,
Hegner, Leigh, etc.

Gilliom Mfg, Inc, 1700 Scherer Parkway, St. Charles, Missouri 63303.  Manufacturer of Gil-Bilt
power tool kits.  Band saws, tilt/arbor saw, combination drill press-lathe, 6 inch belt sander, 9 inch
tilt table saw, spindle shaper, etc.  Catalogue: $1.00.  Used and recommended by a Falco builder.

Trend-Lines, Inc, 375A Beacham St., P. O. Box 6447A, Chelsea, MA 02150.  Telephone: (800)
343-3248, (800) 322-6100, or (671) 884-8882.  Discounter of power tools, clamps, sanding belts,
etc.  Carries Makita, Pony clamps, Jorgensen clamps, Milwaukee tools, Rockwell/Delta power
tools, Freud saw blades, Hitachi power tools, etc.  www.trend-lines.com

Highland Hardware, 1045 N. Highland Avenue, NE, Atlanta, Georgia 30306.  Telephone: (800)
241-6748 or (404) 872-4466.  Full line of woodworking tools and a very interesting catalogue.
www.highland-hardware.com

Bridge City Tool Works, 2834 N. E. 39th, Portland, OR 97212.  Telephone: (503) 282-6997.
Wood working tools. www.bridgecitytools.com

Woodshop Specialties, Coal River Industrial Park, Quality Lane, Rutland, Vermont 05701.
Dealers for Powermatic, Rockwell/Delta, DeWalt, SandRite, Acme, Hegner, etc.  Telephone:
(802) 773-3240

Woodmaster Tools, 2849 Terrace, Kansas City, Missouri 64108.  24-1/2 inch 3-speed band saw.
www.woodmastertools.com

Bratton Machinery & Supply, 1015 Commercial Street, P. O. Box 20408, Tallahassee, Florida
32316.   Discounter of power tools and hand tools.  Carries Jorgensen, Norton, Greenlee, Hitachi,
Black & Decker, Porter-Cable, Biesemeyer, DeWalt, Makita, Hegner, etc.

Shopsmith Inc, 3931 Image Drive, Dayton, Ohio 45414.  Telephone: (800) 543-9396 or (800)
642-8778.  Manufacturer of 5-in-1 woodworking tool.  Combination table saw, vertical drill press,
horizontal boring machine, lathe and disc sander.  www.shopsmith.com

Kuster Woodworkers, P. O. Box 34, Skillman, N. J. 08558.  Telephone: (201) 359-4680.
Manufacturer of “Dynasand” thickness sander kit, clamp kits, etc.  Free catalogue.

Brookstone Company, Vose Farm Road, Peterborough, N. H. 03458.  Telephone: (603) 924-9511.
Specialize in hard-to-find tools. www.brookstone.com

Seven Corners Ace Hardware, 216 West 7th St, St. Paul, Minnesota 55102.  Telephone: (800)
328-0457 or (612) 224-4859.  Complete line of power tools and clamps. www.7cornershdwe.com

Woodworkers Supply of New Mexico, 5604 Alameda N. E., Albuquerque, New Mexico 87113.
Complete line of woodworking tools and supplies.  Catalogue: $2.00.

Summary of Contents for F.8L Falco

Page 1: ...F 8L Falco Construction Manual...

Page 2: ...F 8L Falco Construction Manual Sequoia Aircraft Corporation 2000 Tomlynn Street P O Box 6861 Richmond Virginia 23230 804 353 1713 Fax 804 359 2618 www SeqAir com...

Page 3: ...ted States of America SequoiaAircraftCorporationreservestherighttorevisethispublicationandtomakechangesfromtime to time in the content hereof without obligation to notify any person or organization of...

Page 4: ...nstruction manual includes what we have written to date In the future it will be expanded to add more chapters When we have the time Chapters 11 12 and 13 will be expanded to take you through the cons...

Page 5: ...hru 18 12 4 March 1 2002 19 1 thru 19 8 4 March 1 2002 20 1 thru 20 10 4 March 1 2002 21 1 thru 21 10 4 March 1 2002 22 1 thru 22 16 4 March 1 2002 23 1 thru 23 40 4 March 1 2002 24 1 thru 24 40 4 Mar...

Page 6: ...understanding of the construction of the Falco We are all indebted to those who have contributed their ideas and comments If you find this manual of assistance remember that much of what you are readi...

Page 7: ...l F 8L Falco Construction Manual Revision 4 March 1 2002...

Page 8: ...he Basic Views 2 2 Sections Views 2 3 Dimensioning 2 4 Water Lines Butt Lines Stations 2 4 General Tolerances 2 4 Not to Scale 2 4 A Few Terms 2 5 The Language of Lines 2 5 A Few Symbols 2 6 Revisions...

Page 9: ...ilt Category 5 1 Notifying the FAA 5 3 Chapter 6 Machining Welding Fabrication Introduction 6 1 Aluminum Alloys 6 1 Steel Alloys 6 1 Bronze Alloys 6 2 Plating 6 2 Welding 6 2 General Tolerance 6 2 Dri...

Page 10: ...oning 10 5 Beveling Plywood 10 6 Staples Nails 10 6 Bending Spruce and Birch Plywood 10 7 Clamping Methods 10 11 Drilling Holes 10 14 Bolt Torques 10 15 Drain and Vent Holes 10 15 Chapter 11 Making Ri...

Page 11: ...9 Noise Suppression 14 10 BNC Assembly Instructions 14 10 Chapter 15 Electrical System Navigation Strobe Light System 15 1 Equipment Installation 15 1 Wire Bundle Routing 15 3 Chapter 16 Tail Group As...

Page 12: ...Wing Assembly 24 5 Skinning the Wing 24 27 Chapter 25 Fuselage Preliminary Assembly Kits on Hand 25 1 Other Materials 25 1 Cowling Supports Installation 25 1 Nose Gear Assembly 25 2 Engine Mount 25 6...

Page 13: ...are and Materials A 4 Engines and Accessories A 5 Appendix B References Aircraft Woodwork The Best Books B 1 Aircraft Woodwork Other Books B 2 Aircraft Construction General The Best Books B 2 Aircraft...

Page 14: ...entrate on the parts you will make and the assembly work you will do There will be many details which will not be clear at first but they will come into focus as you approach the assembly So don t spe...

Page 15: ...have heard many such builders confess that they find the prices of the wood parts very fair now that they know what it takes to build the parts Most builders report that they save about 1 00 to 1 50 p...

Page 16: ...would like to buy a nice one In the back of his mind is this nagging worry about the workmanship that went into the airplane When everything is perfect you can almost name your price A beautifully bui...

Page 17: ...he design process is the critiquing of your own work You need to spend a lot of time studying the design playing the devil s advocate trying to simplify the thing comparing the part to other designs e...

Page 18: ...two rolls of color print film You will find that black and white film does not work well as it is hard to see the details in the wood Shoot photographs from every conceivable angle You will feel fooli...

Page 19: ...esigned airplane or they have learned a lot of short cuts and bad habits which they obligingly pass on We would prefer to be the source of all of your answers This way we can be sure that you are gett...

Page 20: ...me as a shock For this situation we offer the following Sequoia Aircraft Corporation is a business We support all of our builders and in return we expect to have the plans purchased from us We make ev...

Page 21: ...l F 8L Falco Construction Manual 1 8 Revision 4 March 1 2002...

Page 22: ...nstallation drawings These are numbered with a three digit number beginning with the number one Drawing No 102 105 134 etc The sheet number for these one hundred series drawings begin with the letter...

Page 23: ...king at the bottom of the house This is the bottom view and because your hand works the way that it does the house has moved above the original view Each side view works the same way The view from the...

Page 24: ...hat it is a knife Bring your hand down on the section line as if you were cutting the part then turn your hand so that your palm is facing your face This is the way sections are shown This view will r...

Page 25: ...st other aircraft is that the dimensions for the spars ribs fuselage frames etc are given for the undersurface of the skin Thus you do not have to make any allowance for the thickness of the skin of t...

Page 26: ...reviate terms Among the most common are Term Abbreviation As in Radius R 12R or 25 R Diameter or dia 15 375 12dia or 250 dia Inside Diameter I D 34 I D or 25 I D Outside Diameter O D 12 O D or 625 O D...

Page 27: ...h It is the designer s way of saying don t bother An equal sign is used quite frequently on the Falco plans It is always used in conjunction with one or more equal signs and it means that the dimensio...

Page 28: ...looking up the part drawing first in the plans index Also you should be aware that all of the individual drawings tell you where a part is to be found in an installation Each drawing has a note that...

Page 29: ...l F 8L Falco Construction Manual 2 8 Revision 4 March 1 2002...

Page 30: ...s a custom built shop You should not overlook the need for vertical clearance Most garages are 8 feet tall inside The ideal shop would have about 10 feet of clearance The reason for this is that durin...

Page 31: ...you skin the airplane the relative moisture content of the wood structure and the plywood skin becomes important if you want to have a smooth wing Most builders do not have such humidity control but...

Page 32: ...ble at machine tool supply stores These companies specialize in selling such tools to industrial customers Accordingly you will not find them in your local shopping center Browse around the store and...

Page 33: ...or aligning the ribs fuselage frames and other things Plumb bobs are cheap and we suggest you purchase at least four of them When you get to the wing fuselage and tail jigs you will end up with plumb...

Page 34: ...jobs a 1 4 drill is adequate but a 3 8 drill is also nice to have around Drills are available in a big price range and you get what you pay for Some of the cheaper Black Decker Sears and Rockwell Delt...

Page 35: ...8L Falco Kit Price List You will need a few transfer punchs A transfer punch is a special type of punch used to locate the center of a hole It works like a centerpunch but the punch is the exact diam...

Page 36: ...omplete kits there will be few occasions when you have to scarf spruce Scarfs for spruce are normally cut with a saw set at the correct angle and may be finished with a sanding block Air Compressor Be...

Page 37: ...grinder You have to be careful since the grinder will eat wood in a hurry Electric Hand Sander An electric hand sander is handy to have around One that you should like is the Skil No 593 Sand Cat Thi...

Page 38: ...Power Tool Kits For those who would like to save some money and take on another kit you can make your own power tools See the entry for Gilliom Manufacturing in Appendix A There is a wide assortment...

Page 39: ...e a messy substance on your hands The glues are often toxic as well You can obtain disposable rubber gloves from a medical supply company These are very cheap and come a thousand to a box To mix and s...

Page 40: ...ller was a single canoe paddle The builder had made a wooden ramp down the side of the mountain to use for takeoff At the same time these inspectors will also tell you that the finest examples of work...

Page 41: ...here is really no question that you will be doing more than 51 of the work on the airplane If the Rotorway helicopter kits can be approved then we should have little difficulty In our conversations wi...

Page 42: ...ey will also tell you how much lead time they will need to schedule the inspection The number of inspections has changed from one office to another and over time In the past the normal was two or thre...

Page 43: ...l F 8L Falco Construction Manual 5 4 Revision 4 March 1 2002...

Page 44: ...ter strength such as 2014 T6 and 7075 T6 These are commonly available in extruded form and may be used There are a number of machined parts which are made of 2024 T4 aluminum For your information we a...

Page 45: ...e galvanic scale When two dissimilar metals are brought in contact they act like a battery in the presence of moisture The more dissimilar the metals the more electrical charge is created Witness the...

Page 46: ...he Boston Gear bushings We offer these bushings already cadmium plated for less than you can buy the un plated Boston Gear bushings Press the bushings in place with an arbor press Ream the I D after i...

Page 47: ...e your own landing gear legs you will find that the bearing surfaces of the upper tube will warp slightly during welding For this reason it is best to weld the upper tube completely with the oleo brac...

Page 48: ...r your fingernails If you do not use any of these cleaners you may use a detergent solution and flush with water The second step is a phosphoric acid etchant treatment DuPont No 225S Cleaner which cle...

Page 49: ...t For additional protection of steel you may use par al ketone Par al ketone is a thick greasy mess that is used on the most difficult situations and where appearance is not important It is normally u...

Page 50: ...cally from a lumber yard The leading edge cap strip of the ailerons are made of beech walnut or oak The reason for this is that the heavier wood is used as an aileron balance weight These three woods...

Page 51: ...y 80 Relative Humidity 90 Relative Humidity 100 Relative Humidity 40 Relative Humidity 30 Relative Humidity 20 Relative Humidity 10 Relative Humidity 2 1 2 F 2 0 0 F 1 9 0 F 1 8 0 F 1 7 0 F 1 6 0 F 1...

Page 52: ...t of Wood 70 F 141 F 212 F Figure 2 The relationship between relative humidity temperature and the moisture content of wood is shown in Figure 2 in a form that may be easier to understand than Figure...

Page 53: ...t if you work in a heated shop in the winter the wood in your airplane will become very dry Because of the contraction of the dry wood one Falco builder had corner blocks crack and pull away from the...

Page 54: ...ll cause the glue to set up so you have to be careful about that There are two hardeners one normal and one fast The working time depends on the temperature and hardener used you will have from 5 to 2...

Page 55: ...essures Like resorcinol this glue does not have good gap filling characteristics This glue has been used for years on the Pitts Special and is used on the Christen Eagle This was also used on the wood...

Page 56: ...20 F Since the temperature performance of epoxy is marginal if you build your Falco with epoxy you must paint the airplane white to use any other color is foolish and dangerous The experience of woode...

Page 57: ...toxic and a number of builders working in enclosed spaces have had serious health problems involving the central and peripheral nervous systems The mixture is quite critical and requires careful measu...

Page 58: ...nt says that our position is exactly the same as theirs that concerns about the temperature performance of room temperature cure epoxies are valid even though they are not aware of anyone having probl...

Page 59: ...f wood together as shown in Figure 5 The glue blocks should be tested in shear so you would put the blocks in a vise or arbor press or just put them on the floor and hit them with a sledgehammer A tes...

Page 60: ...etain these properties for several years of full exposure to the weather at all altitudes of flight even in the most severe climates The finish should be easy to keep clean and should wear in such a w...

Page 61: ...afford relatively low moisture excluding effectiveness but may provide a significant degree of water repellency Slightly penetrating finishes that form little or no coating over the surface of the woo...

Page 62: ...is that moisture trapped under the film coating causes corrosion in metal Tests by the Forest Products Laboratory show however that polyurethane and epoxy paints have excellent moisture excluding eff...

Page 63: ...ate as the epoxy hardens Using epoxies as both wood glue and moisture protection varnish eliminates the need for masking however if you are using other glues resorcinol Aerolite etc you must still mas...

Page 64: ...ews should be filled before further finish is applied Holes in woods on which the wood filler is applied should be filled sufficiently to protect the wood and the durability of the finish but filler a...

Page 65: ...l F 8L Falco Construction Manual 9 6 Revision 4 March 1 2002...

Page 66: ...ements for the scarf joints First the slope of the scarf joint is of primary importance A slope not steeper than 1 in 15 is considered ideal It is best if you can make all of your scarf joints with a...

Page 67: ...tips of the scarf in adjacent laminations may not be less than 10 times the thickness of the thicker of the laminations See Figure 2 All of the laminations in the Falco are made of strips of wood of e...

Page 68: ...be attached to the plywood with small nails This strip of wood will serve as a guide as it will rest against the edge of the board that is the top of the raised table The table will have a short fence...

Page 69: ...ay be used for scarfing spruce as shown in Figure 5 Some builders have used a similar method by making a jig for scarfing spruce with a portable power plane In these cases the plane is guided by track...

Page 70: ...end slippage Blocking or clamping should also be arranged to minimize side slippage and thus prevent unnecessary waste of material Wood pins of small diameter driven into drilled holes are sometimes u...

Page 71: ...e exaggerated Figure 7 Whenever plywood butts up against anything the plywood should be beveled so that only a slight edge is left at the joint The function of the plywood gussets on the wing ribs is...

Page 72: ...nd they protect the wood from bruising They also help to distribute the load from the staples or nails With wood production aircraft it was the practice to use cotton tape under nails and staples This...

Page 73: ...e bending form is raised 5 Quality of the veneer is increased particulary by minimizing cross grain 6 Technique of bending is improved It should be noted that no constant ratio of radius to thickness...

Page 74: ...ywood takes longer to become thoroughly soaked so you will have to soak it for a couple of days The moderate bends of the elevator and rudder leading edges can be easily made by soaking the plywood an...

Page 75: ...a smooth radiused scarf on the plywood This is not as difficult as it may seem since the layers of wood and glue lines reveal any irregularities Next the skin for the other side is glued in place Aft...

Page 76: ...e wing or tail A few builders complain that these methods are not completely to their liking since the plywood tends to lift from the rib while the leading edge radius is being bent Another method and...

Page 77: ...d The clamping blocks will try to slip so you can clamp a couple of blocks in place to keep them from moving or you can drive a couple of small nails through the clamping blocks so that the ends of th...

Page 78: ...ssure The nut may be epoxied in place and you may tap the wood if you wish These clamps work very well but they have a couple of disadvantages They will not work well with fast setting glues such as A...

Page 79: ...You do not do this with wood With wood you use the proper size drill the first time There are a few places in the Falco where you will have to drill through wood and a steel plate This requires a spe...

Page 80: ...ature of the Falco design this will require that holes be drilled in the tail ribs and at other places to allow air to move about the airplane These holes should be positioned so that they will drain...

Page 81: ...l F 8L Falco Construction Manual 10 16 Revision 4 March 1 2002...

Page 82: ...l of the ribs are drawn full size It is important that the ribs be made to the correct dimensions The paper on which the drawings are printed will expand and contract with changes in the humidity The...

Page 83: ...oo elaborate with the jig just locate the blocks wherever necessary to hold the rib pieces in place and to the exact curvature required There are several methods for drawing the curved lines for the a...

Page 84: ...time Corner blocks if required are also glued in at the same time Remember all birch plywood should be scuff sanded lightly before gluing The rib should be sanded smooth before the gussets are glued...

Page 85: ...ibs Because of the twist of the wing there is no centerline to use as the primary reference Instead you use the horizontal reference line The chord line is a straight line which connects the leading e...

Page 86: ...out the dimensions and draw the curve You want to always maintain your dimensions so you need to draw the centerline and horizontal reference line on the chipboard Later you will transfer this to you...

Page 87: ...nds of the outer laminations at the longeron cutout points With this method you would do the inner laminations one at a time with a scarf joint at each end Aerolite is good for this since it sets up s...

Page 88: ...ven box you must use the same number of divisions on the horizontal side as you do on the vertical side Failure to use the same number of divisions will give you an incorrect curve For most drawings w...

Page 89: ...1 1 1 y B 2 y B 1 1 1 x A 2 If you have a Hewlett Packard HP 11C programmable calculator you may use the program shown in Figure 2 Figure 2 The program does the following Program A Stores A Program B...

Page 90: ...spars so that the tapering occurs on the inner face of the caps This way you have the grain of the wood next to the skin parallel to the skin You may also taper the spars by making the spars with non...

Page 91: ...he plans show the spars with a considerable amount of curvature to the ends These can be made in two ways One way is to bend the spruce by soaking the end and bending it This can be done before the sp...

Page 92: ...y taper the rough spar caps in their fore and aft thickness at this time You should not do more than the rough taper since the parts may not be exactly aligned in the jig when you assemble the spar Pu...

Page 93: ...l F 8L Falco Construction Manual 13 4 Revision 4 March 1 2002 to draw the inside framework of the spar on the outside faces of the plywood Glue on the plywood...

Page 94: ...talling the antenna The antenna may be installed on the inside of one of the side skins between the skin and the ribs or the antenna may be installed on the outside of the skin with a small hole drill...

Page 95: ...sible within the wing VHF communications radio waves are vertically polarized some more than others depending on the transmitter antenna A similar antenna designed by Radio Systems Technology was used...

Page 96: ...d slightly by the splitter The engineer who designed this system considered the possibility of installing two navigation antennas and concluded that the use of one antenna with a splitter was superior...

Page 97: ...d with epoxy glue The plywood sheet should be supported by 10x10 spruce strips and the whole affair may be installed between the ribs in any convenient manner You may find that the most convenient loc...

Page 98: ...suspension and do not touch each other This does not apply to metallic enamel final coatings however No tests have been done for such paints and one Falco was painted with metallic Imron enamel and th...

Page 99: ...or not Those that are not certified for IFR may not be legally used as the primary source of navigation for flight in IFR conditions This does not mean that the Loran may not be on during IFR flight T...

Page 100: ...r easier removal of the panel Figure 1 At the antenna end of the coupler a short pigtail is made using a female BNC connector coaxial cable and two ring terminals The coaxial cable should be as short...

Page 101: ...ht well detract from the reception It does not matter if the antenna wire is run around the hinges or up and over the ribs You will find that you will have to snake the antenna wire around things and...

Page 102: ...s of the electrical system the length of the wire to a ground bus is not important but it is important in this situation Grounding the elevator and rudder cables at the forward ends will not work Try...

Page 103: ...oise sensitive pulse in the midst of a lot of crackles and pops These come from lightning and from the devices installed in the airframe The Falco s electrical system is extremely quiet and generates...

Page 104: ...against the end of the outer cable insulation Figure 6 Comb the shielding out and fold back smoothly over the clamp Trim off any excess shielding that extends past the clamp Figure 7 Slip the male or...

Page 105: ...14 12 Revision 4 March 1 2002 Figure 8 Push the assembly into the body as far as it will go Slide the nut into the body and screw in place with a wrench until tight For this operation hold the cable a...

Page 106: ...s are widely available and may be purchased from many different suppliers You will find however that the prices will vary widely Wag Aero and San Val Discount Aircraft Parts have very competitive pric...

Page 107: ...o 5 Landing gear up relay on forward face Landing gear down relay on forward face Fuse holder on forward face Terminal block optional on aft face Frame No 6 Master relay Starter relay Strobe power sup...

Page 108: ...nk The aft bundle will be routed through the holes in the main wing spar to the aft face of frame No 6 Wires will be split off from the bundle as required for the wing tip lights heated pitot micropho...

Page 109: ...l F 8L Falco Construction Manual 15 4 Revision 4 March 1 2002...

Page 110: ...rsity of correct procedures The assembly method presented in this and subsequent chapters is a method that is in constant revision Every builder is urged to comment and offer suggestions for faster si...

Page 111: ...th the leading edge up The ribs are fitted and glued to the spar with the ribs plumbed with a plumb bob All of the spars and ribs have the centerlines drawn on them so it is a simple matter to line th...

Page 112: ...s vertical tail section first When the horizontal tail was assembled a block of wood was used as a spacer between the two stabilizer spars to make sure that they were the correct distance apart The ve...

Page 113: ...edge strip is considerably less stiff than the 30mm strip For this reason it is advisable to support the trailing edge strip during skinning The original drawings showed plywood pads under the hinges...

Page 114: ...k on the Sta 1 stabilizer rib To simplify the construction the drawings now show the tube epoxied to a block of spruce in the main stabilizer spar but the screw and clamp method may still be used Ther...

Page 115: ...inges in the tail group you may think that some of the bolts are too long In the Falco we use MS21042 nuts These nuts are shorter than the nylon stop nuts used on most production aircraft The nuts tha...

Page 116: ...p once the plywood is glued on Glue plywood on forward face of the spar and add plywood pad on the forward face at Sta 4 Scuff sand the plywood prior to gluing Draw centerline on forward and aft face...

Page 117: ...the spar Draw W L 70 on aft face and on the sides of the spar This is to align the forward horizontal stabilizer spar Draw the cutouts for the bottom and side longerons Cut out the longeron cutouts Ch...

Page 118: ...p length of the bolts it seems to be a good idea Scuff sand the plywood prior to gluing Draw spar centerline on forward and aft face of the spar Draw aircraft centerline on forward and aft face of the...

Page 119: ...nstalled at an angle there is a change in the true fore and aft dimension Also the gap in the ribs at the fin Sta 1 and stabilizer Sta 0 does not match the thickness of the forward spars These ribs ar...

Page 120: ...w See Drawing No 403 These two parts may be made as one lamination of spruce and cut apart prior to installation If you don t want to make a lamination these parts may be made of solid spruce If not a...

Page 121: ...Skin 230 Figure 3 Use one 50 x50 sheet of 1 2mm birch plywood and cut in accordance with Figure 3 320 250 Rudder Leading Edge Skin grain 500 450 grain Bottom Rudder Skin grain 350 475 Elevator Traili...

Page 122: ...Stabilizer Skin Figure 5 Use two 50 x50 sheets of 1 5mm birch plywood and cut in accordance with Figure 5 885 780 325 Fin Skin grain 940 780 300 grain Fin Skin grain 1125 250 Elevator Leading Edge Ski...

Page 123: ...ain Stabilizer Skin 660 grain Stabilizer Skin 225 225 225 225 100 100 100 100 690 typ 660 Figure 7 Use one 50 x50 sheet of 1 5mm birch plywood and cut in accordance with Figure 7 150 grain 500 Elevato...

Page 124: ...sure that the stabilizer spar is perpendicular to the fin spar This can be done with a square but it is much better to check the alignment in other ways If the fin spar is held in a vertical position...

Page 125: ...channel nuts for P N 756 To keep from moving anything at this critical stage the screws for the channel nuts should not be installed at this time Re assemble the hinges with the hinge bolts Check the...

Page 126: ...with P N 751 by installing the 1 4 hinge bolt The rudder stop should be in place at this time Assemble P N 757 hinges to P N 753 by installing the 1 4 hinge bolt Figure 2 Clamp these hinges to the fi...

Page 127: ...1 4 hinge bolts and carefully drill the 3 16 holes for P N 757 hinges Install the channel nuts for P N 757 To keep from moving anything at this critical stage the screws for the channel nuts should no...

Page 128: ...have attempted to omit the spacers to their eternal regret Don t do it When the elevator is in the full up position the lower elevator control cable must pass between the two balance weight support ar...

Page 129: ...in line with the lower control cable hole Figure 6 Place one P N 825A arm on the elevator balance weight and drill the two 5 32 holes through the balance weight See Figure 6 Note In the following step...

Page 130: ...the hole with a No 21 drill 159 Use a clamp to hold these control arms in place Figure 8 Clamp the balance weight in place See Figure 8 Use a 5 32 drill bit to align the rivet holes Make sure that th...

Page 131: ...16 deflection can be checked with a combination square Since only one hole is presently drilled in P N 750 there is still some adjustment that can be made The holes should be reamed up to 3 16 Some sl...

Page 132: ...bottom of the slot of the fin spar must be sanded for clearance with the elevator balance weight arms At the top of the slot the upper center fuselage longeron must also be sanded to provide clearanc...

Page 133: ...l F 8L Falco Construction Manual 17 10 Revision 4 March 1 2002...

Page 134: ...enings after the elevator is skinned Figure 2 In the following steps the trailing edge ribs will be installed on the spar It will be important that you maintain the alignment of the trailing edge You...

Page 135: ...the aircraft As you can see from Drawing No 403 the forward face of the closing spar is located 90mm forward of the trailing edge The ribs at Sta 1 and 3 should be installed with the plywood toward th...

Page 136: ...ote In the following steps the elevator trim tab spar and ribs will be installed followed by the trailing edge strip It would seem to be best to install the hinges and then install the ribs trailing e...

Page 137: ...he outboard ribs may be clamped to the elevator ribs using a 3mm shim or temporarily glued to be separated later See Figure 6 Figure 6 Install the elevator trailing edge strip See Figure 7 Figure 7 In...

Page 138: ...s capable of making a sharper bend than is possible with other methods If you wish you may glue a piece of plywood on the spar at the center This will make the installation of the center trailing edge...

Page 139: ...ty job Most builders support the spar off the edge of the jig table with the 20x20 extensions This keeps the spar nice and straight It also requires greater planning in the clamping method to be used...

Page 140: ...ywood wrap around the tip bow which can be sanded to a blunt wedge After the plywood is glued in place the tip is sanded to the final radius After the leading edge skin is glued in place the ugly lead...

Page 141: ...arnishing You should also draw the internal structure on the outside of the skin for stapling or nailing at installation Glue this 2mm skin in place Scuff sand the plywood prior to gluing Glue the 10x...

Page 142: ...ed to work only with the blunt type B screws The nuts were glued in place with epoxy then a small rectangular piece of plywood with a rectangular hole fitted around it and covered with another piece o...

Page 143: ...cut the plywood roughly to size Draw a line down the center of the piece to mark the bend Because the bend is so tight it is a good idea to sand away the first layer of veneer on the inside of the be...

Page 144: ...oes nothing for the speed of the airplane Install P N 775 on the trim tab See Drawing No 402 Section C C Cut the trim tab from the elevator Drill up from the bottom to locate the slot to cut in the to...

Page 145: ...l F 8L Falco Construction Manual 18 12 Revision 4 March 1 2002...

Page 146: ...e forward stabilizer spar and the main stabilizer spar At the main fin spar the longeron will be the same as it is under the main stabilizer spar Figure 1 Install the triangular strips on the aft face...

Page 147: ...In the following steps you will be looping a string over these ribs to align the inboard ribs as shown in Figure 5 and 7 Since the tension of the string will pull the ribs over we suggest you make a w...

Page 148: ...ane If confused see Drawing No 410 Section B B Glue the intermediate ribs for Sta 3 in place Loop a string over the ribs to locate the centerline of the inboard ribs The ribs should be braced for the...

Page 149: ...Sta 1 and 6 This is to align the remaining ribs See Figure 7 Figure 8 Fit the remaining ribs See Figure 8 If you wish you may fit the Sta 0 ribs see Drawing No 401 but these ribs are not installed un...

Page 150: ...ge strip wood block rib wood block in gusset pocket wood block Figure 10 Glue the ribs to the main stabilizer spar and to the forward stabilizer spar Do not glue the Sta 0 ribs in place at this time S...

Page 151: ...he tube close to the final length and angle for easier trimming with a portable disk sander The original drawings showed the trim tab cable tube attached to the Sta 1 intermediate rib with a clamp If...

Page 152: ...ior to bending the leading edges Remember the plywood has waterproof glue between the layers and this prevents the plywood from soaking up water as quickly as spruce Mask off the top skins for varnish...

Page 153: ...of the stabilizer to Sta 1 Scuff sand the plywood before gluing Drill drain holes in the bottom skin These are normally 1 4 holes although 1 8 may also be used Varnish the inside of the bottom skin C...

Page 154: ...dorsal fin is a strip of spruce similar to the leading edge strips of the wing and tail At the base of the dorsal fin you will need some 10x10 gluing strips glued to the top of the fuselage skin As th...

Page 155: ...ribs On the rib above the upper hinges be sure to observe the 80mm dimension so that you have sufficient room to remove the hinge bolt See Drawing No 411 See Figure 1 Scuff sand the plywood before gl...

Page 156: ...that the trailing edge strip is 30mm wide and each rib is joined to it by a 15mm deep notch in the trailing edge strip Figure 5 Fit the trailing edge ribs for Sta 0 and 5 See Figure 5 The Sta 0 rib m...

Page 157: ...r varnishing Fit the 1 5mm plywood skin on the aft face of the spar doublers Note on Drawing No 411 Section B B that a 1 8 vent hole is drilled in this skin Varnish the interior surfaces of the spar b...

Page 158: ...nned with a piece on each side of the rudder to facilitate the compound bend at the upper corner If each separate area is skinned with a separate piece of plywood you will use less plywood but it will...

Page 159: ...skin is a little tricky If you attempt to skin this area with a single piece of plywood wrapped around the leading edge you will find that the skin will pucker out away from the leading edge near the...

Page 160: ...th and epoxy resin to make the two fairings These are P N 857 1 and 857 2 See Drawing No 857 and 410 Make the fairing oversized for trimming at the final installation See Figure 12 Figure 12 Scarf the...

Page 161: ...tip bow Use a steam iron and the same method used on the leading edge tip skins Use alignment pins for the left trailing edge skin and mask the inside for varnishing Draw the internal structure on the...

Page 162: ...it looks better if made in one piece Start by making a pattern of cardboard and then cut the plywood roughly to size Draw a line down the center of the piece to mark the bend Because the bend is so t...

Page 163: ...The simplest installation is to epoxy the nuts in the wood As an alternative you could drill and tap a short piece of 3 16 aluminum and epoxy this in place One other possibility hardware stores sell s...

Page 164: ...he stabilizer there will be plenty of working space around the fin while you are assembling it The third way is to build the fin with the stabilizer clamped in place This method is the same as the fir...

Page 165: ...e the spar near the edge of the jig table or use 20x20 extensions from the table Use a water level to level the main fin spar Use a water level to make sure that the stabilizer is level block and clam...

Page 166: ...n spar is tapered you cannot use a carpenter s square against the forward face to align the rib since this would result in the rib tilting A combination square could be set to the correct angle and a...

Page 167: ...is string Figure 5 Fit the intermediate rib for Sta 2 in place See Figure 5 Trial fit the forward fin spar to the ribs This will require that the alignment string be removed temporarily Sand the forwa...

Page 168: ...ace These ribs must be placed very accurately since they will be used to align all of the ribs in between See Figure 7 Figure 7 Sand the ribs to the correct angle for the leading edge strip Glue the l...

Page 169: ...When the leading edge strip is finally installed it will be somewhat difficult to clamp Because of the angle between the ribs and leading edge strip the ribs will tend to squirt inboard To keep this f...

Page 170: ...g edge strip must be sanded to a smooth radius The fin tip bow does not need to be sanded to an exact radius It should be tapered for the skin to make a blunt wedge shape in cross section After the sk...

Page 171: ...areas directly under the antenna tape Mask the left skin and varnish all areas that will not be glued Figure 11 Varnish the entire structure of the fin except for the surfaces to be glued when the ski...

Page 172: ...the COM antenna on the inside of the right skin Varnish the inside of the right skin The next step will be to close the fin so you must check to make sure that all internal surfaces are varnished Feat...

Page 173: ...l F 8L Falco Construction Manual 21 10 Revision 4 March 1 2002...

Page 174: ...llowing sheets of plywood 1mm birch plywood 3 sheets 48 x48 or 50 x50 2mm birch plywood 2 sheets 48 x48 or 50 x50 We also suggest that you review the kit requirements of Chapter 25 Wing Preliminary As...

Page 175: ...od Others have used threaded steel rods or wooden dowels for the same purpose Clamp all hinges in position on the aileron flap and aft wing spars Check to make sure that the hinges are working smoothl...

Page 176: ...Re assemble the hinges with the hinge bolts and check for smooth operation of the hinges Remove the hinge bolts and drill the 3 16 bolt holes for P N 744 Install the channel nuts for P N 744 Do not in...

Page 177: ...skinning since they will interfere with float sanding and the jigging method Cover the threaded ends of the channel nut bolts with masking tape to protect them from glue during assembly Prime the cha...

Page 178: ...g edge of the aileron flap assembly will include enough extra length for the wing This will simplify the alignment of the trailing edge and insure that the wing aileron and flap will be aligned Figure...

Page 179: ...p at each station to the dimension shown as A in Figure 5 Figure 6 Make a number of angle guides for the ribs by cutting some scrap pieces of wood to 81 1 use the method shown in Figure 6 if you do no...

Page 180: ...eron flutter and that can lead to inflight airframe breakup and fatalities Mark the 95 chord station on each trailing edge rib as shown on the drawings These marks will be used to position the notched...

Page 181: ...aileron ribs See Figure 8 The channel nuts for the aileron and flap hinges should be permanently installed After the diagonal trailing edge ribs are installed most of the channel nuts are difficult to...

Page 182: ...dpapered end will rest on the adjacent rib while you sand the notch A good size of sanding stick to make is 20x20x480 and glue a 20mm wide by 11 long strip of sandpaper to one side sandpaper comes in...

Page 183: ...of the trailing edge but you can work on a short section at a time and leave the rest in clamps Screw a few blocks to the table against the spars and ribs to keep the assembly from sliding around whi...

Page 184: ...he skinning will completely cover the joint between the aileron and flap You do not want to lose track of where to cut Figure 16 Turn the aileron flap assembly around so that its lower surface faces a...

Page 185: ...hinge openings See Figure 20 The leading edge strip should not be cut at this time All you want to do is expose the spar for clamping to the 20x20 jig supports for the next skinning operation Trim the...

Page 186: ...flaps There are occasional builders who skin the ailerons and flaps free of any jigs but very few have been successful at maintaining the alignment Trust to luck if you will but it seems to us to mak...

Page 187: ...e skinning of the trailing edge All you want to do is expose the spar for clamping to the 20x20 jig supports for the next skinning operation Figure 26 Scarf the upper leading edge skin for the trailin...

Page 188: ...Some builders use heavy gauge aluminum angles find something that is straight and use it Figure 28 Fit and install the lower trailing edge skin between Sta 6 and 10 See Figure 28 Figure 29 Fit and ins...

Page 189: ...dge skin between Sta 10 and 14 See Figure 32 Figure 33 Cut out the hinge openings See Figure 33 Trim the trailing edge skins at the trailing edge Trim the skins off flush with the trailing edge strip...

Page 190: ...2 Additional spruce for wing walk access panel corner blocking and other minor framing We also suggest that you review the kit requirement of Chapters 24 Wing Assembly and Chapter 25 Fuselage Prelimin...

Page 191: ...ssure build ups in the front part of the wing as well as in the spar itself Mask off and varnish all internal surfaces that will not be glued on the front wing spar Close the front wing spar Mark the...

Page 192: ...he spar Draw a straight line connecting the chord line at Sta 1 and 14 on the forward face of the spar Locate and mark the final trim lines for each station Mark these on the forward and aft faces of...

Page 193: ...important that the B L 927 5 be used or the screwjacks will not come out right Measure down 85mm from the top of the spar to locate the center of the hole for the landing gear fittings see Drawings No...

Page 194: ...ause there might be some minor differences in the vertical position of the landing gear fittings on the forward wing spar you may temporarily install P N 768 on the forward face and P N 767 on the aft...

Page 195: ...spar level the spar and drill another hole etc It is quite easy to level the spar with a water level on each end of the spar Leveling the spar in the other direction is more difficult If the forward f...

Page 196: ...be reamed to 5 16 The best procedure is to ream the holes of the part to be used as the drill guide then ream the opposite part in place Drill the holes for P N 772 1 through the main wing spar Use t...

Page 197: ...les in fuselage frame No 4 as shown on Drawing No 305 Due to the routing of the rudder cables the 3 8 holes are drilled in different locations than on the main wing spar The 25x50 holes should match t...

Page 198: ...equal to or greater than the cross sectional area at wing Sta 1 so don t worry about this From Sta 1 to Sta 14 sand the top and bottom of the spar as shown by the trim lines and to the contour shown...

Page 199: ...illed on a drill press If the bolts are parallel P N 520 2 will be easy to remove from the bolts If the bolts are skewed slightly the gearbox housing will be difficult to remove requiring the bolts be...

Page 200: ...ar See Figure 12 The locations for the seat track supports are shown at fuselage frame No 5 on Drawing No 310 and these same dimensions are used for the aft face of the main wing spar Drawing No 102 a...

Page 201: ...25 on fuselage frame No 3 as shown on Drawing No 304 Cut the six longeron cutouts in fuselage frame No 3 As with frame No 4 a master template should be used to locate the longeron cutouts See Figure 1...

Page 202: ...ge frame No 3 can be aligned with the aircraft centerline on fuselage frame No 4 Trim the front wing spar so that it matches the inside contour of frame No 3 Figure 16 Drill the 3 8 holes for the rudd...

Page 203: ...ckets on the aft face of the front wing spar Use a drill press to drill these holes To assure alignment P N 701 should be in place during this drilling See Figure 17 Figure 17 Install the rudder cable...

Page 204: ...ry minor point but it does merit some thought and planning Also note that there will be a piece of wood installed on the aft face of frame No 3 above the forward wing spar and below the lower side lon...

Page 205: ...face of fuselage frame No 3 as shown in Figure 18 which shows the aft face These are gluing strips to pick up the inside fuselage skin View A A of Drawing No 157 shows the area where these strips will...

Page 206: ...looring support on the aircraft s right side interferes with drilling P N 717 Fuselage Frame No 5 Figure 21 Glue plywood on the forward and aft faces of fuselage frame No 5 Cut the five longeron cutou...

Page 207: ...fuselage frame No 5 as shown in Figure 22 The relays should be installed so that the small field terminals are on the inboard side and the gear up relay should be on the right side of the aircraft Wi...

Page 208: ...two 20x20 spruce strips to each side of the bottom center longeron as shown in Figure 24 See Drawing No 310 Because these cutouts are also for the wheel well rings they are wider than the 20x20 spruc...

Page 209: ...se the rings are installed with the center of the axle and therefore the center of these rings forward of the frame the slots for the rings are at an angle The slots for the upper rings should be 15mm...

Page 210: ...er to ream the bushing of P N 760 Drill an extra 3 16 hole in the base of each P N 762 as shown on Drawing No 120 To have both parts the same you may match drill the parts by first drilling one part t...

Page 211: ...talled on the aircraft centerline with the screw holes 200mm above W L 440 Drill screw pilot holes for the ammeter shunt install the screws and then remove The ammeter shunt is installed on the left s...

Page 212: ...at the upper aft surface of this part is installed at W L 440 the same vertical position as the 20x15 member of frame No 6 On the forward face of fuselage frame No 6 install saddle gussets for the aft...

Page 213: ...minary Assembly Control Stick Assembly Cut off the top of the control sticks to match the rubber grips supplied See Figure 31 The bottom of the rubber grips should be at the top of the bend At the tim...

Page 214: ...drill the hole for the roll pin One technique that you might want to consider is to use Loctite to bond the gear to the shaft after it is correctly aligned In a few hours the Loctite will harden and...

Page 215: ...t is very easy to over ream with the tapered reamer This is particularly true when an electric drill is used Use a very slow speed and proceed very cautiously For best results use a variable speed dri...

Page 216: ...the roll pins Note The best way to align miter gears with each other is with a single thickness of kraft paper You literally cut a strip of paper from an ordinary grocery bag and press it between the...

Page 217: ...the housing to prevent the gear from moving Always use some mechanical means of preventing the shafts from moving One method that has been used with great success by Falco builders is to drill and ta...

Page 218: ...eft side of the airplane is turned so that the gearbox s shaft and gear is turned until the slotted end of the screwjack sleeve is exactly vertical Then the screwjack on the right side of the airplane...

Page 219: ...elts and turn the drill by hand Figure 38 Install P N 513 1 on the universal joint for the right side of the airplane See Figure 38 This screwjack has left hand threads The end of the screwjack has a...

Page 220: ...N 520 7 miter gear in place as shown in Figure 41 Align the hole in the miter gear with the hole in the shaft Drill through with a 11 64 drill and then ream with a 3 16 drill Install the roll pin You...

Page 221: ...e that the shaft is properly aligned turn the screwjack on the left side of the airplane so that the screwjack end fitting s slot is exactly vertical check to make sure that the screwjack sleeve is st...

Page 222: ...Trial fit P N 723 in the hole at the top of the landing gear leg The washer welded on the gear leg has a machined flat to keep the oleo pin from turning You may have to file on the flat to get things...

Page 223: ...the main wheel by loosening the six bolts Shake some talcum powder inside the tire Install the inner tube in the tire Place the tire and tube on the side of the wheel with the hole for the inner tube...

Page 224: ...bushing with a 3 213 drill then tap with a 1 4 28 tap The grease fitting should be installed on the inboard face so you will have to drill a new hole on one P N 766 Install the straight grease fitting...

Page 225: ...se a 1 2 plastic tubing in place of the 3 8 tubing 2 Install two conduits of 3 8 tubing in each wing one for the strobe light wires and one for the other wires 3 Install the strobe light wire permanen...

Page 226: ...nna on outboard face of Sta 3 and inboard face of Sta 4 in right wing DME antenna on Sta 5 rib in left wing Nav and com antennas on Sta 9 10 11 and 12 ribs aft of the main wing spar See Chapter 24 Fig...

Page 227: ...ut in accordance with Figure 46 Sta 1 to Sta 6 Bottom Wing Skin Grain Direction Sta 6 to Sta 10 Upper Wing Skin Grain Direction Sta 10 to Sta 14 Upper Wing Skin Grain Direction 550 310Bottom Wing Walk...

Page 228: ...then cut the wing skin to fit the aircraft Grain Direction Sta 10 to Sta 14 Bottom Wing Skin 680 Wing Tip Skin 250 680 Wing Tip Skin 250 300 Wheel Well 200 300 Wheel Well 200 Grain Direction Sta 10 to...

Page 229: ...l F 8L Falco Construction Manual 23 40 Revision 4 March 1 2002...

Page 230: ...mbly of the wing so it might be a good idea to read this entire chapter before making the jigs The fuselage centerboard see Figure 1 is made of 1 or 3 4 plywood It is essential that the jig be constru...

Page 231: ...enterboard for these braces Note that the brace for fuselage frame No 6 is for the aft face thus it is 17 4mm aft of fuselage station 6 These horizontal braces should be glued in place and supported w...

Page 232: ...pieces for easy dissassembly Bolt plywood plates as shown on Figure 3 and then saw the template into two pieces As an alternative the template may be made entirely of boards 1366 5 303 5 246 5 820 10...

Page 233: ...ll have to lift the front spar slightly to install the intermediate leading edge ribs You should install the main landing gear legs to make sure that the landing gear fittings are in the proper alignm...

Page 234: ...ear fittings should be installed on the front wing spar The four control stick support brackets should be installed on the aft face of the front wing spar The rudder pulley brackets do not have to be...

Page 235: ...tring tight and extend it to the fuselage centerboard Drill a hole in the fuselage centerboard Pass the leading edge alignment string through the hole in the fuselage centerboard and continue it to th...

Page 236: ...spar the rib is installed slightly outboard of the rest of the Sta 1 ribs In Figure 6 and all subsequent illustrations in this chapter the supports of the centerboard are not shown for frames No 3 4 a...

Page 237: ...3 and 4 in place as shown in Figure 7 Sand the aft faces of the ribs as necessary for alignment with the leading edge alignment string Figure 8 Clamp the remaining leading edge ribs in place as shown...

Page 238: ...p or bottom of the wing to stabilize the ribs and to keep them from racking over remember top or bottom refers to the top or bottom of the wing in its normal position in the aircraft not in the jig Gl...

Page 239: ...blocks may be continuous from the top of the wing to the bottom This is the simplest installation but it is also the heaviest The best approach is to make the corner blocks so that they are the same t...

Page 240: ...n the two tubes with each other Figure 13 Drill the torsion tubes for the two AN3 15A bolts See Drawing No 709 1 Some of the flap torque tubes are made with the smaller diameter tube shorter than inte...

Page 241: ...lace on Sta 2 wing rib See Figure 14 Sand the ribs so that they are aligned with the trailing edge string Figure 15 Trial fit the aft wing spar in place If not previously done the aft wing spar must b...

Page 242: ...to fit the aft wing spar Remove the aft wing spar Check to make sure that the chord lines of the ribs for Sta 1 and 14 align with the trailing edge string Glue the ribs for Sta 1 and 14 to the main w...

Page 243: ...ve the rib and drill the four 3 16 holes on a drill press If you wish you may start drilling the holes with all parts clamped in the wing to assure that you have the supports in the proper position bu...

Page 244: ...in in place as long as possible and should be used to check the alignment while skinning In the following steps leading up to the skinning of the wing you will do a number of minor installations wheel...

Page 245: ...f what type of wheel well is planned These stringers are bowed into place that is they take a bend that follows the curve of the bottom of the fuselage Figure 20 Glue the two 20x20 spruce members on t...

Page 246: ...well rings in place See Figure 22 Because of the contour of the seat supports these rings are installed at an angle with the front end higher than the aft end To make things work out right the ring i...

Page 247: ...pen air wheel well installation fit and install the lower wheel well ring See Figure 23 At the aft end of the wheel well install a 20x10 spruce post between the upper ring and the lower ring This will...

Page 248: ...door installation glue the 60x15 inboard supports and the 75x15 spruce strips in place Figure 26 For wheel well door installation fit the upper wheel well ring This ring must be notched to match the u...

Page 249: ...om of the airplane install a 20x20 spruce post to make the corner with the wheel well skin The aft wheel well skin will be glued to the aft face of this post then the inboard skin will be glued in pla...

Page 250: ...d of the opening for the landing gear See Figure 30 for clarity all framing on the upper side of the wing has been eliminated from this illustration On the bottom of the wing install the framing for t...

Page 251: ...and Drawing No 202 Glue P N 202 2 P N 202 3 and the wing tip bow in place Install the wing tip navigation and strobe lights Glue the corner blocks shown at the outboard ends of the main wing spar and...

Page 252: ...t aileron cable must be installed with the bolt head on the bottom Check that the control cables are centered on all of the holes drilled in the wing ribs Adjust the holes as needed with a round file...

Page 253: ...d finally with a 21 drill Deburr the hole by lightly twisting a larger drill in the holes and insert the rivet If you do not have a rivet gun you may set the rivet with a hammer although it is best to...

Page 254: ...foil element is glued to the inboard face of the Sta 9 and 12 ribs again sandwiched between two plywood or spruce strips Install spruce corner blocks to reinforce the corners of the antenna Install th...

Page 255: ...see Drawing No 315 is removed Sta 10 11 Sta 9 12 Figure 37 Install the VHF NAV antenna in the right wing See the instructions in Chapter 14 Antenna Installation See Drawing No 160 and 161 As shown in...

Page 256: ...is what causes the wing skin itself to be smooth Fit the upper wing skin for Sta 1 to Sta 6 This will require a 50 x50 piece of 2 5mm birch plywood An extra piece of plywood at the trailing edge must...

Page 257: ...that the skin would be flat around the opening and would not be the proper wing contour Scarf the lower wing skin for the next inboard and next outboard skins Bend the leading edge for the lower wing...

Page 258: ...e channel nuts may be bedded down in and coated with epoxy Cut openings in bottom wing skin between Sta 1 and 6 for the side load fittings Figure 38 Glue on the bottom wing skin between Sta 1 and 6 Ch...

Page 259: ...1 and 6 Check the alignment of the wing After this skin is glued on the wing will be torsionally rigid from Sta 1 to 6 and reasonably rigid on the un skinned outboard section Use plywood nailing strip...

Page 260: ...h the inside surface of the upper wing skin between Sta 6 and 10 Figure 41 Glue on the bottom wing skin between Sta 6 and 10 Check the alignment of the wing Use plywood nailing strips over the scarfed...

Page 261: ...per wing skin clamped in place Install two small nails as alignment pins so that the skin may be glued in place accurately Trace the outline of the ribs and spars on the inside surface of the skin for...

Page 262: ...e bottom wing skin as shown on Drawing No 201 Sheet 2 Figure 44 Remove the aileron and flap from the wing by sawing the trailing edge strip Separate the aileron and flap from each other by sawing then...

Page 263: ...on for closing the wing between Sta 10 and 14 varnish the inside of the bottom wing skin and all interior surfaces of the wing except for those areas to be glued At the leading edge and at the tip of...

Page 264: ...2 Figure 46 Feather sand the leading edge to a smooth radius Install the stall strip See Drawing No 201 Sheet 2 Use a back rabbet bit and rout the plywood for the three access panels in each wing Figu...

Page 265: ...angle to match that of the upper wing skin in the center Cut and fit the upper wing skin between wing Sta 1 and the outboard seat support See Figure 50 This skin must be soaked in water and clamped i...

Page 266: ...100mm forward of the forward face of fuselage frame No 6 cut it to match the seat support This will provide clearance for the rudder cable and access to drill the flap motor and torque tube mounting...

Page 267: ...with the grain direction fore and aft You will need a little extra material on the inboard and outboard end say 30mm or so for clamping while the end is being bent The extra material on the outboard...

Page 268: ...for the upper tip skin This scarf is a rounded type of scarf due to the radius of the wing tip Mask and varnish the inside surface of the upper wing tip skin In preparation for closing varnish the in...

Page 269: ...l F 8L Falco Construction Manual 24 40 Revision 4 March 1 2002 Install the wing tip lens Remove the wing from the jig and place in a horizontal position in preparation for the fuselage assembly...

Page 270: ...stainless steel Asbestos or Fiberfrax ceramic paper insulation is installed between the firewall and the fuselage frame Fiberfrax is a relatively new material you can get it from Wicks Aircraft or Air...

Page 271: ...t will turn in the bushings If necessary use emery cloth or 400 grit wet or dry emery paper on the inside of the bushing We prefer to wet sand with a little oil on the paper Wipe all grit from the ins...

Page 272: ...n gently slide P N 655 over the piston and part of the way down Slide P N 660A over the nose gear piston P N 660A is longer than the P N 660 that may have been installed in the nose gear assembly Inst...

Page 273: ...N 663 nose gear rocker arm on the top of the nose gear strut Do not drill the bolt hole yet Align the nose gear rocker arm with the nose gear fork The two arms on the rocker arm are angled toward the...

Page 274: ...he inner tube valve stem Pull the valve stem through the hole Put enough air pressure in the inner tube to round it out but not enough so that it starts to expand Install the other side of the wheel a...

Page 275: ...experience has been that the steel bushings for P N 720 do not require reaming for the bolt to fit If the bolts are a relatively tight fit we would prefer that these bushings not be reamed since it w...

Page 276: ...ocation of P N 605 is shown in Figure 4 Install the MS35207 267 screw and AN315 3 check nut included in the Electrical kit in P N 618A upper drag strut See Figure 4 Install P N 708 drag strut supports...

Page 277: ...44 holes as shown in Figure 5 These holes are for MS35489 6 grommets for the 1 4 O D brake lines which will be installed later Put the P N 761 back on the rudder pedal torque tube Fuel Tank Band Mount...

Page 278: ...erline and W L 0 on the aft face will be the same as on the front face If not already done cut the exhaust ports Cut the front face to the correct shape shown in the drawing The exhaust port shield fi...

Page 279: ...selage frame No 1 by gluing on the closing plywood Draw the airplane centerline and W L 0 on the aft face of the fuselage frame On the aft face of the fuselage frame draw B L 340 and B L 200 for the f...

Page 280: ...5 11 Revision 4 March 1 2002 Figure 9 Glue on the 2mm plywood pads on the face just closed These pads are installed on both the forward and aft faces so if they have not already been installed on the...

Page 281: ...tract with a smooth action of the drag struts If the post of the upper drag strut hits the bottom of the slot in the fuselage frame sand the frame for clearance Note When the nose gear is retracted it...

Page 282: ...ime Install the landing gear up limit switch on P N 877 up limit switch support Position the up limit switch support so that the roller of the up limit switch contacts the center of the MS35207 267 sc...

Page 283: ...fuselage frames Figure 13 Install P N 824 1 cabin heat fitting on the fuselage frame This is installed with No 6x1 2 TRA screws See Drawing No 131 Center the fitting on the hole since the vacuum syst...

Page 284: ...ble support with the cabin heat cable and other hardware shown on Drawing No 131 If you wish you may temporarily install the cable end fittings on the arm of the cabin heat valve The only purpose of t...

Page 285: ...possible use the mounting bracket supplied by Christen If applicable drill the two 3 16 holes for the Christen P N 806 4 breather tee See No 302 for the location of these holes If possible use the act...

Page 286: ...the face of the frame will not work very well and will require substantial shimming to fit the longeron Therefore these lower side longeron cutouts should be undersized for final fit at the installat...

Page 287: ...61 rudder pedal supports On the aft face of P N 734 draw a line connecting the centers of the two 3 16 holes This will be used for locating the band mounts vertically The bolts for these fittings are...

Page 288: ...ll the four 3 16 holes Make a cardboard or paper template of the aft face of frame No 1 to be used as a pattern for cutting the sound deadening insulation that will be installed later If drafting pape...

Page 289: ...vision 4 March 1 2002 Figure 19 Install the two 30x11 spruce pieces on the aft face of fuselage frame No 1 See Drawing No 121 Figure 20 Install P N 116 62 alternator shunt and the fuse holder for F3 a...

Page 290: ...re 21 The upper members of the box between frame No 1 and 2 will be installed at an included angle of 102 Since you will have a similarly matching 78 on the front face of frame No 2 make the two strip...

Page 291: ...t holes must be larger than the matching hole in the frame The MS35489 14 grommets for the 1 2 wire require a 13 16 hole in the firewall The MS35489 11 grommets for the 3 8 wire bundle require a 5 8 h...

Page 292: ...ying spruce member The brake reservoir is installed at B L 360 and is held in place with a clamp that will have two No 6x1 2 TRA screws located 3 38 between center Figure 24 If available you may insta...

Page 293: ...o 1 at the forward face that is with the undersurface of the fuselage skin The fabric covering will add a little to the thickness of the fuselage skin and for final alignment you can build up the fuse...

Page 294: ...place The ends of these parts are already marked at their approximate ends for trimming Cut the ends to the correct length and notch them to fit around the engine mount lugs If the supports do not mat...

Page 295: ...ructure on the inside face of the closing plywood for varnishing See Drawing No 303 Cut the inside face of the frame to a width of 164mm to allow for the 2mm plywood used for the nose gear bay wall Fi...

Page 296: ...r to the face of the frame will not work very well and will require shimming to fit the longeron Therefore these lower side longeron cutouts should be undersized for final fit at the installation of t...

Page 297: ...the angle of the strips installed on the aft face of frame No 1 thus the angle between the front face of the frame and the top of the strip is 78 The exhaust port will be skinned with a piece of 2mm...

Page 298: ...2002 Figure 30 If the lower floor is to be installed see Drawing No 315 install the flooring supports on the aft face of the frame These supports may be 10x10 spruce as shown above or you may use 10x1...

Page 299: ...uselage frame No 2 and 3 See Drawing No 315 Because of the location of the outboard exhaust port framing strips these saddle gussets are partially cut open at the bottom If the lower floor is installe...

Page 300: ...frame at an angle As a result a cutout for the longeron that is perpendicular to the face of the frame will not work very well and will require substantial shimming to fit the longeron Therefore thes...

Page 301: ...wing No 312 to avoid interference problems between the shoulder belt supports and the fuel tank mount Install saddle gussets for the two 20x15 luggage compartment floor supports located at B L 100 See...

Page 302: ...f these strips of spruce should be located 10mm out from the inside edge of the lamination of the fuselage frame These strips should be run all the way around the upper forward face of the frame above...

Page 303: ...ge Frame No 8 If not already done draw W L 0 and the aircraft centerline on the two fuselage frames No 8 Be particularly careful to draw the aircraft centerline on the the horizontal brace since this...

Page 304: ...between the frames See Drawing No 321 These washers are temporary spacers that will be used during the fuselage assembly If you wish you may use ordinary hardware store washers under the bolt head and...

Page 305: ...aft centerline on the horizontal brace This will be used in the construction of the battery box Figure 39 Cut the four 30x15 longeron cutouts See Drawing No 313 Use the master template Draw the instal...

Page 306: ...eron cutouts See Drawing No 313 Use the master template Fuselage Frame No 11 If not already done draw the aircraft centerline and W L 0 on the fuselage frame Figure 41 Cut the four 30x15 longeron cuto...

Page 307: ...s from the drawing it should have solid wood internally aft of Sta 12 and the 50mm notch should be changed so that the top of the jig aft of Sta 12 is 50mm below the top of the jig since it is not pos...

Page 308: ...of re work was necessary This problem can be avoided by installing fuselage frame No 1 with the engine mount and nose gear in place This allows you to position fuselage frame No 1 so that the nose gea...

Page 309: ...intent is to build as much rigidity into the fuselage as possible before putting the lower side longerons in place Fuselage Assembly Figure 1 Make four supports as shown in Figure 1 from two by ten lu...

Page 310: ...the rest of the jig Draw the aircraft centerline down the top of the fuselage jig Draw the fuselage stations on the top of the fuselage jig Measure from a common point Sta 1 to Sta 2 then Sta 1 to St...

Page 311: ...the installation of the nose gear screwjack support The post should not be wider than a normal two by four 3 5 so you will be able to retract the nose gear with the wheel removed The split post at th...

Page 312: ...The aft support must be removable so install it with bolts Figure 8 Place the fuselage jig in place on the wing assembly Slip fuselage frames No 7 8 9 10 and 11 over the jig See Figure 8 Figure 9 Leve...

Page 313: ...Falco Construction Manual 26 6 Revision 4 March 1 2002 Figure 10 Install the one by two s for fuselage frames No 7 8 9 10 and 11 Figure 11 Glue the fin spars to the horizontal stabilizer spars See Fig...

Page 314: ...ision 4 March 1 2002 Figure 12 Install the tail assembly on the fuselage jig See Figure 12 Figure 13 Install fuselage frame No 2 on the jig with its one by two brace See Figure 13 Install the engine m...

Page 315: ...ine through the tail section Secure this alignment string on each end and pull tight Use a water level to check that this alignment string is level Figure 15 Clamp the upper side longerons in position...

Page 316: ...al sanding for the longeron fit in the longeron cutouts Because there is a slight bend in this longeron you may either soak and bend this piece into a slightly bowed shape or make it in two straight p...

Page 317: ...ng that the fuselage frames are vertical in the jig use a plumb bob Sand the longeron cutouts to fit the left side longeron The other longerons should hold the frames in position Clamp this longeron i...

Page 318: ...il later The reason for this is that they require a significant amount of twisting at the aft end which could cause the fuselage frames to become distorted on the fuselage jig Figure 19 Clamp the left...

Page 319: ...osition See Figure 20 Sand the cutouts to fit Clamp the left 30x15 shoulder belt support framing strip in position Sand the cutouts to fit Check the alignment of all fuselage frames Check the alignmen...

Page 320: ...ming strip in place This strip is at the bottom of frame No 1 2 and 3 Sand the cutouts to fit Do one last check of the alignment of all fuselage frames including the alignment of the nose gear in the...

Page 321: ...is 10mm outboard of the inside of frame No 7 This is for the inside fuselage skin see Drawing No 315 The coaming strips or gunwales to boatbuilders may be made by laminating two or three strips of spr...

Page 322: ...No 3 and 4 in place Glue the right cockpit coaming strip between frame No 3 and 4 in place Glue a strip of spruce on the inboard face of the left upper side longeron between frame No 2 and 3 See Draw...

Page 323: ...ocks are also used for the bolts which hold the engine mounts in place see Drawing No 114 Spruce is strongest in the direction of the grain Also end grain joints are not particularly strong In general...

Page 324: ...ward face of frame No 8 See Figure 25 Fit and glue the two 35x150 corner blocks for the right side longeron at the forward face of frame No 8 Fit and glue the two 35x150 corner blocks for the bottom c...

Page 325: ...per corner block is not installed at this time due to the construction of the battery box Figure 27 Fit and glue the two 35x150 corner blocks for the right side longeron at the aft face of frame No 8...

Page 326: ...side of the lamination should coincide with the inside of the cockpit coaming At the aft upper end the diagonal frame should just rest against the forward face of frame No 7 While fitting this diagona...

Page 327: ...h 1 2002 Figure 29 Sand the longeron cutout for the top center longeron in this diagonal frame Clamp the top center longeron in place Figure 30 Cut fit and sand the cutouts for the 20x10 stringers in...

Page 328: ...al frame No 6 Fit and glue the 35x150 corner blocks for the top center longeron on the forward face of frame No 8 Fit and glue the 35x150 corner blocks for the right side of the top center longeron on...

Page 329: ...2 and on the inside of the upper side longeron as shown in Figure 32 This strip is to pick up inside cockpit skin Do this on the left and right sides of the airplane Figure 33 Cut and fit the 15mm wid...

Page 330: ...and the detail showing the installation of this frame It is very important that this frame is installed exactly as shown If you compare this to the windshield it will not make sense to you right now b...

Page 331: ...002 Figure 36 Glue the top center tank support in place after trimming it to fit to the diagonal frame At the outboard end of the diagonal frame glue a 40mm corner block on the forward face of the fra...

Page 332: ...the nose gear bay walls as shown in Drawing No 306 See Figure 1 Do not glue this in place at this time Figure 2 Fit and glue in place the vertical supports for the aft end of the nose gear bay walls S...

Page 333: ...nd glue in place the 20x18 diagonal braces See Figure 3 Figure 4 Fit and glue in place the extra blocking for the forward end of the nose gear bay See Figure 4 These are not dimensioned on any drawing...

Page 334: ...wall inboard faces with 2mm birch plywood Figure 6 Drill the four 3 16 holes in the right nose wheel bay wall for P N 717 per Drawing No 105 To drill these holes turn P N 717 2 bracket upside down on...

Page 335: ...han check the fit of P N 717 2 and maybe draw it s outline so you can put the corner blocking in place correctly P N 717 2 will be removed zinc chromated and assembled at a later stage Figure 8 Instal...

Page 336: ...same paint that is used on the outside of the airplane If you plan to use stainless steel in the nose gear bay you should install it now and allow for the thickness of the steel under the nose gear u...

Page 337: ...aft face of frame No 1 in a butt joint and this should be reinforced with corner blocks The rest of this chapter covers a number of different little odd jobs There is no reason to do any of these rem...

Page 338: ...s see Chapter 23 Figure 13 At the forward end the 30x15 floor supports are supported by saddle gussets see Chapter 23 Figure 18 The plans show the two 15x15 members these are supports for the trim tab...

Page 339: ...and 4 See Figure 12 Figure 13 Install the flooring supports between Sta 2 and 3 See Figure 13 Figure 14 Install corner blocks between the seat supports and the 20x20 spruce strip on the forward face o...

Page 340: ...artment floor supports See Figure 15 Figure 16 Install the luggage compartment flooring support at B L 315 Because the aft end butts against the cross member of frame No 7 the best way to make the joi...

Page 341: ...ent panel pedestal which you can see on Drawing No 831 1 The two holes are for wiring and plumbing The larger hole on the right side will take most of the wiring but there will be a few things which w...

Page 342: ...edge should be 10mm from the outboard edge of the outboard floor support to leave room for the gluing strip for the inside cockpit side walls Cut the openings for the control sticks Figure 20 Fit and...

Page 343: ...oor board for the luggage compartment floor See Figure 21 Do not install any of the screws yet since their location may conflict with the installation of the strobe power supply Figure 22 Fit and inst...

Page 344: ...to locate the holes this way The two inboard holes should be located just inboard of the plywood floor so that the screw heads will be hidden under the removable center luggage compartment floor The...

Page 345: ...forward face of frame 4 and 6 After you install the seat track supports and at other occasions you ll need to make changes to the carpet patterns We ll try to remind you when to do this but you can k...

Page 346: ...r the rear cockpit bulkhead See Figure 26 Figure 27 Install the 10x15 spruce strips on the aft end of the center removable luggage compartment floor These strips are permanently glued in place to the...

Page 347: ...type of battery is completely sealed and gives off no gases when it is being charged Although these batteries are in the same amp hour category as the Gel Cell the manufacturers claim that a very low...

Page 348: ...oard to fit See Figure 29 This floor board should rest on the cross braces of frames 8 and 9 and on the support just installed on the side longeron 285 150 50 80 355 13 16 Figure 30 Locate the center...

Page 349: ...ide of the battery A nylon bar is installed over the bolts and battery and is held in place with wing nuts The nylon hold down bar has the 1 4 holes drilled at 10 13 between centers for the Gill PS6 1...

Page 350: ...mm in from the center of the holes for the hold down bolts This way the blocking for the hold down bolts can be located right next to the floor supports and will stronger for negative g aerobatics If...

Page 351: ...l F 8L Falco Construction Manual 27 20 Revision 4 March 1 2002 Figure 35 Glue the floorboard assembly in place See Figure 35 which is a view looking forward at frame No 8...

Page 352: ...l F 8L Falco Construction Manual 27 21 Revision 4 March 1 2002 Figure 36 Fit and install the center wall of the battery box See Figure 36...

Page 353: ...l F 8L Falco Construction Manual 27 22 Revision 4 March 1 2002 Figure 37 Fit and install the 15x15 brace on the center wall of the battery box See Figure 37...

Page 354: ...l 27 23 Revision 4 March 1 2002 Figure 38 Fit and install the 15x15 spruce brace on the center wall of the battery box at frame 8 See Figure 38 Fit and install the 15x15 spruce brace on the center wal...

Page 355: ...ruction Manual 27 24 Revision 4 March 1 2002 Figure 39 Fit and install the 15x15 gluing strip on the battery box floor at frame 8 See Figure 39 Fit and install the 15x15 gluing strip on the battery bo...

Page 356: ...lco Construction Manual 27 25 Revision 4 March 1 2002 Figure 40 Fit and install the forward wall of the battery box at frame 8 See Figure 40 Fit and install the aft wall of the battery box at frame 9...

Page 357: ...ure 41 Figure 42 Glue the laminated bow for the forward end of the battery compartment door in place See Figure 42 Figure 43 Install the bob tailed 35x150 corner block on the top of the side longeron...

Page 358: ...3 This stringer extends only back to frame No 2 These stringers and other views of the exhaust port framing can be seen on Drawing No 201 Sheet 1 and Sheet 2 Some builders have installed the inboard s...

Page 359: ...side of the exhaust ports The bottom of the fuselage has a slight convex shape so you may bend the short stringers or make them a little oversized and sand to shape In either case you may use the curv...

Page 360: ...nstall the four 15x15 strips of spruce which form the upper corners of the box These should be tapered on the bottom aft end so that the top of the box will fit against the strip on the forward face o...

Page 361: ...Gear Screwjack Support Assembly Remove the nose gear screwjack support from the airplane and install the bearing and retainer See Drawing No 717 1 It s a good idea to put some wet zinc chromate betwee...

Page 362: ...r 28 Fuselage Assembly Part 3 Kits on Hand To do the work covered in this chapter you should have the following Kit No 807 1 Canopy Equipment or 807 2 Kit No 809 1 Fuel Tanks and Equipment Figure 1 In...

Page 363: ...the longeron requires a surprising amount of twisting and clamping to get it into place Some builders have soaked the longeron and clamped it into place in advance Others have glued blocking on the fo...

Page 364: ...ttery box diagonal supports Install the framing for the access panel s for the rudder cable pulley At a minimum you need to install one access panel on the right side of the aircraft Many builders ins...

Page 365: ...pplied in four pieces with scarf joints at the top center bottom center and upper side longerons An exception is the top skin from Sta 12 to 13 which most builders do in one piece It s quite easy to m...

Page 366: ...in one step The elevator trim tab cable and the aluminum tubing that is used as a conduit in the stabilizer is a little messy What you have to do is to cut the aluminum tubing off so that you can inst...

Page 367: ...vision 4 March 1 2002 Figure 9 Cut the battery box opening Figure 10 Cut out the fuselage jig in front of the forward fin spar Install the block for tail tie down Measure and note the location of the...

Page 368: ...the forward face of the forward fin spar Drill the hole for the nylon tubing used as a conduit for the tail light wires Epoxy the aft end of the tubing in place The aft end of the tubing should be flu...

Page 369: ...in the main fin spar for the elevator balance weight arms at the bottom See Drawing No 402 Sheet 2 Section B B Install the upper elevator stop or if you are going to install the piece of stainless ste...

Page 370: ...g No 201 Detail J and proceed at least through step 3 to provide room for maneuvering the router even so you will find that not any router will work in such close quarters and you may have to use a la...

Page 371: ...is tilted slightly nose down for smoother action with the cables Cut the holes in the sides of the fuselage where the rudder cables exit to check the position of the pulley Install the hose clamps on...

Page 372: ...e to install clamps to secure the cable This is one of those things that does not lend itself to precise dimensional layouts You will simply have to install the clamps where the cable falls naturally...

Page 373: ...the router even so you will find that not any router will work in such close quarters and you may have to use a laminate trimmer or a Dremel Moto Tool Varnish the inside of the last fuselage skin inst...

Page 374: ...2002 Figure 22 Skin the fuselage on the left side from Sta 8 to 10 Varnish the inside of this fuselage skin Figure 23 Install the static port fitting on the left side of the airplane Figure 24 Instal...

Page 375: ...stalling the outside fuselage skins is the only sensible thing to do With the framework still open you can cut the interior skins scarf them and glue little blocks in the dorners to make the skins sna...

Page 376: ...You simply apply glue and then staple the plywood in place starting at the center of the panel at one of the longerons and working out in a fan shaped pattern Builders who have installed the skin in o...

Page 377: ...this but if you want to be extra careful then you can just jam some cut to exact width boards across each frame to ensure that nothing moves Install the blocks required for the canopy track See Drawin...

Page 378: ...l 28 17 Revision 4 March 1 2002 Figure 29 Glue on the fuselage skin from Sta 3 to 6 on both sides of the aircraft Figure 30 Make the cabin fresh air inlet Install earlier Figure 31 Fit the interior co...

Page 379: ...8L Falco Construction Manual 28 18 Revision 4 March 1 2002 Figure 32 Glue on the fuselage skin from Sta 1 to 3 on both sides of the aircraft Figure 33 Cut the opening for cabin fresh air inlet Figure...

Page 380: ...g the block to the approximate shape required gluing the block in place and then sanding the block to the final shape At the time that you fit the skin you will do some additional shaping of this bloc...

Page 381: ...h 1 2002 Figure 36 Scarf the side skin from Sta 1 to 3 in preparation for skinning Figure 37 Skin the bottom front of the fuselage from Sta 1 to 3 Be sure to skin over the exhaust port openings Figure...

Page 382: ...tank Install the framing for the aft fuel tank filler cap opening At this time we don t have a good drawing for you but the access door is installed with a piano hinge and a flush catch required by t...

Page 383: ...ood in the groove for the canopy frame At the deepest part of the groove you should see the spruce block not plywood Assuming you have good drawings or know what you are doing cut out the opening for...

Page 384: ...be in the solid spruce dorsal fin block and position it under the canopy Try sliding the canopy and when you have the tube centered glue the block in place Figure 44 Glue the framework for the dorsal...

Page 385: ...ard Top Fuselage Section Figure 46 Install the blocks of wood on diagonal frame No 2 to support the forward fuel tank See Drawing No 121 Install the hanger straps for the forward fuel tank Figure 47 I...

Page 386: ...will eventually cover the remaining area back to frame No 3 At each side this strip must be the same width B L position as the top lamination of frame No 3 and then the strip is curved so that it join...

Page 387: ...l F 8L Falco Construction Manual 28 26 Revision 4 March 1 2002...

Page 388: ...ustable Clamp Company 431 No Ashland Avenue Chicago Illinois 60622 This company specializes in clamps Send for free literature or send 0 50 for 32 page how to clamp it catalogue www adjustableclamp co...

Page 389: ...rtland OR 97212 Telephone 503 282 6997 Wood working tools www bridgecitytools com Woodshop Specialties Coal River Industrial Park Quality Lane Rutland Vermont 05701 Dealers for Powermatic Rockwell Del...

Page 390: ...shops due to lack of precision and quality www jettools com Delta International Machinery Corp formerly Rockwell Power Tool Division Call 800 438 2486 or 800 438 2487 in PA for name of local distribut...

Page 391: ...count Aircraft Parts 7520 Valjean Van Nuys California 91406 Telephone 800 423 3281 or 818 786 8274 A mail order company specializing in brand name aircraft parts A good source for intercoms strobes et...

Page 392: ...rmerly Dick Waters Inc this company specializes in suppling homebuilders www dongeorgeaircraft com Aviat Inc The Airport P O Box 1149 South Washington Street Afton Wyoming 83110 Telephone 307 886 3151...

Page 393: ...l F 8L Falco Construction Manual A 6 Revision 4 March 1 2002...

Page 394: ...ANC 18 is the basic reference for wood aircraft designers and it is full of graphs and formulas Few Falco builders will profit from this book ANC 19 is the Bible of aircraft woodwork There isn t a bu...

Page 395: ...been developed since that then Available from John Roby Aircraft Woodwork By Ruth Spencer A very good little book that any Falco builder who wants to read all he can on wood aircraft construction wil...

Page 396: ...ation Maintenance Foundation Good course in basic aircraft systems Sheet Metal Volume I Sheet Metal Volume II Available from Experimental Aircraft Association Excellent Air Force manuals reprinted by...

Page 397: ...e from the Experimental Aircraft Association Complete Metalworking Manual By R H Cooley Available from Brookstone Company 123 Vose Farm Road Peterborough New Hampshire 04358 Aircraft Covering Painting...

Page 398: ...eir value for the Falco builder Dave Thurston is the consulting engineer who has approved all of the changes to the original Falco design All three books are published by McGraw Hill Available from yo...

Page 399: ...ear U S funds The Taunton Press 52 Church Hill Road Box 355 Newtown Connecticut 06470 For credit card subscription orders call 800 243 7252 or 203 426 8171 www taunton com WoodenBoat Nothing about air...

Page 400: ...Yellow Imron 7455 31 24316 54701 8550 White Orange Orange Yellow Yellow Yellow Modena Torino Maranello C1 C2 C3 C4 C5 Imron 78390 1021 44128 4992 99 Beige Orange Red Red Black Imron 92095 5351 99 99 W...

Page 401: ...Orange Black Imron 4296 24316 60659 7455 99 White Yellow Orange Orange Black Imron 24316 60659 7455 99 White Yellow Orange Orange Black Imron 43938 24316 60659 7455 99 Cream Yellow Orange Orange Blac...

Page 402: ...k Imron 71537 6334 White Gray Gray Imron 99 5027 6334 Black Red Gray Imron 55137 5027 99 Gray Red Black Imron 6334 5027 99 Gray Red Black Imron 5351 2063 White Blue Blue Imron 43073 Green White White...

Page 403: ...l F 8L Falco Construction Manual C 4 Revision 4 March 1 2002 Imron 5351 5027 White Blue Red Imron 5027 2063 White Red Blue Pure white No color tint added to base white paint...

Page 404: ...he user s preference in regard to the assembly and clamping times given below In cold conditions the faster hardener should be used Glue line temperature should be at least 10 C 50 F using Hardener GB...

Page 405: ...quare metre 2 3 4 to 5 1 2 lb sq ft Hardener GBP X or GBQ X 100 to 150 grammes per square metre 2 to 3 lb sq ft Assembly Times From the moment at which contact is first made between the resin coated a...

Page 406: ...contain excessive moisture this may cause poor bonding It is therefore good practice to store the wood in reasonably warm and dry conditions for several days before gluing For best results the moistur...

Page 407: ...ed clothing removed and washed before re use All information is based on results gained from experience and tests and is believed to be accurate but is given without acceptance of liability for loss o...

Page 408: ...colite Adhesive G 1131 can be used advantageously in assemblies such as laminated boat keels arches and trusses or where it would not be economical or feasible to use heat for curing because of the si...

Page 409: ...e working life of the mixed adhesive Table 1 indicated the relationship between useful working life and temperature of the mixed adhesive Table 1 Adhesive TemperatureUseful Working Life 60 F 7 1 2 hou...

Page 410: ...F 80 F 90 F 100 F Maximum Permissible Open Assembly Time 10 mins 5 mins 1 min 0 mins Maximum Permissible Closed Assembly Time 60 mins 45 mins 30 mins 15 mins The times in this table are based on using...

Page 411: ...laminated phenolic plastics and many other plastics such as ureas the cellulose plastics except cellulose nitrate nylon methacrylates polyvinyl alcohol polyvinyl acetate and foamed polystyrene not po...

Page 412: ...and pattern may be required to control vapors below OSHA regulations Flash point is between 73 F and 100 F Keep away from heat sparks and open flame Keep container closed when not in use Penacolite H...

Page 413: ...arrier Resin Ethanol pH 3 5 Mixed Uses General Weldwood Waterproof Resorcinol Glue is especially recommended for exterior structural application where maximum durability is required under severe servi...

Page 414: ...to when it becomes too thick to be spread of Resorcinol is very sensitive to temperature since it is a chemical reaction The working life of Resorcinol will vary with the quantity but is approximatel...

Page 415: ...of tools Small to moderate areas may be spread with Resorcinol by brush small notched trowel or paint roller Large surfaces or industrial applications normally require a glue gun application or finely...

Page 416: ...re at which the assembly is maintained during the initial curing period The recommended minimum time under pressure for stress free joints is shown in the following table Minimum Time Under Pressure a...

Page 417: ...joints with Weldwood Waterproof Resorcinol Glue are usually in excess of the strength of the wood bonded When tested on hard maple in block shear re ASTM D905 Resorcinol bonds have a compression shear...

Page 418: ...ed contact with skin and breathing of vapor First Aid In case of contact with skin wash thoroughly with soap and water If eye contact occurs flush with water Call a physician immediately KEEP OUT OF R...

Page 419: ...and are mixed in a 1 1 ratio Aerodux 500 resins with Hardener 501 meet the requirements of BS 1204 Parts 1 and 2 Type WBP BS 1203 Type WBP and DIN 68 705 AW 100 and can be released in accordance with...

Page 420: ...the Aerodux 500 and mix thoroughly Addition may be measured by weight or volume Pot Life Pot life of resin hardener mixture in relation to temperature Temperature of Resin Hardener Mixture C F Resin...

Page 421: ...00 M med 8 5 hrs 5 hrs 4 hrs 2 hrs 1 25 hrs 45 min 500 S slow 10 hrs 5 5 hrs 4 hrs 3 hrs 2 hrs Note Minimum pressing or clamping times stated are those required to give 1 33 kN 300 psi dry shear stren...

Page 422: ...g when subjected to exposure to weather or very wet conditions This is because certain soluble materials in the uncured resin are absorbed and retained by the board and may subsequently be leached out...

Page 423: ...risks Keep the uncured materials resin hardener and resin hardener mixture away from open flames electrical elements etc and firmly seal the containers when not in use If the materials catch fire eit...

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