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Silence Aircraft Twister Kit, Assembly Manual, Page: 12 / 26

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Silence Aircraft Twister Kit Assembly Manual Download Page 12

Revision 1. 6 

1.6 

General 

1 

Tools 

To build the 

Twister

 you need the following tools: 

-

 

Paint brush 

-

 

Scissors 

-

 

Power drill 

-

 

Pop rivet pliers 

-

 

Set of wrenches and screwdrivers 

-

 

Torque wrench 

 

General Torques for Screw/Bolt Connections 

 

(Bolts/screws slightly greased) 

M5 

5Nm 

M6 

9Nm 

M8 

23Nm 

M10   46Nm 

-

 

Twist drill set, 1-12mm (.040"-0.50") 

-

 

Long nose pliers, long type 

-

 

Caliper gauge 

-

 

Set of files 

-

 

Sanding paper (80, 100, 220, 500 wet sanding paper) 

-

 

2 ratchet straps, each 8m (25 ft) long 

-

 

Rotary grinding/cutting tool (e.g. Dremel) 

-

 

Reciprocating saw (e.g. Jig Saw) 

-

 

Orbital DA sander 

-

 

Spray gun 

-

 

Vise (5” or 6” clamping length) 

-

 

Tape measure (metric) 

-

 

Wooden stir sticks (e.g. tong depressors) 

-

 

Mixing cup (un-waxed) 

-

 

Disposable protective gloves (Latex or Nitrile) 

-

 

100º countersink 

-

 

Scales 0-2,000g (0-oz), 0.5g (0.02oz) precision (balance beam or electronic) 

-

 

Nicopress tool  (e.g. from Aircraft Spruce) 

-

 

Mold release wax 

-

 

Polypropylene packaging tape, 50mm (2") wide 

-

 

Keyhole saw 25-70mm (1"-2.75") 

-

 

Level, ca. 300mm (12") long 

Summary of Contents for Twister Kit

Page 1: ...Revision 1 6 ii Silence Aircraft GmbH Kapellenweg 54a 33415 Verl Germany Aircraft Assembly Manual Twister Kit Revision 1 6 ...

Page 2: ...terweights 2 2 4 Laminating the Seams and Ribs 2 3 Wings 2 3 1 Installing the Outboard Self Aligning Bearing for the Aileron 2 3 2 Installing the Mounting Bearing for the Flap 2 3 3 Installing the Root Rib 2 3 4 Cutting the Holes for the Counterweights 2 3 5 Cutting the Wheel Well 2 3 6 Installing the Fuel Tanks 2 3 7 Installing the Aileron Drive 2 3 8 Installing the Flap and the Aileron 2 3 9 Ins...

Page 3: ...16 Assembling and installing the control stick 3 17 Installing the elevator push rods incorporating PFA MOD 329 003 3 18 Assembling and fitting the canopy 3 19 Installing the NACA air supply 3 20 Installing the trim 3 21 Laminating the seams and reinforcing the wheel well 3 22 Installing the baggage compartment cover safety belt and seat pan 3 23 PFA MOD 329 008 Parachute Seatback 4 Tail 4 1 Insta...

Page 4: ...11 Installing the Cowling 6 Avionics 6 1 Selecting and Arranging the Instruments 6 2 Creating the Cut Outs in the Instrument Panel 6 3 Rounding the Cut Out Edges 6 4 Laminating the Instrument Panel 6 5 Installing the Instrument Panel in the Fuselage 6 6 Creating the Structure behind the Instrument panel 6 7 Wiring Loom 6 8 PFA MOD329 001Removing and disabling Emergency Flap lowering switch System ...

Page 5: ...manual was translated from a German original Measurements The design of the Twister is based on the metric system All US conversions given in the text are for guidance only All dimensions in the figures are in millimeters mm unless otherwise stated ...

Page 6: ...terial thickness it is going through to avoid having the threads in bearing and when using self locking nuts make sure there are at least 1 1 2 threads showing You should not be able to thread the nuts on by hand if so the locking feature is worn out The best practice it to not reuse self locking nuts or at least minimize their re use When securing with Loctite always mark it with witness paint in...

Page 7: ...cantilever low wing plane with cruciform tail unit retractable two wheel landing gear and flap system Optionally a rescue system can be installed in the cockpit cell There are two fuselage variants one prepared for mounting a rescue system and one for use without a rescue system Wing span 7 5 m 24 6 ft Length 6 18 m 20 28 ft Wing area 8 718 m 93 84 sq ft Max take off weight MTOW 420 kg 881 95 lb M...

Page 8: ... kt 130 mph Maximum Flight Speeds Speeds converted for sea level Stall speed 30 flaps VSF 75kph 40 47kt 46 60mph Stall speed no flaps VS 85kph 45 87kt 52 82mph Maneuvering speed VA 209kph 112 78kt 129 87mph Maximum speed VNE 300kph 161 88kt 186 41mph VD 330kph 178 07kt 205 05mph Maximum speed 30 flaps VFE 125kph 67 45kt 77 67mph When using a rescue system the maximum speed is limited to the maximu...

Page 9: ...nents Sanding and filling the surfaces Mechanical assembly Wiring laying the wire harnesses Painting If you are not sure about the tasks listed above ask a professional Important If any component is damaged e g by sanding through the fiberglass skin contact the manufacturer in order to determine whether the component can still be used or can be repaired To build the Twister you need a work area me...

Page 10: ...ass fabric 280g m Twill FK144 92125 1000mm 39 37 Fiberglass fabric 296g m Twill FK144 92626 1000mm 39 37 Aramid fabric 170g m Twill Washed 1000mm 39 37 Carbon fabric 200g m Twill 1000mm 39 37 Carbon fabric 245g m Twill 1000mm 39 37 Carbon fiber tape 125g m UD Epoxy 25mm 0 98 Carbon fiber tape 300g m UD Epoxy 50mm 1 97 Carbon fiber tape 300g m UD Epoxy 75mm 2 95 Peel ply 100g m Twill 500mm 19 69 Pe...

Page 11: ...escription Thickness Density Aramid honeycomb 3 2mm 0 13 cell diameter 3mm 0 12 48kg m 3lb cu ft Aramid honeycomb 3 2mm 0 13 cell diameter 3mm 0 12 29kg m 1 81lb cu ft Aramid honeycomb 3 2mm 0 13 cell diameter 5mm 0 20 48kg m 3lb cu ft Aramid honeycomb 3 2mm 0 13 cell diameter 5mm 0 20 29kg m 1 81lb cu ft Aramid honeycomb 3 2mm 0 13 cell diameter 7mm 0 28 48kg m 3lb cu ft Aramid honeycomb 3 2mm 0 ...

Page 12: ...s Sanding paper 80 100 220 500 wet sanding paper 2 ratchet straps each 8m 25 ft long Rotary grinding cutting tool e g Dremel Reciprocating saw e g Jig Saw Orbital DA sander Spray gun Vise 5 or 6 clamping length Tape measure metric Wooden stir sticks e g tong depressors Mixing cup un waxed Disposable protective gloves Latex or Nitrile 100º countersink Scales 0 2 000g 0 oz 0 5g 0 02oz precision bala...

Page 13: ...s Combining different materials to form a composite with enhanced properties and synergies is a common process in nature the section of a strand of merino wool or a bamboo stem shows structures similar to the cross section of a unidirectional carbon fiber reinforced epoxy resin CF EP Nature remains the model not only for the microstructure of fiber reinforced plastics but also for the application ...

Page 14: ...fiber composites are used mainly for economic reasons In view of the high fuel costs space agencies are prepared to spend up to 25 000 euros for every kilogram saved In aviation the figure is 250 750 euros per kg in the automotive industry 0 2 50 euros per kg with the exception of racing As fiber composites are usually more expensive than compact materials e g metals and place higher demands on de...

Page 15: ...neral rule is that a fiber composite results only from the combination of resin and fibers i e it is produced directly by the processor Therefore the properties of the end product depend almost entirely on careful processing and curing as well as on component design fiber orientation fiber percentage number of plies and fabric Strength The strength of a fiber composite is determined to a large ext...

Page 16: ...ing and impact strength as well as the ability to absorb energy are mainly influenced by the fibers These properties can be influenced by the choice of fiber materials the fiber content and the orientation of the fibers Curing The properties of the cured and molded reactive resin i e of the molded part depend not only on the starting material but also very much on the control of the curing process...

Page 17: ... Polycondensation e g phenol formaldehyde resins In polycondensation the reaction of the starting components releases by products e g water The reaction can controlled in a step by step process In general precondensed resins are used which in most cases can be cured by applying heat Elongation at Break When subjected to tensile stress the resin must not break before the fibers Otherwise cracks in ...

Page 18: ...ength given that foreign matter is often the root cause of bond failure For this reason peel plies are applied on most bonding surfaces of the Silence These fabrics which are marked by a blue or red thread are pulled off by hand The resulting rough surface is ideal for bonding After pulling off the peel ply do not touch or soil the bonding surfaces Fitting This step involves the removal of burrs a...

Page 19: ... solvents are among others various alcohols and acetone Although they were frequently used in the past do not use chlorinated hydrocarbons CHC such as chloroform methylene chloride TRI carbon tetrachloride etc unless it is absolutely necessary CHC are harmful to health and poorly biodegradable Building the Silence does NOT require the use of CHC so for the above reasons they should not be used ...

Page 20: ...echnical requirements are minimal so it is mainly used for minor series and simple part geometries as well as for building the Silence The molded part is cured at room temperature without application of pressure Ambient conditions of the working area min 20 C 68 F room temperature around 60 humidity good ventilation a Poorly degreased b Well degreased Water collects into droplets Water forms a fil...

Page 21: ...ly to storage and processing but also to curing and post treatment of the resins and molded materials Below are some simple guidelines which can help you to process epoxy resins and optimize product quality by choosing the right temperature and adhering to some basic rules Storing Epoxy Resins Store epoxy resins at a temperature between 15 C and 25 C 59 77 F When stored for longer periods at tempe...

Page 22: ...r However reducing the viscosity by adding thinners or solvents is only possible to a limited extent and can cause the molecular chains to break On the other hand by raising the temperature by only 5 C 9 F you can reduce the viscosity by almost 50 without affecting cross linking properties For optimum working slightly warm the resin and the forms Resins should have a minimum temperature of 25 C 77...

Page 23: ...in system used for the Twister lamination resin L285 hardener H286 requires 18 hours of annealing at 80 C 176 F 1 4 Safety Over the last few years epoxy and polyester resins have become increasingly important and are now used in a wide range of applications Despite this so far no severe health problems have been reported which could be attributed to dermatological or toxic effects of liquid plasti...

Page 24: ... the affected person from the workplace at the first signs of skin irritation but to give the skin time to adapt and desensitize Allergies Allergies are uncontrolled defensive reactions of the body The many symptoms range from swellings to very itchy pustules and blisters In this case the best advice is a change of workplace Safety Precautions Apart from some operational installations the personal...

Page 25: ...duct used it is a known fact that the toxic effects depend on the amount and duration of exposure Ensure sufficient ventilation of the working areas if possible by installing an extraction system The air flow must carry the vapors away from the processor therefore an extractor directly at the mold is recommended Vapors from solvents e g styrene are heavier than air and best extracted near the floo...

Page 26: ...able R 20 Harmful to health if inhaled R 36 38 Irritates the eyes and skin Danger Notices R 51 53 Toxic to aquatic organisms can retain its harmful effects in waters for longer periods Danger Notices R 7 Can cause fire R 22 Harmful to health if swallowed R 34 Causes chemical burns Danger Notices R 34 Causes chemical burns R20 21 22 Harmful to health if inhaled swallowed or allowed to contact the s...

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