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Chapter 5 - Fuselage 

5.5 - Front seat reinforcement 

Page 53 

 

 

 

excess overhanging the edge of the plywood stiffeners or sand these edges to shape after 

curing. 

 

5.5

 

Front seat reinforcement 

Cut the front seat reinforcement from the supplied two-layer prepreg panel material. 

Review the sketch below, locate and install rigid points for positioning the control. The 

installation of rigid points is more easily done right after the cutout of the prepreg panel. 

Cut out the front of the panel for placement of hard points. Once positioned, cover the 

rigid points with 2-layer BID tape with at least 1 inch overlap the edges of the cutout. 

CORRECT DIMENSIONS 

 

Summary of Contents for 400

Page 1: ...VELOCE Manufacturing Manual 400...

Page 2: ...11 3 6 4 Anti slosh valve 12 3 6 5 Fuel sensor 12 3 7 Fuel cap 13 3 8 Tank bridge 14 3 9 Rigid point for aileron horn 15 3 10 Bonding of the top coat 15 3 11 Tank closing lamination 16 3 12 Fuel Test...

Page 3: ...1 1 Spars lamination 33 4 2 1 2 Elevator Spar 33 4 2 1 3 Stabilizer spar 33 4 2 2 Ribs Lamination 33 4 2 3 Trim trab hinge preparation 35 4 3 Top coating mounting and installation 35 4 4 Elevator and...

Page 4: ...al and horizontal stabilizers 66 5 12 1 Installation of the right rear fuselage 66 5 12 2 Installation of the horizontal stabilizer 69 5 12 3 Bonding of the station cave 70 5 12 4 Gluing of the vertic...

Page 5: ...leron horn 95 6 5 Installation of the Elevator Push Pull Polen 97 6 6 Installation of the Rudder Horn 97 6 7 FLAP TORQUE TUBE INSTALLATION ACTUATION 99 6 8 CRUISER FLAP PIVOT HANGERS ACTUATION 100 6 9...

Page 6: ...ion of top coating 145 8 5 1 Gluing the top coating 145 8 6 Closing of the external face 146 8 7 Assembly of the Aileron Components 147 8 8 Balance 147 9 Rudder 148 9 1 Rigid point on spar 148 9 2 Ass...

Page 7: ...tions but if you do not have any experience it is recommended to look at other reference texts and possibly some test projects with composite construction Working with some practice in using composite...

Page 8: ...ectional glass fabric laminations This fabric is cut and laminated at 45 if not specified The small radii on the edges using MICRO micro glass spheres or FLOX pastes are approximately 1 8 inches which...

Page 9: ...e sourced locally Make sure the beams between the contours are straight and not curved reinforcing the beams with plywood fillets or cutting them from a board can help them stay straight The beams mus...

Page 10: ...late for assembling these items Elongated sandbags such as those made from old trouser legs are ideal for securing the coating to all surfaces a total of 500 kg for gluing the bottom coating to each w...

Page 11: ...ction hold the spar against a bright light to identify the corners of this solid block and mark the center The center of this block must be positioned on the BL 24 where it will be drilled for the rea...

Page 12: ...at the centerline of the sandwich panel of each rib Their positions are BL 27 5 BL 52 BL 85 BL 118 BL 125 BL 157 5 right and left Remembering that for BL 125 there is only the front rib Pay particular...

Page 13: ...way as for the rear spar Place in position on top cladding center of top liner coincides with BL 0 locate and mark all bonding surfaces including rib positions Make sure all surfaces are free of any p...

Page 14: ...end of the tank bay The open area in the nose of the wing is for the aileron control rod coming out of the fuselage and the crank will be mounted in this small bay to transfer its movement to the ail...

Page 15: ...ed into these parts is a inch aluminum sheet to provide a rigid non porous material for screws and fittings Cut out a 4 x 2 5 rectangle from the aluminum De shave all sharp corners clean and rough all...

Page 16: ...and away from it where the underside of the wing will be as shown in the figure Secure this line with the temporarily assembled structural members of the wing cut any required location for line place...

Page 17: ...il it heals 3 6 5 Fuel sensor The first rib is the logical place for positioning the fuel level sensor device installation No system is provided in the kit fuel level measurement however the tubular c...

Page 18: ...ges of the mark clean the core material without damaging the outer liner Rough the coating areas around this cut and the metal surfaces of the fuel cap in the glued areas clean the debris from the are...

Page 19: ...layers Allow healing Drill 2 holes of 1 with center to 7 8 the top and bottom edges and the 1 from the trailing edge of the ribs of the BL 118 and BL 125 Pass the PVC pipe sections through these hole...

Page 20: ...with the front face aligned with its internal flange see figure Cut the casing and dig the core in these positions Prepare a FLOX paste and glue this hard spot in place Roll in place with 3 layers 1...

Page 21: ...ee of any debris grease or oils which could interfere with the bonding process Secure and lightly tighten all surfaces with weights and clecos or screws until cured Check that the fixation has not dis...

Page 22: ...the tank Take the laminated parts provided in the kit These have resin for the tank take care that these faces with the resin are located inside the tank Cut the piece so that the edges overlap the s...

Page 23: ...WRITE 3 14 electrical conduit Even if you are planning an aircraft for daytime VRF only it s a good idea to make provisions for the wiring to come out at the wing tip The easiest way to ensure protec...

Page 24: ...rs and internal bulkheads Spare lamination of this insert can cause a tank leak if it penetrates an area of flange bonding Cut a square sheet of 1 5 inches inch thick aluminum side place over the inne...

Page 25: ...panel should be hardened for better durability by removing the core from the edges a little and filling with a MICRO paste After removing and preparing the panel cover the entire inner surface of the...

Page 26: ...lecos on the leading edge with a distance of 10 cm between them Place plastic tape over the aileron inspection cover area Apply a thick layer of FLOX MICRO about inches above the surfaces you wish to...

Page 27: ...BID tape in the areas where the hinges will be mounted to the aileron and 6 layers in the flap hinge areas 3 places in the bottom shell for the flap hinges 2 places in the top shell for the aileron hi...

Page 28: ...g Using the pre drilled hinges as a guide mark the holes in the trailing edge of the wing section and carefully drill for the mounting screws Install the anchor nuts on the underside of the wing side...

Page 29: ...r storage and handling reasons but this is the obvious place to describe the process in the manual The wing tips are removable fixing it with approximately 16 screws downgraded anchor nuts Finishing o...

Page 30: ...of curvature extended around the nose of the part The bottom surface has a subtle angle on the centerline the taper in the horizontal empennage thickness is all over the bottom surface generating a s...

Page 31: ...plates to the table with epoxy 5 minutes Cut a piece of 1x2 straight wood or equivalent material with a length of 116 inches and ensure that the trailing edge of the rib template template is aligned t...

Page 32: ...and right on the top and bottom parts of the cladding Mark the points where the left and right BL 57 intersect the horizontal stabilizer spar placement line Likewise mark where the left and right BL 5...

Page 33: ...nd the area within 2 inches of each rib Sand the area 2 inches from the front of the back of the spar to the rear edge hinge line of the stabilizer 4 1 1 Horizontal stabilizer spar Locate the horizont...

Page 34: ...line will locate the front face of the elevator spar Separate the two outer parts of the elevator spar and remove the back shell and core from the central area where the phenolic material will be plac...

Page 35: ...and BL 57 R and L cut with a fine tooth saw Cut slightly larger and sand to final size controlling fit with liner The BL 5R and L ribs will have their inner side aligned with their respective lines th...

Page 36: ...vator ribs is similar to the horizontal stabilizer except for the BL 5 L and R ribs These are positioned with the inner face on the designated line as follows This angle can be accomplished by cutting...

Page 37: ...ndicular to the trailing edge with the aid of a square Carefully remove the inner liner as well as the core in the demarcated area It is recommended that this same procedure be used to prepare the tri...

Page 38: ...ch long BL 57 L to BL 57 R prelam strip overlapping each surface by one inch and also over the previously added material To support the spar in its proper position during curing glue temporarily BL 30...

Page 39: ...ide strip and cut Mix a small amount of FLOX for one make a small radius on both sides of each rib and at the intersection with the spar Apply a small amount of resin where the prelam will be added Ap...

Page 40: ...arting at the leading edge of the center of the mount Take as long as necessary and try not to sand the ribs too much The closer the fit is the better Align the top and bottom liner across the leading...

Page 41: ...cutter spars and the elevator spar taking care not to overfill this area put some FLOX about 1 4 inches high along the trailing edge to glue this surface area as well Carefully position the top casing...

Page 42: ...sed successfully in this cut When the cuts are complete file the corners of each coating 4 5 Trim Tab Before the trim tab is cut demarcate on the outer surface of the top and bottom coating top and bo...

Page 43: ...MICRO paste and place the horn in place Allow healing Give the necessary finish 4 7 Surface closing lamination Make a 3 ply sized prelam to be placed on the face of the stabilizer spar and around the...

Page 44: ...L 5 to BL 17 L and R and BL 42 to BL 54 L and R Locate and mark the location of the hinges on BL 6 5 to BL 15 5 and BL 43 75 for BL 52 75 on both sides right and left and measure 2 millimeters forward...

Page 45: ...eded This part will center on BL 0 Using the horn as a guide drill the eight holes with a drill 3 16 and temporarily mount in place with screws AN3 10A and locknuts Remove the horn and cut the elevato...

Page 46: ...e counterweight tip and its respective fitting into the horizontal stabilizer see figure below Glue in place with a MICRO paste and laminate with 2 layers over the finish Dig the edges of the elevator...

Page 47: ...rweight closing ribs Tape the rib holes together Remove the elevator from the support location and position it vertically so that the swings are down and the resin impregnated lead cures in the forwar...

Page 48: ...below Dig the core and place a MICRO paste for finishing Roll out triangles below rectangle corners with anchor nuts to attach the servo cover Make a slit in the line to exit the actuator arm Foam the...

Page 49: ...ow will prevent the hassle of stopping the fuselage assembly in the middle of the process The figure above shows the major precast components of the fuselage assembly which includes associated parts s...

Page 50: ...glue line and this is where it should be flattened Carefully check these lines before using them for cutting Precisely cut these lines to provide properly located edges for leveling and clamping 5 2...

Page 51: ...rectangular section wood which is a reasonably straight and reasonably lace free material The list of suggested stations and dimensions of the outer width of the fuselage these points are shown below...

Page 52: ...l of both sections If the parts have been flattened correctly the vertical position will be established by the flattened corner of the upper part over the face of the notch of the lower part along the...

Page 53: ...and prepare the sides of the fire wall for gluing laminate a layer of fiberglass cloth over them and allow to cure Disassemble the upper part of the fuselage and set it aside the fire wall will be in...

Page 54: ...ling the lamination job What you leave unfinished in one work session will have to be repaired before continuing on to the next work session Prepare the inner face of the fuselage flange area and two...

Page 55: ...inner section of the lower fuselage with a FLOX paste The location of these reinforcements is shown in the following figure The long gusset must be attached to the edges of the top gusset The lower e...

Page 56: ...ts Clean and rub with a coarse sandpaper all areas that will be covered with layers BID glued around the reinforcements Make paper patterns approximately the shape and sizes shown in the attached draw...

Page 57: ...e lower ones with a total of 8 layers Lamination of these gussets can be performed in two stages by decreasing the amount of overlap by about 1 inch at each stage this will prevent accumulation of all...

Page 58: ...the supplied two layer prepreg panel material Review the sketch below locate and install rigid points for positioning the control The installation of rigid points is more easily done right after the c...

Page 59: ...Correct if necessary and cut the front panel cladding in this line with a little space to each side Remove the core material from this strip helping to bend the flange of this reinforcement Heat the b...

Page 60: ...ement before gluing Dig the core from the edges of this panel and pass a FLOX paste in this cavity protruding from the edges position the panel at the bottom of the fuselage designated for it place th...

Page 61: ...the patch Install this back panel with the bottom edge on the station 78 and the upper end on the station 89 Cut the back cladding near the fold line and dig a triangle into the core to make it easier...

Page 62: ...n width on the front and back face Final bonding of the upper surface of the flange should be postponed until the final assembly of the top of the fuselage as these layers overlap in this assembly 5 7...

Page 63: ...member that station 0 reference is the junction where the firewall is aligned Reference the desired station in terms of the reference station Test cam adjustment in proper position trim as required fo...

Page 64: ...rt the plywood with a MICRO folder cover the back face with 4 layers of BID large enough for a complete overlap around the patch and extending outwards to the edge of the frame the front 4 layer reinf...

Page 65: ...e added to assemble the rudder pedals Cut out the four pieces of 1 4 inch thick plywood from the hard points and locate them on the top surface of the floor panel at the positions designated in the fi...

Page 66: ...lation of the fastening rivets and rivet the nut on the panel Cut the center section of the top floor panel denoted between the two marked curves leaving two inch edges to maintain the alignment of th...

Page 67: ...brackets are cured cut out the 2 inch edges left in the center section of the top panel and prepare the separate top sections and rear closure sections in the same way as the brackets test them for f...

Page 68: ...t the fit of the panel in the center of the landing gear box and make the necessary adjustments to fit it Clean and roughen the side and bottom surfaces where gluing will take place Dig the core on th...

Page 69: ...of the gusset in the area for the train mounting bolts overlapping the sides of the fuselage wall and the faces of the seat gusset as shown in the figure Scale the overlaps of these two sets of layers...

Page 70: ...lywood panel provided and cut out the internal reinforcements French hand to the bekelet from the drawing provided cutout 32 layers of IDB 12 5 8 inches long by 5 7 8 inches wide to be glued to the fi...

Page 71: ...ucture Allow to cure and trim any overhanging edges 5 12 Vertical and horizontal stabilizers The surface of the aircraft s horizontal stabilizer is located above the horizontal fuselage junction line...

Page 72: ...ll holes close to the dorsal fin and use a metal plate to hold the fixed parts in place as shown in the figure below Check the horizontal empennage cut lines that are marked on the mold and should be...

Page 73: ...demarcate the section cut line for positioning the horizontal stabilizer The right rear fuselage and the left part below the horizontal stabilizer will be glued Clean and prepare the joint surfaces fo...

Page 74: ...d with the fuselage centerline measuring forward to the firewall at each end The chord line of the horizontal section of symmetrical airfoil must be nominally defined in WL 3 5 level line in inches Wh...

Page 75: ...nished plane by applying BID tapes in 2 layers of 4 inches width 2 layers of 5 inches wide and more 2 layers of 6 inches wide 6 layers total to improve smoothing in these areas for the final aircraft...

Page 76: ...spar will be located with the rear face to 1 5 8 inches in front of end edge of outrigger If necessary sand the surfaces to obtain a better fit Prepare the surfaces of the parts and the right inner f...

Page 77: ...n of the upper frame rib and spar of the vertical stabilizer on the left casing the cap strip of the spar being optional In these places pass a wide duct tape to prevent the coating from sticking to t...

Page 78: ...er and make a horizontal stabilizer preparation where the liner will be glued After preparing all surfaces prepare two FLOX pastes a more humid one to be applied on the cap strips and on the lower edg...

Page 79: ...rs of 2 inch wide BID on the edge between the position of the plates After these are cured remove the clecos and plates and laminate 2 layers of 2 inch wide BID at these locations also laminate 1 extr...

Page 80: ...however make the temporary fit with the finish of the upper part of the fuselage position this finish with the help of the window cuts and demarcate the position of the frame aligned with the rear edg...

Page 81: ...2 blocks of phenolic material from inch of thickness 3 long and 2 75 wide Cut out a strip of PVC foam from inch thick 45 5 long and 2 75 wide also cut out two strips of this material about 54 long and...

Page 82: ...Rear spar location and installation As mentioned before the assembly of the wing is necessary to establish the steps to follow Position the assembled wing in its respective position on the fuselage Pl...

Page 83: ...that the wing is correctly positioned evenly between the right and left sides Now check that the rear spar has remained above the lower edge of the fuselage With the help of a ruler draw a line on th...

Page 84: ...Test the spar fit before doing any trimming so as not to overcut After a satisfactory fit dig out the core of the exposed parts a little about 1 8 prepare a FLOX paste and pass over the gluing locatio...

Page 85: ...it dig the core of the panels where they will come into contact with other surfaces for bonding To position these it is necessary to make a temporary fit of the upper fuselage together with the aircra...

Page 86: ...llows the top finish of the panel 5 15 Front seat rear assembly Cutout from the 2 layer prepreg panel provided on the rear sides of the front seat Position the lower front side of the finish in place...

Page 87: ...the laminate piece 2 internal and 2 external see figure below and laminate 6 more layers in the same position on the piece allow the cure Remove the corner and finishing pieces in it Remove excess mat...

Page 88: ...tion for gluing the seat backs Cut the 2 layer prepreg panel panels into place Make adjustments as necessary Prepare the surfaces for gluing and dig the core of the panel where it will be in contact w...

Page 89: ...t the inner paneling of the panel and remove the core Laminate 3 layers of BID on the rectangular part from the inside Make a paste with FLOX and fix the NACA input on the inside as shown below 5 17 2...

Page 90: ...inch edge exceeding the dimensions of this reinforcement 5 17 3 Alignment Level the lower fuselage Prepare the upper fuselage level line align with the fire wall first as done for the lower fuselage A...

Page 91: ...n place with the help of the clecos remove the excess from this paste Allow healing 5 18 Luggage compartment cover Fit the rear interior finish fit the rim of the edge of this cover and demarcate wher...

Page 92: ...sired replace 3 inner layers of BID with 3 layers of carbon Finishing the lid fitting it into this rim Do the same finish performed on the BL 126 frame lid referenced in the section 5 12 6 Place the h...

Page 93: ...the path to be split into two sections with a good stabilization point near the middle of the span This elbow also establishes the desired proportion of elevator movement in relation to the pilot s c...

Page 94: ...rface of the rear seat back and install the mount using the 4 10 32 flat head screws provided MS24694 S56 See figure as a guide for these operations Four chamfered washers A315 017 24A are also provid...

Page 95: ...ole through the spar box together with the spar With the wing still in place make sure the phenolic and rear wing spar are centered drill a hole of XX inches centered through these spars 5 21 wing fus...

Page 96: ...engine shaft 5 23 INTERNAL FINISHES The position of the panel is defined by the fit provided by the front side finishing columns Fit the trim and ceiling trim for better positioning align the panel an...

Page 97: ...brace with the pivot line on the WL 11 5 and the yoke mount centered on the fuselage careful elevator actuation rod is not centered on mounting the control cross Using the mounting brackets as templa...

Page 98: ...crew into the front gusset of the front seat for initial assembly With the arm mounted by this screw check the highest position for the second screw and drill through both the arm and seat panel with...

Page 99: ...ween the two sides of the selector and a 1 4 inch spacer with area of influence of at least as much as a 3 16 washer between the selector and the inner wall of the tunnel This bolt will use a self loc...

Page 100: ...el sections 6 4 Aileron Horn Installation The horn aileron two pieces left and right must be fabricated from a 0 125 inch 1 by 1 inch aluminum channel section provided in the kit using the attached dr...

Page 101: ...ion for the arm insert a piece about 1 16 inches shorter than the arm extension but two inches wide Close with 2 layers of BID with at least 1 2 inch of overlap everywhere Drill the holes and assemble...

Page 102: ...the same way as the wing access panels building a flange area with nuts On the other half of the elevator left install nuts for the actuator arm plate to aid in the final installation of the actuator...

Page 103: ...elf lubricated bushings provided in hat shape If the bushings do not have a tight fit in the bore a drop of epoxy or one of the locktite compounds will secure them in place Mount the horn for both sup...

Page 104: ...le approximately centered 6 7 FLAP TORQUE TUBE INSTALLATION ACTION The drive torque tube flap is a one piece assembly for the 4 spot plane and it mounts on the rear face of the rear spar perform secti...

Page 105: ...ue tube assembly by installing the actuating arm CS 32 on each end of the torque tube These should be installed as precisely parallel as possible to avoid dangerous eccentric flight loads when the fla...

Page 106: ...medium bracket in this location the bracket should be close to the plane s centerline if the assembly is good This center mounting bracket can be mounted with 10 32 hex head screws since the surface...

Page 107: ...ol components 6 9 ROUTING RUDDER CABLE AND INSTALLATION Measure the length of the cables to provide the desired rudder pedal position at the neutral rudder position Install cable thimbles and cable bu...

Page 108: ...free end of the tube to the front of the dashboard through the seat bulkhead to the front At the rear of the tunnel the plastic rudder cables will be closed ttreated in a similar way binding them to...

Page 109: ...control funtions be placed against the incursion of any loose objects that could jam the controls The rearmost section of this tunnel under the seating area must use the full height sides to prevent a...

Page 110: ...Chapter 6 Fuselage Translations includes mechanics 6 9 ROUTING RUDDER CABLE AND INSTALLATION Page 105 CONTROL TUNNEL luggage area FIGURE Tunnel of protection for the baggage area...

Page 111: ...e cables and just a little longer than the horn shank at the front end height can be reduced as you go aft if you wish Unless you have enough panel stock remaining select an appropriate section of loc...

Page 112: ...The front end of the device is the rod Break round the edges of these holes to avoid stress concentrations The gear legs and center sections must be dressed flat before the roller pins are installed...

Page 113: ...inch clearance between the gear and the fastening screws Using the heavy bearing washers and the 1 4 inch rubber material provided in the kit on the inside fuselage side of the mounting holes the mac...

Page 114: ...o facilitate the separation of the recess gears as well as provide cushioning against the destructive effects of point loads to the compound The gear legs are supplied pre drilled to the top shafts Tr...

Page 115: ...the spar and along the fuselage wall Bond in place with little dabs of silicone adhesive using duct tape to hold in place while curing 6 12 Rudder Pedals Manufacture the four rudder pedal mounting blo...

Page 116: ...e floor panel with the hard points installed using the rudder mount or other inch pipe sections and use the blocks as a drilling sketch for the eight pins 10 32 hex head screws with about 2 inches lon...

Page 117: ...nics 6 12 Rudder Pedals Page 112 to the right side Study the action of these links very carefully before making any revisions A U shaped cutout of at least one inch square must be placed on both the f...

Page 118: ...ce between the seats and the nominal location rudder pedal The floor panel however must be installed with the ears front side against the firewall as shown in this way it becomes part of the engine mo...

Page 119: ...hell and other layers from the molding process Carefully sand the perimeter of the molded part to remove any dangerously sharp edges Seal of the outer door perimeter according to the molded lines on t...

Page 120: ...ocations for the door armrest air mounts must also be added to the inner door panels Lay four BID ply at the bottom of the window frame front hat hardening frame section centered about 17 inches above...

Page 121: ...with masking tape Position the window at the opening again and again mark the opening more precisely at this point Cut the masking tape to this line and expose the area that will be attached to the w...

Page 122: ...ect indication is provided to ensure that the lock has occurred A rectangular aluminum tube section is provided for the fabrication of this handle The pivot points for the pressure tubes are in line w...

Page 123: ...ue on the handle The end of the spring can be tied to the wall of the latch cabinet and a little dry micro will seal the ends of the wires to avoid scratching yourself in the future A heavy spring is...

Page 124: ...ll areas for correct fitting particularly checking around the cuff Clean and sand all bonding surfaces Apply adhesive to both surfaces especially the hinge area be careful around areas around moving p...

Page 125: ...ent from the hinge surface to the surface of the door assembly Lightly screw the hinges to the door recess taking care not to distort the components or extrude excessive MICRO FLOX out of the ordinary...

Page 126: ...shims in the desired location Sliding one of the hard insert parts into each of the locking pins making a rubber washer for the door s insertion space will aid in positioning this system Adjust the lo...

Page 127: ...e a generous fillet miniature size at any angled intersections Make up a BID four pre lam layers about 5 centimeters wide and about 8 centimeters high and apply to each of these four locations see ske...

Page 128: ...the opening Allow a minimum of 1 2 inch of title overlap in the cut operation As before peel back cover the protector and mask with tape to the opening edge two layers as before Irritate the bonding a...

Page 129: ...mended that the windshield be left out for a while longer INSTRUMENT PANEL The aircraft instrument panel put four is a precast panel which is also optional for the put two kit It s probably a good ide...

Page 130: ...one used for the engine mounting pads see sketch After the parts are separated and cleaned use a minimum of 2 10 32 screws on each end to secure the panel The upper area is left open at this point and...

Page 131: ...or seat anchor belt installations must all have been inserted during previous fuselage assembly operations and must be ready for the following steps If any of the domains referred to in the steps belo...

Page 132: ...hard point on the tunnel sidewall and the castellated nut spanner to prevent the belt movement from loosening the nut The hard spot for the outer belt back section is through the fuselage wall just ah...

Page 133: ...that has worked well on the factory plane Seat panels must be fabricated from the 1 4 inch pre preg panel sections included in the kit The two front seats are separated by the central control tunnel a...

Page 134: ...R SEAT ASSEMBLY The rear seat bottom can be manufactured similarly to the front seat as single panels on each side of the control tunnel Meanwhile the generous head quarter in the rear seat area will...

Page 135: ...and out as the elevator is actuated see figure one rough idea of how this is done Roughly run the cable through the fuselage to the entrance to the control console tunnel between the seats Avoid poten...

Page 136: ...conflicts Fabricate a control lever as per the drawing below from a remaining piece of 1 16 inch aluminum foil or equivalent material purchased locally The smaller the hole should be the closer to the...

Page 137: ...g pressure washer and another washer Install a castellated nut and tighten to desired friction level and install cotter pin Anchor the Bowden housing to the interior tunnel wall with a cable tie about...

Page 138: ...suit the type of landing surface where it will be in operation The seeding must be rotated enough so that even with a flat tire and in a landing attitude the fairing will not reach the surface Refer...

Page 139: ...of gear must be free to rotate to allow for steering on the ground and the interface with the gear leg fairing is an extra place of concern during installation The gear wheel fairing nose comes as a...

Page 140: ...the bolts extending across this surface do not rub into the tire or wheel watch the placement and trimmed length for this If the fixing holes are exploited as suggested rather than using self locking...

Page 141: ...s of each other exactly the same but turned in the opposite direction The original sketches and instructions will be given for the right flap with the left flap identical but reversed 7 1 Bottom cladd...

Page 142: ...long and 3 5 inches wide which should be slightly wider in width to be ground into the top surface later to position the top coat 7 1 2 Bottom Mount Place the spar such that the front face is 13 inch...

Page 143: ...he lower edge of them Make a dry MICRO paste and spread over the hollow edges and under the plywood rib Laminate the inner surface of the spar and the ribs with 2 ply 2 inch wide BID tape The plywood...

Page 144: ...ass work 7 3 Preparation and bonding of the top coat Select the appropriate top coat to be used for this flap and remove any plastic peel ply or any other debris observed Trim top of liner as required...

Page 145: ...and allow to cure When the glue has cured laminate 3 layers of BID on both outermost ribs overlaying the inner surface of both coatings Trim the corners and freely open the holes in the inner rib wher...

Page 146: ...e hinges and locally trim the flap corners approximately 1 16 inches to fit the hinge slightly within the flap surface This will help maintain minimal gap and a smoother surface at the wing flap inter...

Page 147: ...ere is no difference between the left or right aileron coatings Clean these and all related parts removing all peel ply and cleaning all spare parts or other burrs From finishes on cladding to trim on...

Page 148: ...plastic or waxed paper on a flat surface Allow a cure Remove any spare glass and proceed with aileron assembly 8 2 Initial assembly of the lower half Prepare a flat surface for mounting the aileron an...

Page 149: ...place with tape Place the aileron mount in the respective wing position The thickness of the aileron must not be so great as to allow interference with the wing structure with the movement of the aile...

Page 150: ...th wax for future glass work 8 5 Top coat installation Position the top casing in position on top of the mount and carefully inspect the ribs and spars for fit Rework any high spots observed by sandin...

Page 151: ...re outer surfaces for final closing glue Roughen and clean all glue areas remember to make a small radius with a MICRO paste on the corners Apply 3 coats of BID to all outer surfaces of ribs and spar...

Page 152: ...e areas cut a recess about 1 16 for the hinge cradle Align the aileron with the trailing edge of the wing in the final position and drill the holes and install the hinges We suggest using flat head re...

Page 153: ...nd the corners to remove sharp corners and materials which extend beyond the molded corners Sand the piece finishing it Locate the marked parts of the spar and ribs and cutout from the laminate panel...

Page 154: ...spar to improve the fit of the casing angles Locate the rear rib sections and establish positions with the top surface of the top of the rear top rib aligned with the top inside corner of the hinge li...

Page 155: ...fill with a dry MICRO paste Laminate with 2 ply BID tape 2 inches wide on the back side for the entire length of the spar Glue the back and front ribs in place and laminate with 2 ply 2 inch wide BID...

Page 156: ...at as to allow interference with the fuselage structure with its movement It should rotate freely between 25 to 30 degrees to both sides without interference 8 13 Rudder actuating arm After defining t...

Page 157: ...railing edge for alignment Place an angle bracket with weights over the lining bonding areas on the spar and trailing edge and weights on the ribs THE ASSEMBLY WILL BECOME RIGID AFTER THIS OPERATION I...

Page 158: ...rudder Check continuity from top of vertical stabilizer to rudder If satisfactory secure placement and laminate top of rudder with 2 layers of 2 inch BID tape Allow healing Take a block of styron foa...

Page 159: ...es with 2 coats of BID Allow healing Trim the spare and finishing material from the part with 100 sandpaper 8 15 Balancing Cut a hole about 1 inch in diameter in the front rib about 4 inches behind th...

Page 160: ...the rudder so the counterweight is down and allow for healing Take the cut out piece for the hole fill with MICRO and fit this into the hole and laminate with a 2 ply BID tape overlapping 1 inch from...

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