12. Wings, Flaps, Ailerons and Struts

Transcription

1 12. Wings, Flaps, Ailerons and Struts Fit Aileron Hinges Reference: Drawing 20270K2 Photo 12.1 Parts Required: Aileron LS N Aileron RS Hinge 3/16 A1 (4) Hinge Pin (4) PH0059N Rivet 73 AS 6-4 (16) Materials Required: LC3600 LC3600 Procedure: Epoxy Resin Epoxy Hardener Fibre Flock 1. Position the hinges as per Drawing 20270K2 and drill the rivet holes 2. Mix Resin/Hardener/Flock and bed the hinge leaves in place. 3. Rivet the hinge leaves in place, prior to curing. Photo 12.1 An installed hinge leaf. Fit Aileron Hinges

2 Drawing 20270K2 Aileron Assembly Details Fit Aileron Hinges

3 Fit Ailerons Reference: Drawings and 20210K1 Photos Parts Required: Wing LS N Wing RS Aileron LS N Aileron RS Aileron reinforcement Left N Aileron Reinforcement Right Aileron Reinforcement Centre (2) Hinge Leaf 3/16 A1 (4) N Aileron Attachment Plate Reo (2) PH0409N 2-Lug Anchor Nut (4) TAPK 3-3 Rivet (8) TAPK 6-6 Rivet (24) Material Required: LC3600 Resin LC3600 Hardener Fiber Flock AF303 Glass Cloth Procedure: 1. Ensure peel cloth has been removed from Aileron attachment area. Fit Aileron Attachment plate into joggle recess. Drill & screw a self tapping screw into each end of the plate. Fit Aileron attachment plate into joggle 2. Trim fibreglass plate to fit around the flap & sit flush in the joggle. Fit Ailerons

4 3. Attached glass plate to a large piece of plywood or chipboard with some 5 min araldite. You will need to put a layer of packaging tape onto the glass plate so the 5 min araldite does not stick to it. Ensure you have the plate Peel Cloth removed from aileron attachment area on Wing flat against the board as this is how the finished product will turn out like. 4. Place board onto wing & check that the plate is sitting the recess. You should see a 2-3mm gap (1/8 ) This is filled with epoxy & flock. 5. Measure in as per Aileron Drawing above. 6. Position Hinges onto the top of the Aileron & mark each end of the hinge on the aileron. 7. Position Aileron onto wing & transfer marks onto Aileron pre-mould plate. Fit Ailerons

5 On each wing you will need a left (for the Left wing) or right (for the ring wing) Two x Centers Position Aileron reinforcement into marked position. Position reo so that the contoured edge fits the aileron channel & the flat sits onto the aileron plate. Aileron Reo s in Right hand wing positioned where Aileron hinges locate. 8. Insert Aileron Reo s into channel. To determine which reinforcement goes where, there should be four reo s that have curled ends (this is call Centre ) & 2 that have a curled end at one end only ( Left & Right ). The straight edge buts up against the wing tip end. Fit Ailerons

6 9. Sand Reo s to shape to ensure it sits against the glass plate. Position the hinges as per Drawing 20270K2 and drill the rivet holes 10. Mix Epoxy Resin & divide into two portions. 11. Wet all bonding surfaces with Epoxy resin. 12. Apply Flock to Aileron Pre-mould joggle Joint, this will require about 2mm (1/8 ) of flock to fill the void. 13. Position Aileron Pre mould Plate onto wing into joggle. Let the Flock squash out, then scrape of the excess. Smooth flock with you epoxy resin brush. Fit Ailerons

7 14. Apply Flock to Aileron reinforcement plates & insert into channel in correct positions. 15. Lay 2 x (AF303) 220 x 160 AF303 over each hinge reinforcement over each reinforcement, making sure the cloth has been evenly spaced over reo. 16. Lay 1 x (AF303) 1250 x 160 over the full length of the channel. Let glass hang over edge, as this will be trimmed when cured. AF303 glass cloth being applied to Aileron pre-mould strip. 17. Remove peel cloth from hinge Reo (reinforcement) and flap attachment areas. Rivet the hinge leaves in place, prior to curing. Turn the wind upside down 18. Allow to cure. 19. Fit Aileron to pre-mould strip, line the edge of the aileron with the wing tip & the trailing edge of the flap to form a straight line. Note: The aileron will have to sit above the pre-mould strip & might need sanding at each end for this to fit between the wing tip & Flap. 20. Mark the edge of the aileron onto the pre-mould strip to form a cutting line. 21. Using a jigsaw of hand hacksaw, cut along marked line. Sand with a straight sanding block. 22. Position the aileron hinges to Aileron only and mark the rivet holes. Note: This is best done by positioning the hinge on top of the surface & allowing the thickness of the hinge pin between aileron & the Aileron pre mould plate. (The hinge leaf where the pin goes through will need to be lifted half way over the skin). Fit Ailerons

8 23. Mark all holes using the hinge as your template & only drill the two outer holes for the rivet to 5/ Attach the hinge leaf to the aileron using M4 x 12 machined screws. 25. Centrally Position Aileron onto wing & line the edge of the aileron with the wing tip & the trailing edge of the flap to form a straight line. Allow a hinge pin thickness between the aileron & the pre-mould strip. 26. Repeat procedure #24 & #25. Note: If the aileron is not flush with the wing skin, you may need to cut a thin shim to put between the hinge & the skin of the aileron or wing. 27. Check for full deflection using the Aileron Template. 28. Remove screws from wing & aileron & drill rivets holes to 3/16. Countersink holes enough so the rivet head sits below the surface of the skin. 29. Screw MS screw into a lug anchor nut from top to make a drilling jig. Refer to Photos. 30. Drill the holes for the anchor lug nut. Drilling Jig for Retained nuts 31. Sand back all bonding surfaces of Aluminium hinge & pre-mould strip. Clean with acetone. 32. Bond the hinges with Epoxy/flock & rivet into place with TAPK 6-6 or 6-4 countersunk rivets. Rivet the hinge on the aileron first & then rivet hinge leaf to Aileron pre-mould strip with aileron still attached. This way your will be assured that the alignment will be correct. 33. Remove aileron from wing after finish riveting & clean excess flock off with a small about of Acetone. 34. Rivet the 2-lug anchor nut for the hinge pin retainer into place. 35. Allow to cure, then assemble aileron to check movement. Fit Ailerons

9 Drawing Wing Assembly Fit Ailerons

10 Drawing 20210K1 Wing Assembly Detail Kit Fit Ailerons

11 Fit Flaps to Wing (Please note: the same procedure applies to the long wing except there is 4 hinge points instead of 3 hinge points. Reference: Drawings and 20210K1 Photos Parts Required: Wing LS N Wing RS Flap LS N Flap RS Flap Mounting Arm (6) Material Required: LC3600 LC3600 AF303 Procedure: Resin Hardener Fibre Flock Glass Cloth 1. Ensure Peel cloth has been removed from wing in the three flap pivot points for each wing. 2. Place 3 straight edges across the lower surface of the wing & use a weight at the end to secure in place. This can be Peel Cloth removed in flap pivots position. a piece of wood, aluminium or steel angle. 3. Attach flap to wing using the three straight edges as a clamping point. Ensuring that the lower surface of the flap is level with the lower surface of the wing skin and clamp to wing, as shown in photo. See photos Flaps clamped to straight edges. Fit Flaps

12 Insert a 2mm spacer between flap & wing 4. Insert a 2mm spacer to determine the gap between the flap & the wing skin when it is in the up or neutral position. See Photos below. 5. Cut 6 x ¼ steel Bundy tube spacers out of length provide on card (about 6-7mm. The length is determined by the thickness of the flap arm. Please note: The ¼ steel tube that is to be inserted into arm should protrude by 1mm (1/8 ) either side of the threaded stainless steel insert & should be free to rotate. This stainless bush that has been inserted into the wing for you may need reaming to ¼ to allow the steel insert to rotate. 6. Insert Steel bushes onto flap pivot arms. 7. Locate fibreglass channel flap hinge brackets onto flap pivot points. Insert AN3 bolt into each hinge. Refer to photo 8. Rotate flap pivot arms onto wing & mark the outer position of each arm. 9. Sand each hinge lightly, making sure you have no peel cloth or gellcoat near your bonding area. 10. Remove flaps from wing & put a layer of packaging tape (celler tape or something with a shiny surface) to flap channel & leading edge of flap where bonding. This will stop the flap from bonding to the wing. ¼ Bundy tube to be inserted into flap pivot arms Marking Flap Pivot points Fit Flaps

13 11. Mix about 9oz of LC3600/Fibreflock. Dividing half the quantity resin & mix one half into flock. 12. Wet all bonding areas with LC3600 epoxy resin. Fill flap channel pivot arms with flock & rotate onto wing. Filling Channel with flock & making a radius around flap arm 13. Apply 3 layers of AF303 (1 x 200 x 100, 1 x 200 x 150, 1 x 200 x 200) or marked cloth supplied to each hinge attachment, refer to photo. Pay particular attention to the root of the hinge to use suitable ply pieces to hold these reo pieces under end plug until cured. Left: Applying Flock to Flap Arm Right: Applying Fibreglass to Flap Arm. 14. Apply peel cloth to glassed hinge areas. 15. Cure: then remove peel cloth and sand excess cloth. Fit Flaps

14 Left: Flap Pivot arms with Peel Cloth. Right: Sanding glass when resin has cured. Fit Flaps

15 Fit Aileron Cable Reference: Drawing 20400K4 Parts Required: PC00294 Aileron Cable PC0089N Cable Clamp PC0099N Cable Anchor AN3-5A Bolt (2) AN Washer (2) MS Nut (2) PB0019N Rod End Female PH0636N Nut Jan S/S 3/16 UNF Material Required: Procedure: 1. Tie Aileron Cable to string which has been factory fitted to Aileron Cable channel in wing. Pull the Aileron Cable into position and discard the string. 2. Mount cable with Cable Clamps, Cable Ailerons and hardware as shown in drawing 20400K4. 3. Fit Rod End Female and locknut to end of cable. 4. Repeat Items 1 4 for other wing. Drawing 20400K4 Aileron Cable Att. Plate Details PLEASE NOTE THIS HAS BEEN PUT IN BY THE FACTORY. Only use this as a guide Fit Aileron Cable

16 Fitting Wings, Struts and Fairing to Fuselage Trial Fitment Reference: Drawing (Refer Procedure 12.2) Parts Required: Wing (2) AN3-10A Bolt (6) AN Washer (14) AN Washer (20) MS Nut (13) PH0139N Screw 6g x ½ (8) PH0646N Screw 6g x ¼ (30) AN4-13A Bolt (4) AN Nut (4) AN5-15A Bolt (2) AN Washer (2) MS Nut (2) N Flap Push Rod (2) PB0009N Rod End Male (4) PH0636N Nut Jam 3/16 UNF (4) AN3-12A Bolt (2) AN3-7A Bolt (6) Spacer Sleeve (6) Cable Wedge (2) PH0259N R-Pin (2) PB0019N Rod End Female (2) Material Required: Procedure: 1. While the wings are still not fitted to the aircraft attach aileron cable to aileron horn with AN3-10A bolt. Ensure that here is an AN washer on each side of the rod nut and that a AN washer is installed on the outboard side of the rod end so as to ensure that the cable is not released, should the bearing fail. Complete with MS nut. 2. Fit perspex inspection cover to recess in bottom outboard section of wing with 6g x ½ pan screws. 3. Repeat steps 1 2 for other wing. YOU ARE NOW READY TO TRIAL FIT THE WINGS AND WILL PROBABLY NEED THE ASSISTANCE OF ONE OTHER PERSON. 4. Position the wing on the floor taking care not to damage the wing strut attachment lug. At this stage the Aileron should be attached to the wing but the Flap should not be attached. Fitting Wings etc Trial Fitment

17 5. Lift the inboard (root) end of the wing into position (Aileron Cable through hole in fuselage) and attach to the wing attachment fittings in the fuselage with AN4-13A bolts. AN washers and MS nuts. 6. Lift the outboard (tip) end of the wing and attach the Wing Strut with AN5-15A bolts or close tolerance bolt, AN washers and MS nuts at the wing end and AN5-15A bolts, AN washers and MS nuts at the fuselage end. It is most importance to attached the strut to the wing first using an AN5 (5/16 ) bolt & offer it to the fuselage wing strut beam. If you have to put any side loading onto the wing strut for it to line up with the strut beam you will need to do the following. a. Insert a soldering iron into the stainless bush. b. Heat bush enough to soften the resin. c. Insert a rod into the bush & carefully twist the bush in the direction need for it to line up with the beam. d. When bush has cooled down repeat #6. e. Remove the wing strut from the wing & repeat procedure #6. Repeat steps a-d if you find that the strut does not line up with the wing. Note: DO NOT OVERTIGHTEN THESE BOLTS. They should be just tight enough to prevent rotation. Overtightening may result in failure of the Wing Strut Lugs. 7. Before attaching Flaps, fit push rod 160mm Aluminium rods to flap with male ball joints and jam nuts in each end. On the flap end of the push rod, fit 1 x AN3-12A Bolt, 5 x washers, 1 x MS nut, 1 x washer on each side. 8. Fit the flaps to the Wings with AN3-7A bolts, nuts, AN washers and 8mm ¼ steel tube Spacers Flap as shown in Drawing Attach to the flap drive with AN3-10A Bolt ensuring an AN washer is fitted on the outside of the rod end bearing. 10. Fit a rod end female to the inboard end of the aileron cable together with a jam nut PH0636N. 11. Anchor aileron cable to seatback restraint with cable wedge and R. Pin. 12. Fit rod end female to aileron bellcrank with AN3-10A bolt, AN washer x 1, AN washer. 13. Repeat steps 4 12 for other wing. 14. Ensure aileron and flap controls operate smoothly. 15. Fit wing root fairings with 6g x ¼ self tapping screws. 16. Fit lower wing strut fairings with 6g x ¼ self tapping screws. Be careful not to drill holes in wing strut beam under seats. 17. Fit upper wing strut fairings with 6g x ¼ self tapping screws. Be careful not to frill holes in wing spar which is 25mm each side of wing attachment lug. 18. Wings are now able to be removed for preparation and painting. Remember to remove the flaps and aileron cables from seatback anchors, before removing the wings. Fitting Wings etc Trial Fitment

18 Assemble Flap Handle Reference: Drawing Parts Required: Flap Position Pin (1) MS Cotter Pin (1) AN4-11 Bolt (1) AN310-4 Nut (1) Aluminium Washer (2) Nylon Washer (2) Flap Handle Assy (1) Spacer Sleeve (4) N Push Rod Inner (1) AN Washer (6) AN3-6A Bolt (1) Flap Control Rod Assy (1) Push Rod Flap (2) AN316-3 Nut (6) MS Nut (8) AN3-11A Bolt (6) AN Washer (20) PB0009N Rod End Male (6) Material Required: K219 5-min Epoxy Fibre Flock Procedure: 1. Before gluing flap handle cover to flap handle place nylon and aluminium washer inside first then glue together with K219 5-min and flock on the inside of the flap handle cover, then place onto flap handle. Allowing the 5 min to bond all the way around. Then cut and drill as per drawing. After the flap handle is complete with the holes drilled and cuts made, you will have to fit the male ball joint and pin position flap lever. 2. Counter sink flap handle enough to the head of the bolt is flush (Shown is section BB on the drawing) then assemble as per drawing Bolt pin flap lever on the flap handle as shown in section AA on drawing Fit flap handle to flap mount plate as per drawing section BB. Assemble Flap Handle

19 Drawing Flap Assy Controls Assemble Flap Handle

20 Fitting Push Rod from Flap Handle to Flap Shaft Reference: Drawing (Refer procedure 12.6) Parts Required: N Push Rod Inner PB0009N Rod End Male (2) PH0636N Nut Jam S/S 3/16 UNF (2) AN3-11A Bolt (2) AN Washer (8) AN Washer (2) MS Nut (2) Material Required: Procedure: 1. Screw aluminium push rod inner onto the male ball joint and jam nut on the flap handle. Screw a male ball joint and jam nut onto the other end of the push rod. 2. Bolt male ball joint onto flap shaft and flap handle as per drawing Section CC. Fitting Push Rod & Flap Handle