Jabiru Aircraft. Fit Ailerons

Transcription

1 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 (4) Hinge Leaf 3/16 A1 (6) N Aileron Attachment Plate Reo (2) PH0409N 2-Lug Anchor Nut (6) TAPK 3-3 Rivet (12) TAPK 6-6 Rivet (48) Material Required: LC3600 LC3600 AF303 Resin Hardener Fibber Flock 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 fiberglass plate to fit around the flap & sit flush in the joggle. Fit Ailerons to wing Page 1 2/16/04

2 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 Peel Cloth removed from aileron attachment area on Wing the glass plate so the 5 min araldite does not stick to it. Ensure you have the plate 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 38mm from each end of the Aileron & mark. From the opposite end to the Aileron Horn measure in 810mm & mark. This will be the hinge position. See Aileron Drawing below. 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. On each wing you will need a left (for the Left wing) or right (for the ring wing) Two x Centers Fit Aileron to Wing Page 2 2/16/04

3 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. 9. Sand Reo s to shape to ensure it sits against the glass plate. 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. Aileron Reo s in Right hand wing positioned where Aileron hinges locate. Fit Aileron to Wing Page 3 2/16/04

4 Position the hinges as per Drawing 20270K2 and drill the rivet holes Fit Aileron to Wing Page 4 2/16/04

5 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. 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. Fit Aileron to Wing Page 5 2/16/04

6 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. AF303 glass cloth being applied to Aileron pre-mould strip. 19. Allow to cure. 20. 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. 21. Mark the edge of the aileron onto the pre-mould strip to form a cutting line. 22. Using a jigsaw of hand hacksaw, cut along marked line. Sand with a straight sanding block. 23. 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). 24. 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. Fit Aileron to Wing Page 6 2/16/04

7 26. 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. 27. 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. 28. Check for full deflection using the Aileron Template. 29. Remove screws from wing & aileron & drill rivets holes to 3/16. Countersink holes enough so the rivet head sits below the Drilling Jig for Retained nuts Fit Aileron to Wing Page 7 2/16/04

8 surfacof the skin. 30. Screw MS screw into a lug anchor nut from top to make a drilling jig. Refer to Photos. 31. Drill the holes for the anchor lug nut. 32. Sand back all bonding surfaces of Aluminum hinge & pre-mould strip. Clean with acetone. 33. 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. 34. Remove aileron from wing after finish riveting & clean excess flock off with a small about of Acetone. 35. Rivet the 2-lug anchor nut for the hinge pin retainer into place. 36. Allow to cure, then assemble aileron to check movement. Fit Aileron to Wing Page 8 2/16/04