Glass Cloth (supplied pre cut) Fibre Flock

Transcription

1 Fitting Horizontal stabiliser:- Reference: Parts required: Drawing Photos Upper & Lower Fuselage Assy Horizontal Stabiliser Material required; LC 3600 LC 3600 AF 244 Resin Hardener Glass Cloth (supplied pre cut) Fibre Flock Procedure: Please Note:- Since the aircraft is sitting on its own wheels no trestles are necessary but it would be advisable to have a support under the trim assembly. Photo shows a joined fuselage. 1. The Upper and Lower Fuselage halves have been factory joined with the horizontal stabiliser pre-fitted but it is a good idea to double check before bonding. 2. Match the centre of the Horizontal Stabiliser, at the lower edge, with the centre of the Lower Fuselage (see Photo) Note that the bottom surface of the Horizontal Stabiliser is the side OPPOSITE the hinge reinforcing. Centreline of stab and fuselage Photo Positioning of the Horizontal Stabiliser 3. Pre fit the Horizontal Stabiliser to the Lower Fuselage and secure with 4 x self tapping screws, after correctly aligning the Stabiliser with the horizontal centre line and the centre marks referred to in para 2 above. Clamp each side of a straight edge approximately 2-3 meters long ( a heavy aluminium angle makes a good edge) to the front of the front door frames, level with the water line. Measure equal distances from the waterline back to the leading edge of Stabiliser and also check that it is parallel with the waterline. Refer Photo Fitting Horizontal Stabiliser Page 1 26/02/04

2 Straight Edge across doorframe should line up with horizontal Photo Straight edge across waterline. Straight edge clamped to fuse join line 4. You are now ready to disassemble the work that you have completed in paras 1 3 and to prepare to permanently join the components. 5. Prepare all joining surfaces by either removing peel cloth or lightly sanding, ensuring that they are clean and free from dust, dirt, gelcoat if in contact or other contaminants. 6. Joining: Note Make sure you have attached the elevator & trim cable as this will be difficult to do after stab is in. Mix LC 3600 resin and hardener. Put a Fitting Horizontal Stabiliser Page 2 26/02/04

3 quantity of resin/hardener aside which will be used to coat the joining surfaces prior to apply the Fibreflock paste that you now make with the remaining resin/hardener. Mix in some Fibreflock to achieve a firm paste. (Too wet and it will sag and not too dry) Brush a thin coat of resin / hardener to all joining surfaces, on both parts to be joined. Refer photo 7. Locate the Horizontal Stabiliser in the Lower Fuselage. Triple Check alignment of the Stabiliser with the waterline marker and that each end of the Stabiliser is of equal distance and parallel with the join line. 8. Apply resin/fibreflock paste to the Stabiliser, along the top & bottom joining surfaces on the fuse. This is done by prizing the two halves apart with a implement (chisel) & with a suitable spatula apply the resin/fibreflock paste to the joining surfaces of the joggle-joint flange & applying in the gap. If you have a empty corking cartridge, fill with epoxy & flock & pump into void. See Photo. Ensure 100% coverage. Photos Applying Resin/Flock of of all all joining surfaces where surfaces stabiliser where is stabiliser in contact is in with contact joggle with joggle 9. After applying flock & happy with the amount of flock in the join, screw the two joining surfaces together with self-tapping screws on the top & bottom. See Photo 10. Try to get as much flock into the radius on the inside of the top-stab as possible. See Photo 11. After resin has cured (12-24hours later) prepare the joggle of the horizontal stabiliser join line by 300mm with 50mm overlap over LE. 300mm Fitting Horizontal Stabiliser Page 3 26/02/04

4 sanding all gelcoat off bonding surfaces. This will be a 50mm (2 ) area over the All Reinforcement Layers Wrap Around Leading Edge And Extend Aft 50-mm Reinforce This Area Upper & Lower Surfaces Both Sides of Aircraft 2 Layers AF303 Reinforcement to Overlay, existing HT to Fuse Joint Section ViewThrough Reinforcement Extend Reinforcement Spanwise 300-mm joggle or to the top of the radius & 250mm out onto the horizontal stabilizer side. 12. Next apply 1 layer of AF303 (100mm x 700mm) over the joggle. The Cloth needs to be 50mm either side of the joggle which wraps around the top & bottom. Then lay 2 layers of 300mm x 350mm over the 100mm x 700mm. The cloth should start from the trailing edge of the stabilizer & over lap on the leading edge of the stabilizer to give four layers 300mm 2 Layers AF303 Top and Bottom Fitting Horizontal Stabiliser Page 4 26/02/04

5 on the LE only. See photo & drawing. 13. Clean up the excess resin with acetone. (Any dribbles of resin are extremely hard to remove once the resin has dried.) 14. Peel Cloth joint when complete & let cure. 15. Using a piece of Styrofoam (cut from the wing packing) 225mm long, 57mm high & 27mm deep or the depth of the channel. 16. Insert foam into channel of horizontal stabiliser as per photo. 17. Project a line from the outer edge of the stabiliser to the lower radios of the rear channel. Mark onto foam & cut. 18. Chamfer the edge of the foam at each corner so you have a nice radios. Applying flock to fuse-stab 19. Sand all bonding areas where gelcoat has been applied or there is a shinny surface. 20. Mix Epoxy Resin & flock, divide into two. 21. Wet all bonding areas that are to have glass on them. 100mm (4 ) 22. Apply Epoxy & flock to foam. Fitting Horizontal Stabiliser Page 5 26/02/04

6 23. Lay 3 layers of AF303 (320mm x 700mm) over the foam block & 50mm (2 ) either side of the block & onto the top fuse. See Photo. Pre Fitting Rear fuse Reo Gusset Area to be glassed with 3 layers of AF303 57mm 225mm 24. Let Resin Cure & trim excess glass. Fitting Horizontal Stabiliser Page 6 26/02/04