CHAPTER 3 REVISION LIST ‘The following lst ofrevisions will allow you toupdatethe Lancair IV construction manual chapter listed above Under the "Action" column, "R&R" directs you to remove and replace the pages affected by the revision. "Add" directs you to insert the pages shown and "R" to remove the pages. Description (Changed 2" line from bottom. Added text to DS. Clarified text in Step F2, paragraph 1. Changed text in Note. 3-38 thru 3-39 3-40 B-41 and 3-42 R&R ‘Added page. KEK ‘Moved pages for the new page 3-40. = ae M aeCHAPTER 3 FAST BUILD HORIZONTAL STABILIZER AND ELEVATOR REVISIONS ‘From time to time, revisions to this assembly manual may be deemed necessary. ‘When such revisions are made, you should immediately replace all outdated pages with therevised pages. Discard the outdated pages. Note thaton the lower right comer of each page is a "revision date”. Initial printings will have the ‘umber'0" printed and the printingdate. All subsequent revisions will have the revision number followed by the date of that revision. When such revisions are ‘made, a "table of revisions" page will also be issued. This page (or pages) should >beinserted in front ofthe opening page (this page) ofeach affected chapter. Anew "table of revisions" page will accompany any revision made to a chapter. Arrows "Most drawings will have arrows to show which direction thepartsare facing, unless the dravring itself makes that very obvious. "A/C UP" refers to the direction that, ‘would be up if the part were installed in a plane sitting in the upright position. In ‘most.cases the part shown will be oriented in the same positionas the partitself will be placed during that particular assembly step. However, time goes on and changes are made, so careful attention should be paid to the orientation arrows. ‘That old cartoon of the guy agonizing over the plans for his canoe, built one end ‘up, one end down, should not happen in real life. Especially to you. Fi —“(Giapers [me arr - SSCONTENTS 1, INTRODUCTION 2, SPECIAL PARTS,TOOLS, AND SUPPLIES LISTS, 3, CONSTRUCTION PROCEDURE, HORIZONTAL STABILIZER ASSEMBLY CRADLE, HORIZONTAL STABILIZER HINGE BRACKETS ELEVATOR HINGE INSTALLATION ELEVATOR TRIM TAB COUNTER BALANCING THE ELEVATORS CLOSING THE HORIZONTAL STAB AND ELEVATORS ELEVATOR TRAVEL STOPS anny OMPE ee Far WEB | eS1. INTRODUCTION ‘The horizontal stabilizer (H. Stab.)is comprised oftwo structural skins(upperand lower), and an internal structure consisting of sparsand ribs. Thisisasymmetri- ‘eal airfoil so upper and lower are the same. You'll notice that there is a 1" LE. Joggle that does make the two halves look different. The half that has the wrap ‘around L.E. with joggle is the half that must be firstlaid into the assembly cradle that you'l be making and for the sake of discussion, we willcall this half the lower skin, On the fast build the spars and ribs are already installed in the lower half. ‘The H. Stab, is also tapered, which means that the thickness will vary. The thickest partis atthe center line and the thinnestisat the tip. Astraight line will exist from any relative % of chord atthe root to the same % of chord at the tip. For example, the points along the 25% chord will form a straight line. ‘The elevator consists of.a left and right half. The internal structures completed except for the installation of the trim tab and the counterweights, AAR WEB | |S2. SPECIAL PARTS, TOOLS, AND SUPPLIES LISTS A. PARTS # PN QTY DESCRIPTION 1) 1008T-FB-PR 1 —_UpperH. Stab, Skin 2) 1008B-FB-PR 1 Lower H. Stab. Skin with Premolded Structure 3) EL-053-0 5 H.Stab. Hinges (Not shown: (20) 1000-8 nutplates and (40) AN426A3-4, (20) AN3-GA bolts, and (20) 'AN9G0-10 washers used to secure the hinges to the H. Stab..) 4) 1009TL-FB-PR 1 Upper Left Elevator Skin 5) 1009TR-FB-PR 1 Upper Right Blevator Skin 6) 1009BL-FB-PR 1 —_LowerLeft Elevator Skin with Premolded Structure 7) 1009BR-FB-PR 1 —_LawerRight Elevator Skin with Premolded Structure *8) 9020016 1 Elevator Weldment Note: refer to the following figure for mounting hardware 9) REH-053-U 4 Elevator Hinges (Elevator) (Not shown: (8) K1000-3nutplates and (40) AN426A3-4 rivets, (8) ANS-5A bolts, and(20) ‘AN960-10 washers used to secure hinges to elevator. 10) 2020016 1 Left Side Premolded Counterweight 2.020026 1 Right Side Premolded Counterweight 1) S6A, 1 Trim Tab Servo (Not shown: (5)MS24693-$28 screws, (5) K2000-06nuiplates, and (10) AN426A3-4rivets| ‘tw socure it) 12) 5.020016 1 ‘Trim Tab Access Plate 13) 1063T = 1—_Upper Trim Tab Skin 14 10638 = 1 Lower Trim Tab Skin 15) MS20001 2 Trim Tab Hinge (Not shown: Trim tab actuator arm TT-02, (4) hard rivets to secure it.) = Chapters [REV ANIOTOS Beare wers [Sesupplied with an BL-085-02. "Note: Youmay have been st Fig. 3 Horizontal Stabilizer Breakdown und Elevator Horizontal Stab. atB. TOOLS Rivet squeezer or bucking bar ‘Shot bags (10 Ibs. - 25 Ibs, assorted weights are great) Sabre or band saw Level, flat table top, approximately 11! long and 30-36" wide nails Or wood screws hammer or screwdriver 6 level Drill motor Drillbit, V8" Drill bit, #12. Drillbit, #40, 100° countersink Cleco tool and about two dozen Clecoes (a real handy tool for this project, but not mandatory) ‘Dremel tool with a ball grinder bit Beat gun 1 Rotary cutter (Looks like a Pizza cutter, but a pizza cutter WILL NOT WORK), available through Lancair. Lset Bondo™ Plasticapreaderset- available from auto parts stores, contains 3 spread- ers of varying sizes. 1 8*wideroller for wetting out BID tapes. Metal ones are easiest to clean. Beebe gee TW Chapters | REV. "ANI/-05-98 ae vrs | eeC. SUPPLIES 130 ale 5 ale ake ak ak 1 ake ae 1 a at a ah ae ake ae ake +#6x8/5" pan head shoot metal serews Instant glue pes, of wood (about 3" x3" x 1/2") to brace aft spar during bonding Release tape (clear, thin packaging tape, 2" or 3" wide is good) Artists spray adhesive or similar Wood glue Bondo™ Plastie spreader (for the Bondo™) Nails or wood screws for fabrication oferadles Sandpaper, #40 grit Red felt ip marking pen MC (Methylene Chloride) cleaner Hysol structural adhesive ‘Tongue depressors/ mixing sticks [Acetone (aone pint can from the hardware store should seeyou through the whole aireraft construction ifused sparingly) Mieroballoons Flor Epoxy Plastie sheet for preparing BID tapes (2or mil thick (maximum 8 mib) painter's dropeloths work great. Tape measure po. 0.2/4" x 31-718" for BLD cradle pes, 10-34" 25-172 for BL34 eradle pes, 10.8/4" x 21-1" for BL 60 cradle pos 66" 1-1/2" x 2"x 1/8" hick) 80" angle iron pes. 85" 1-1/2" 2"x 1/8" thiel) 90" angle iron Tv, ANIOESH a Chapters JA IV-FB |” orizona ta and levator‘3, CONSTRUCTION PROCEDURE A. BUILDING THE HORIZONTAL STABILIZER ASSEMBLY CRADLE, ‘The assembly cradle is needed to insure that a "true" H. Stab...with no twists or ‘warpsis the result ofyour work. You'll make the simple airfoil sectioncradlesthat must be aligned with each other. Using a level, flat table top is ideal, but not. ‘essential. What is essential is thal the chord line references on the airfoil cradles be properly aligned with each other and that good straight lines be established ‘between these three airfoil section cradles. Horizontal Stabilizer Cradle Patterns Fig. 3A int & Row. #s ‘top Cradle Print & Te ove Shows cutout for the Tins 2s US" iron angle supports. Cradle Location ‘Bottom Cradle ‘34 from centerline “Alignment line. This line ‘is used to align all the cradles "SH Marks the fwd face ofthe aft spar "Wir Marks the fed face of the ford spar Note: ‘This tab should be in the same level (horizontal) plane for all cradles. NOTE; Precision pre-cut eradles are available through Lancair. 7 ‘Chapters [Rev Anion ae Ake wee | eSAl, Locate the three patterns A.051,A-052, and A.055 for the H. Stab. airfoil sections, ‘You'll bemaking two of the BL34.and BL60cradlesand one for BLO. Using spray adhesive or similar, glue them to the 1/2" thick particle board. You've been supplied with twocopies ofthis blueprintso thatone copy can alwaysremain intact asa reference, At this time check the blueprints for seal: Chord lengths Station Chord length ‘Tolerance BLO 28.88 218" BL34 22.11 28" BL60 1730 2 U8" NOTE: Sometimes patterns are distorted in the blueprinting process. A2, Cut the patterns out using a sabre or band saw, Cutjust along the inside of the line and then sand up to it. NOTE: You may have to use a shim where the two cradle halves clamp together to compensate for the saw blade thickness Horizontal Stabilizer Table | Fig. 3:4:2, re . eS wt + Suggested height. Adjust if desired! 72 “<< Chapters [RE _ANILOE-OG Meevrs | eeeAS. Construct a table for yourjig. We suggest a box-frame structure as shown inthe [¥] above figure. Itis not important that the table is 100 percent level. ‘The cradles «will be perfectly leveled. The table must be sturdy. Ad. Draw astraight line 14"from the aft end of the table. Drawporpendicularlines to ‘this at BL 0, BL 34, and BL 60 (the cradles will be centered on these lines). Installing the Support Braces Fig. AS *Por example, if the cradle is ‘made from 1" particle board be vertical then offset by 1. The cradles Should be centered on the line. |A5, Install the cradle supports. Use 2x 4's or equivalent. Screw to table. raevers (=Leveling the Cradles Fig. As, All of these "tabs" should. be in the same level (horizontal) plane ‘Align cradles to this reference line AG, Install and align cradles. Following is the criteria for aligning eradles: 1, Align fore/aft by using the alignment mark on all the cradles, 2, Alleradles should he set heightwrise by leveling the tabs to the same horizontal plane- see figure Al. We suggest using a water level for this step, Hint: Start by placing a shim underneath all the eradles- this allows you to bring cradles down as necessary to align. AT. Once level, secure all the cradles to the cradle supports with wood screws, Chapters [RIV._ANUEOGS Bee WEB | | acneInstalling the Angle Iron Fig FA5. Install the 1-1/2" = 2"« 1/8" angle iron as shown Note: Itis okay to have the angle iron. extend past the BL 60 yey 7 Chapters | REV, ANU/4-05-98 TV-FB [2° [7 ier stan. ana tovatorB. HORIZONTAL STABILIZER HINGE BRACKETS ‘With the cradle complete, you can now begin building the H. Stab.. ‘The first step is to position the H. Stab. in the cradle and trim the H. Stab. TE. BL. Position the H. Stab. in the eradle. In summary: 1. The H. Stab. should be centered. 2, The H. Stab. should be pushed forward into the cradle. It should fit well in the cradles. Look underneath to check the fit. Itis acceptable to use some weight inorder to conform the H. Stab..to the eradle, ‘Trimming the Horizontal Stabilizer TE. Fig OBA. Mark for H. Stab T. Aft Spar——>] Bevel T.E. on 45° as shown Lower H. Stab skin ‘Stab TE. = Chapter3 | BEV. "AN/4-06-98 RAR WEB | |eBQ, Trim theH, Stab. trailingedge. Ibis 15 5/8" as measured back from the L.E. at BLO. ‘This should correspond to the aft edge ofthe angle iron you installed. Usingalong board sander(atleast 2A. long),sandthe'T-E. straight. Alsosand aslight45"bevel on the T-E, (not toa sharp point, see fig. 2:B:1). B3, _Re-position the H. Stab.. Now use Bondo or similar to temporarily secure the H. ‘Stab, tothe cradles. You may have to de-wax the skin with MC and sand theskin ‘with 80 grit to obtain a better bond, Horizontal Stabilizer Top View Fig. a2. Fwd BL4 rib BL 34 rib Aft BLA ri Fwd spar web Main spar’ 7 Closeout ‘BL 60 hinge / BLOhinge” BL 32 hinge gor ge ee Eee Bua hinge BL a2 hogs nas BA, Removeallpeelply from theinnersurfaces ofboth upper and lower H, Stab.. skins, Be sure all oft is removed (most of it probably already is) WARNING: Structural bonds can NOT be made over peelply. Be sure to remove all peelply from bonding areas. Failure to do so will result in structural failure of the component, 4 ARCA WV-FB <1 Shapers [RTE “Horizontal Stab, and BlevatorChecking Hinge Alignment Fig. a3. Shining 060 = - 3B Sa [a AAR WEB | eSB5. Checkthehinge alignment, Thealignment was done atthe factory butyoushould double check this. Use Clecoes to hold the hinges in place. Pull string through the center of the bearings. The string should be centered on the outboard bearing ‘and must be tight. Perhaps the easiest way to hold the string in place is to use a ‘tongue depressor with a small slot cut into the side. Tie a knot in the end of the string and slide the string through the slot. Before getting started, check that the outboard hinge is centered between the BL 60 cradles, In other words, the conter of the bearing should be centered on the chordline. Ones you verify the outboard hinges are aligned, they become the reference for aligning the rest of the hinges. "The best way of making small adjustments away from the web is to apply alayer of miero/flox (use about 50/50 micro and flox) between web and bracket (see Fig. 2:D:3.). Be sure to apply release tape to the hinge so it can be popped loose after the micra/flox cures, You'll have to allow this to cure before rechecking the alignments. Ifthereareany moreareasofmis-alignment, fll hheholes with micro/ flox and redrill them to U8". BG. _Drilltheholes ofthe hinges and thespartosize(the I/S"*holesarepilotholes). The recommended method for doing this is as follows: 1, Drill two of the 1/8" holes of each hinge out to 3/16” on the drill press. 2. Reinstall the hinges ou Ue spar and hold in place using two clecoes. 3, Drill the 1/8" holes in the spar to 9/16" diameter. 4, Repeat the procedure for the two remaining holes. ‘The alternative method isto use a hand drill and drill one hole ata time, Drillas, straight as possible. B7, Install the nutplates for the hinges. Method #1. Mtiod number one requires «bucking br and a ppeumaticrivet squeeze ‘With this method the rivets are secured directly to the spar. Using the exi Bibtholesinthesparsetthenutplate Usethenutplatoasa quiets drillthe #40 holes for the rivets. Frenne TV-FB |e [fae ics ‘Horizontal Stab, and Elovator Title Na NOH ed OOFInstalling the Nutplates, Method #1. Pig. SBS. Pod ating EOE) mn ‘Method #2. ‘Method number two does not require any special tools other than a rivet squeezer. First layupa six BID on adlat surface andletcure. Mount the nutplates, ‘on the 6 BID and bond the 6 BID in place. Installing the Nutplates, Method #2, Fig. 5356. 1000-8 mutpattos Separate the! plscor if required Se nuenne 7 [Chaps [Rav _avaapa8 Beevers PSS Tae rn, rss ot A a OT©, ELEVATOR HINGE INSTALLATION w ‘The hinge halves that install into the H. Stab. be installed to set the elevators, The elevator weldment should also be installed for this step. ‘Top View, Hlevator/ Horizontal Stabilizer Big. dC. Chapters [Rev aNeaE6 “Horizontal Stab. and Elevator 318 Toran el a yO a OTElevator Hinge Weldment Fig. 8162. 1, Elevator control horn weldment, left side PIN 9-020016 (EL-055-02) 2, Elevator control horn weldment, right side PIN 9-020016 (FI-056-02) 3. AN3-TA bolts, 8 ples 4, AN960-10 washers, 3 ples 5, AN365-1082A locknuts, 3 ples 6, Bellerank bracket (part of horizontal stab assembly, shown for reference only) PIN BL-063-T [aa onta 8 and atorCenter Elevator Hinge Weldment Fig. 8:03, Install dhe two ales ofthe elevator hinges and push Z the spat up agains the hinge. When positioning the levator inthe ib up against the weldment, Apply 3 layers of duct tape tothe ‘outboard sides of the levator weldaent. Cl. Install the center elevator hinge weldment. Vor this step, itis necessary to cut-a slot in the center eradle to fit the weldment. C2, Position the elevators. In summary: L. The inboard rib should be up against the weldment. 2, The spar should be forward up against the elevator hinges. 3. The elevator should be weighted down into the cradle. Once aligned, tempo- rarily secure the elevator hinges with superglue. Ifalignment is correct you can tuse clecoes or serews, If there is any mis-alignment, make adjustments as indicated in step BS. — ‘Chapter ‘BBY, AN1/4-05-98 ARCAR TFB | Saunas Tira ono GD nS He OATSCutting Holes for Hinges in Elevator Fig. x i ‘Top Elevator Skin Nevatoe Spa 3 ‘The opening is determined by elevator travel. ‘There should be 1/8" clearance between opening and hinge at full travel | w= ACP BLAST hingeHorizontal Stabilizer! Elevator Gap Fig. 3:05. Note: ‘The 0" gap should be constant through the entire travel range (3. Afterremovingthe assembly from the cradles, check the H. Stab.elevator gap. All ‘you need to do is make sure there is some clearance, Ideally there should be 05" between the H, Stab, and elevator as shown in Fig. 9:C:5, and end gape as shown in Fig, 3:C:6. To cheek clearange through full travel, refer to Fig. 3:C:4 and open upthe hinge slots asnecessary. Mostlikely some body work will berequired toxet aconstant gap through the entire travel range (this is normally done after the H. Stab. and elevators are closed). ANGE WEB || Chapters [nev ANWao5o6 Horizontal Stab and ElevatorDrilling Holes for Elevator Hinges and Horizontal Stabilizer Fig. 8056 i a || ff z fe L. | HE gas a 7] iB ua ‘ it =e? | 8 = [ae oo ARH WEB |= SeC4, _ Drill the holes for the elevator hinges and the elevator weldment to full size. The ‘weldment should be centered heightwise on the inboard rib. Installing the Elevator Hinges, Method #1 Fig. 30-78 . NBA bol eos -ANSS5-4284 Erector hinge (90) Tact : Qo “aNseoste AN0-10 >: washer < *ANGIUA batt ACHR WEB |= ass mar deelInstalling the Elevator Fig. 80°, ANSGS-28A, pe AND016 i000 vipat plitin mile equa C5. Install the elevator hinges using either of the above methods, 2 Se Beevers [= eeInstalling Nutplates for Elevator Weldment Fig. 8C. Ke10003 poms feces “en sod tn ran (SB Nie) oa AN426A3-5 rivets, 1000-4 nutplate 6BD Bottom elevator skin Chapters [REV ANIEO595 Install the nutplates securing the elevator weldment [a5 | Horizontal Stab, and Rlevator Aicra ve | |D, ELEVATOR TRIM TAB ‘One of the improvements of the new Lancair TV Fast Build kit is the premolded trim tab, The premolded trim tab consists ofan upper and lower trim tab skin, The ‘two halves are simply bonded together. ‘The trim tab is easily removable by the serews that secure the hinge. ‘The servo fits in a premolded joggle. It is covered by the trim tab access panel. ‘Trim Tab Exploded View Fig. Da. Jone derse ei oe 5.02016 pny l ‘coe: Panel fnssuossos ‘Trimming Lower Hlevator Skin for Trim Tab Fig. 82, = CORE AREA 22° p20" a Chapters [REN ANiieas PRA WEB | oeInstalling the Elevator Hinge n an Bo not drill any holes atthe A ‘oiuator arm Tecan Section AA ‘Bevel this edge to match the shape ofthe clevato D1. Cutout the section of the bottom elevatorskin forthe trim tab. Use thedimension from Fig. 8:D:2. Note: On thecradle templates therearemarks for the TE, ofthe elevator (see Fig, ‘:A:1). Verify that the elevators have been trimmed to these marks. D2, Remove the red that holds the trim tab hinge halves together. Reverse thehinge holes and reassemble the hinge. D3, Cutout an 18" section of the trim tab hinge. The hinge spans from BL3 to BL 21 (BL 21 is where the joggle for the hinge in the trim tab ends). Fi (chapters [RN ANwomo Aeeewere [= eS Ta Sr Dn ORTDé, Lay out the hinge, activator arm, and roughly position the servo. Be sure to provide sulficient mounting room far the activator arm. Theactivatorarm mounts on the trim tab side. When satisfied with the positioning, dill 18" pilot holes through both sides ofthe hinge and through the mounting tabon the elevator, Use clecoes to hold itin place. D5. On the forward half of the hinge, mount the nutplates (to the hinge). Use the 1000-06 nutplates and AN426A3-4 rivets, Ifthis + your first time riveting, we ‘suggest you practice elsewhere! Read up on riveting procedures. On the aft half ofthe hinge, mount the nutplates to the trim tab, “The K1000-06 nutplates use a #29 drill for screw hole and #40 drill for the rivets. “Use a 100° countersink. ‘itting Lower TrimTab Skin Rig Ds. | ‘Trim the T.E. to match the rest of the elevator BL24 BL21 D6. Fitthe lower trim tab skin. - The outboard edge of joggle should align to BL 21. + The hinge should fit in the joggle. D7. _Drillthe 1/8" holes through the oggle oflower trim tabskin once satisfied with the alignment. D8. Drill holes to size and install the nutplates. AInALD Saf chaniers [ee oes ikCARTVEB eeSand the Bonding Surfaces Fig. ODS, D9. Fit the upper trim tab skin, = Trim the outboard end, = Trim the. E. 7 Chapters | REY. "ANI/4-05-98 Re MRT BB | | tsa susan Teter opel Sas a Sig aFitting the Upper Elevator Skin Fig HDS, Pay close attention to the Bt in this area. There should be natural transition tothe elevator: A rB oe “Trim upper skin as necessary to fit into josste 2 ayers of duct tape should be’ ‘used to simulate the 2 BID ‘applied later, See Fig, 7. 1 Ghapiers [Rev ANSE OS _ FNCARTV-FB |[0 [ee eeD10. Fit the upper elevator skins, When fitting the upper elevator skins, it may be necessary to sand a small amount off the joggles. Pay close attention to the fit between the H. Stab...and the elevator. In the upper left olevator skin itis also necessary to remove a section for the trim tab, ‘TRIM TAB: Carefully trim the elevator skin forward to get the 05" gap. Trim the outboard end to approximately BL 24-1/8". D11. Prepare the trim tab skins for bonding, -Using 40 grit sandpaper, throughly sand all bonding surfaces, -Vacuum all the bonding surfaces and keep clean prior to bonding (don't touch). Bonding Trim Tabs Pig. aa. Mound enough epoxyifios to provide Me" ponding re NY use elecoes ar lamps tw pall the leading edges together ssesight TE. D12. Bond the trim tab halves together. "rst brush pure epoxy on all bonding surfaces. -Mix an epoxy flox mixture and apply it ta the T.E. and L.B. of lower skin, ‘Mound it in a "V" shape to avoid trapping any air in the bond. -Lower the upper trim tab skin into place as shown in Fig. $:D:7. a reeves | ee ee Teer bri Sn ORB, COUNTERBALANCING THE ELEVATORS ‘The elevators of the Lancair IV are 100% mass balanced. The premolded counterweights provided will be trimmed as required to balance the elevators (we prefer to close the elevators with plenty of weight and then drill the excess out after closing). ‘The elevators must move freely in order to balance them. You CAN NOT BALANCE an elevator that is not freely floating on the hinges. IMPORTANT NOTICE: Balance the left and right elevator separately because they require different amounts of counterweight. Before starting, the trim tab, servo, hinge, and all hardware must be installed, ‘The goal isto get as close as possible to the finished weight of the elevator. El, Drop the counterweight in place. Place the top skin in place. Note that what is still missing is the adhesive for closing, primer, and paint. Balance the elevator such that the LE. of the counterweight arm hangs freely 1" below the 100% balanced position. This means that you will be trimming off the lead counterweight. The goal is to have the weight as far forward as possible so trim off the aft side of the counterweight as necessary. Installing the Counterweights Fig. 81 Lead counterweight Apply a2 BID reinforcement AAR W-FB Sa] Stators [ne anes orizontal Si. and ElevatorE2. When satisfied that you have sufficient counterweight, install the premolded lead with epoxy/flox. Apply a 2 BID reinforcement to the aft side af the counterweight. ES. When the elevators are closed and primed (ready to paint), check the balance again. Prior to paint, the counterweight should hang approx. 1/2" below the 100% balance position. Ifnecessary, drill excess weight out.Fill the holes with micro and. apply a 2 BID on top. Check the balancing again after paint, Ifmore weight is needed, lead shot can be inserted in the holes and topped off with micro, then touched up with paint. Ifeven more weight is needed after paint, there is an optional arm that ‘can be bolted to the hinge weldment. The arm will carry more weight on the end, Broa ye |= eeF. CLOSING THE HORIZONTAL STABILIZER AND ELEVATOR FL. Drill vent holes in ribs, webs, and the skin as shown in Fig. 8:F+1 Horizontal Stabilizer and Elevator Vent Holes Big SL _ Acar WEB See] Ghariera_ [Ree anionsWARNING: ALL INTERNAL BAYS MUST BE VENTED. Failure to vent these ‘bays could result in excessive internal pressure at high altitudes and cause structural ‘damage that could result in component failure, F2._ Check the fit of the upper H. Stab. and elevator skins. A few things to look for: 1, Place pieces of "play dough’ every 6" on the spars, ribs, etc., use 2 layers of uct tape to simulate bond thickness. Lower the upper skins in place. Clamp the cradles in place and weight the skins down as if you vere closing. Look over the H. Stab, and elevators, There should be no visible bumps or irregularities, and it should fit the cradles well. ‘Remove the weights and cradles, ‘The pieces of play dough should be .01 thick orless. If in excess ofthis, perform an epoxy flox release. Epoxy/fiox release: ‘The areas to be released must he sanded and cleaned with MC. The ‘upper skin must be release-taped (duct tape, clear tape or equivalent) in these areas. First apply pure epoxy to the bonding areas with a brush and then the epoxy/flox mix. Lower the upper skin in place and clamp cradles in place. Weight down as if closing. Leteure. ‘When checking the fit, take note ofthe fit in each area. Practice the closing a couple of times before getting started. Get all the things you may need for closing- weights, clamps, straight edges, cleeoes, ete. Decide what you will use to hold the leading edge joggles together during bonding (wood screws, clecoes, duct tape?) F9. De-wax all the ribs, spars, and joggles using MC. Apply a generous amount ‘with a clean rag or paper. Follow immediately with another clean rag, Preparing Surfaces for Bonding Fig. P-2, Elevator spar LB. jostle “outha it ‘ee. Beevers eS ceF4, Using 40 grit sandpaper, sand all bonding surfaces, Fig. 3:F:2 shows the bonding surfaces of lower H. Stab. and lower elevator halves, Also sand the corresponding bonding surfaces of upper H. Stab, and elevator skins. Clean all bonding surfaces with MC. Note: Before starting the closing process the elevator and the H. Stab... must be positioned in the cradle. The weldment and hinges should be bolted in place (don't forget the duct tape spacer on the weldment) Applying Adhesive to Bonding Surfaces of Elevator Fig. 25. Bley Cross Section @ BL 29 Mound a 816""W shape of Hysolflox sou, 5 7 ales Pile 316" + eposviflox on vib Mound sufictene pea to sve Remove 186161 ot core Seto bond aren Iara (ea from ie BL29 : SMELT ibe Tae form a ‘towel that you ll with eponslo. Closing the Blevators F5, Apply pure Hysol to the inboard and outboard ribs, the spars, the leading edge Jjogale and the parts of the counterweight arm that are to be bonded. Apply Hysol to the corresponding areas of the upper skin, Apply epoxy to the TE. and the BL 29 and BL 17 rits. Apply epoxy to the corresponding areas of the upper skin. Mix in flox with the Hysol and epoxy. Hysol: Mix in 1 tablespoon per 2 ounces of Hysol. Epoxy: Mix in enough flox to give it the consistency of peanut-butter (when you lifta batch up with the mixing stick, it shouldn't fll off the mixing stick!) Apply the Hysol/flox and epoxy/flox mixes to their respective bonding areas of the lower skin and structure. Refer to Fig. 3:F'3 6, When satisfied that all bonding surfaces have been sufficiently covered, carefully lay the upper skin in place and weight it for cure. Once clamped in place, you should see squeezeout along the TE. and LE,, inboard rib, ete. Take a peek at ‘whatever you can get to and assure yourself there is sufficient squeeze out. eager a] enor _FCAR TFB eeNOTE: Once again you must use a straight edge to check that-your skin is, not howed. Youmay have toshuffleyour weights around to allowroomfor the straight edge check, butit's worthit. Thisis forall the marbles, socheck and double check. Readjust weights ifnecessary. F7, When the Hysol has cured, sand the outboard joggles ofeach elevator. Clean with MC, and apply 2 BID, 2" wide strips.n the joggle. FS, When the 2BID has cured, sand it with 40 grit and smooth the outboard edges of the elevators with micro. Sand the micro to the same curvature as the horizontal stabilizer. F9, Remove the center hinge assembly and sand the inboard side of the BL 3.2 elevator ribs, Clean with MC and apply 2 BID, rolling onto the upper and lower levator skins. Like you did on the spar mounting bolts, push some modeling clay, Silly Putty, ete. into the two mounting bolt holes on the inboard rib to prevent resin from clogging the threads, Trim around the bolt holes when the glass isin the green cure state, You can naw remove the three layers of duct tape from the arms of the center hinges assombly that rested against the inboard elevator ribs. ‘When the 2 BID is in the green cure state, trim around the bolt holes and remove the clay plugs. ‘The surfaces that the weldment arms rest against should be absolutely flat. See Fig, 3:F°5. Weldment Arm Mounting Fig. &F5. ‘Top elevator skin 2 BID closeout—>| a K 1000-4 nutplate Weldment arm ‘Bottom elevator ‘board rib ‘skin ver WEB "(Ghar [nave Horizontal Stab and ElevatorNOTE: To remove the bolts that secure the center hinge assembly to the elevator ‘spars, you must grind an aecess hole in each elevator L.E. Make this hole just large ‘enough so you can remove the bolts with a 3/8" socket. 10. ‘Toremave and install the other hinge bolts, you will have to notch the bottom, leading edge of the elevator, Remove just enough carbon so you can get to the bolts with needle-nose pliers. As you will soon discover, installing the elevator is not all fun ‘and games, especially when it's mounted on the fuselage and you have to hald the levator while aligning and bolting the hinges, upside down. A wonderful tool to simplify this procedure is made from a long AN3 bolt with the threads cut off. See Fig. 8:F:6, Use the tool to align the elevator hinge half with the horizontal stab hinge half that has the 1/4" bearing pressed into it, Insert: the proper AN4 bolt into the other side of the elevator hinge half, wiggle it slightly, and push the alignment tool out with the bolt. Easy! Hinge Alignment Tool Pires HEAT THE BOLT WITH A PROPANE WTO BEND, LE OR GRIND THE READS SMOOTH. ID THE END. | ANS-408 got 2 BID Reinforcement at Trim Tab Locations Tie 87 an a | Trim tab ss ‘apply a2 BID ALi? Av ‘o09 ||_Chapters [Rev ANvi-05-98 Gar wres [= ee‘Closing the Horizontal Stabilizer F11._Mix upa batch of Hysol and apply it to all bonding surfaces, After applying a thin film of Hysol to both bonding surfaces, its a good idea to mix some flox in with the remaining Hysol (1 tablespoon of flox for evory 2-3 oz. of Hysol) and apply a slightly thicker coat of the adhesive to one of the bonding surfaces. Always mound ‘the Hysol slightly higher in the center of the capstrips to avoid air bubbles in the ond, ‘Bond the top stab skin into position with structural adhesive over all capstrips the fwd L.E. joggle and the aft spar cap. Use small sheet metal screws to squeeze the joggle joint together. Place one every inch along the L.E. joggle and be sure that ‘there is a little adhesive squeeze out when the screws are snugged down. If you don't see any squeeze out, remave the top skin and apply more adhesive NOTE: When using the sheet metal screws to hold down the joggle joint, be careful to only snug up the serew. Ifyou twist too hard, you could strip the screw loose in the composite parts. You should not use pop rivets to secure the joggle joint in the H.Stab.. L.B. because it would be impossible remove all ofthe drilled out pop rivet. later, and small pieces of the pop rivets would be forever rattling around in the stab, WARNING: With any compression bond, you must see a small amount of squeeze out to verify that adequate adhesive was applied. Ifno squeeze out is seen, remove the part and apply more adhesive. Failure to adequately bond the structure could result in total component failure. Clamp and weight the skin down along the aft sparin a manner similar to that used when you bonded the spar to the lower skin, Use plenty of weights to press the skin down on the rib and spar structure (25 Ib. lead shot bags work the best). ‘Take note to verify that there is some adhesive squeeze out along the aft spar cap to top skin bond line, If you don't have any squeeze out, you may not have enough adhesive and you should pull the skin off and reapply adhesive. Wipe off any excess squeezed out adhesive and allow to cure. After full cure, remove the sheet metal serevis used to clamp the leading edge joggle. Fill the above screw holes with a mixture of epoxy combined with 50/50 micro & flox. ALS, Chapter3 | REV. "AN/4-05.08 a aG, ELEVATOR TRAVEL STOPS G1. Raise the elevator to its full up travel limit of 26°. A Smart Level or dial type protractor is handy to check control throws, or you can use the Blueprint pattern gauge. Lock the elevator in this position with a piece of serap wood and a blob of Bondo or instant glue. NOTE: You will have to notch the trailing edge of the H. Stab.. to attain full elevator travel. Do not notch any more than is necessary to get the proper deflection. ‘Travel Range Fig. 3G er sree. G2, Cuta 1/4" x3" x 2" piece of phenolic, Sand both sides of the phenolic thoroughly with 40 grit sandpaper. Also sand the bonding surface of the H. Stab. G3, Install the phenolic with Hysol™ or epoxy flox. At the same time, forma fillet around all sides of the phenolic for the 4 BID. Clean all bonding surfaces with, MC. G4, Install a 4 BID to secure the phenolic. G6, Set the travel by grinding a notch in the phenolic. Dire Chapters [REV __ANTLOGE AER IV-FB |_| vrinonia stand HlevatorPhenolic Travel Stop Fig. 362. ‘Trimming the Inboard Edge of the Elevator Skins Rig 863. ste clearance, G6. The inboard edgesofthe elevatorare trimmed after theelevatorsareinstalled on the airplane. Trim the inboard edge of the elevator skin such that there is always 8/16" of clearance between the elevator and the rudder/vertieal stab. Chapters [Rv aae Horizont Stab. and Blevator