Message-Id: <5.0.2.1.2.20010515060042.043c6670@olsusa.com>
Date: Tue, 15 May 2001 06:03:57 -0400
To: lancair.list@olsusa.com
From: "Carsten" <carstens@lancair.com> (by way of Marvin Kaye <marvkaye@olsusa.com>)
Subject: Factory comments regarding ES horizontals
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Reply-To: lancair.list@olsusa.com

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          <<  Lancair Builders' Mail List  >>
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At Lancair we follow any source of feedback with interest.  Over the years 
a majority of the changes made to existing kits have been a result of 
customer feedback.  In response to the recent postings regarding the ES 
horizontal stabilizers we'd like to offer our comments.

Before we address some of the issues in particular, let's keep in mind some 
of the issues regarding the construction of larger composite parts:

1)  A thinner laminate (such as the trailing edge and leading edge of the 
horizontal and elevator skins) tend to curl as they come out of the mold.

2)  A structure does not take on its final shape until closed.  This is 
especially true for the ES horizontal stabilizer.  In trying to build these 
parts to the tight tolerances we all like, we need to keep these 
characteristics in mind through the entire
process.

We certainly agree in sharing information and letting our builders know of
the issues.   In regards to the ES horizontal stabilizer we have compiled a 
summary of the issues we are aware of and our suggestions:

1. " The horizontal stabilizer does not match the cradles along the leading 
edge.  At the center cradle the horizontal is approximately Ľ" away from 
the cradle"

Solution:  Make sure you have horizontal cradle blueprints with rev B.  The 
alignment reference marks of the cradles have been adjusted.

2.  "The horizontal stabilizer hinges appear to not be centered on the spar".

Comment:  In the end, we want the bearing to be centered, not necessarily
the base. Don't expect the spar to be perfectly vertical!  The base will
therefore most likely move a little off the centerline of the spar in order 
to center the bearing.  I suggest to install the two outboard cradles, then 
use the cradles to determine the centerline of the airfoil and set the 
bearing (of the hinges) accordingly.  The manual does explain how to adjust 
the hinges using a flox pad as necessary.

3.  "The elevator appears thicker on the outboard ends than the horizontal".

Comment:  The best way to accurately verify the fit is to lay the entire
assembly back in the cradles and start checking.  Quite often what we find
is that the unsupported skin aft of the spar tends to "curl" in.  This may
cause the elevator to appear "thicker than the horizontal.  This can be
adjusted when installing the 3 BID closeout after the horizontal is 
closed.  On the other hand if the spar is indeed too low, this can be 
adjusted with a release on the spar.

The above are some of the more common issues we feel are "part" of the
construction.  However, there have been parts we have shipped that have 
been outside of an acceptable tolerance (yes, incorrect!).  We take this 
very seriously.  A wrong part is costly, embarrassing, and not to mention a 
major hassle to the customer.  As part of our quality assurance we review 
each case and make it our objective not to have the same issue arise twice.

As a final note, we recently upgraded the ES jigs at our offshore 
facility.  We have incorporated many of the new techniques we have learned 
from other projects.  We would like to assure everyone of our continued 
commitment to improve and support all our products.

Carsten Sundin

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LML website:   http://www.olsusa.com/Users/Mkaye/maillist.html
LML Builders' Bookstore:   http://www.buildersbooks.com/lancair

Please send your photos and drawings to marvkaye@olsusa.com.
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