X-Virus-Scanned: clean according to Sophos on Logan.com Return-Path: Sender: To: lml@lancaironline.net Date: Tue, 08 Oct 2013 21:43:13 -0400 Message-ID: X-Original-Return-Path: Received: from mailout14.yourhostingaccount.com ([65.254.253.112] verified) by logan.com (CommuniGate Pro SMTP 6.0.7) with ESMTP id 6507408 for lml@lancaironline.net; Tue, 08 Oct 2013 16:46:21 -0400 Received-SPF: pass receiver=logan.com; client-ip=65.254.253.112; envelope-from=SRS0=tOwIB1=TS=airframesinc.com=brad@yourhostingaccount.com Received: from mailscan09.yourhostingaccount.com ([10.1.15.9] helo=mailscan09.yourhostingaccount.com) by mailout14.yourhostingaccount.com with esmtp (Exim) id 1VTeA7-0002CO-KM for lml@lancaironline.net; Tue, 08 Oct 2013 16:45:47 -0400 Received: from impout02.yourhostingaccount.com ([10.1.55.2] helo=impout02.yourhostingaccount.com) by mailscan09.yourhostingaccount.com with esmtp (Exim) id 1VTeA7-0002WG-O7 for lml@lancaironline.net; Tue, 08 Oct 2013 16:45:47 -0400 Received: from authsmtp12.yourhostingaccount.com ([10.1.18.12]) by impout02.yourhostingaccount.com with NO UCE id akln1m00C0FdXoS01klnvb; Tue, 08 Oct 2013 16:45:47 -0400 X-Authority-Analysis: v=2.0 cv=HIVB5/Rv c=1 sm=1 a=HGMQmSJeTODcyIIOOD8qAg==:17 a=eVmwlQb-OvUA:10 a=ccZf1vCkMuYA:10 a=-jJjFhJq1GgA:10 a=27qnZCq6AAAA:8 a=Ej3Gi83c25cA:10 a=Ia-xEzejAAAA:8 a=jJrOw3FHAAAA:8 a=XLbtBGh9nhO_r-p6CbUA:9 a=wPNLvfGTeEIA:10 a=pQtlzSjw8oMA:10 a=eabnt9pGaVEA:10 a=k1ZXgcqWoEYA:10 a=EzXvWhQp4_cA:10 a=FU4QsWcZpzsA:10 a=NWVoK91CQyQA:10 a=zKLsGP37zY0wOft1:21 a=s2Nv6UTwngh18H-d:21 a=SSmOFEACAAAA:8 a=yMhMjlubAAAA:8 a=ZFRZVk9UAAAA:8 a=pGLkceISAAAA:8 a=3epCiQQVMYcqGqxq-z4A:9 a=gKO2Hq4RSVkA:10 a=_W_S_7VecoQA:10 a=6YRDNICTpUEA:10 a=MSl-tDqOz04A:10 a=E1VWHYOC2WxAsZoz:21 a=IX5258C6NbcqIHB6:21 a=ATAMDuPljpti7I0V:21 a=t1ijpx9AV50gTBtUFlM2vg==:117 X-EN-OrigOutIP: 10.1.18.12 X-EN-IMPSID: akln1m00C0FdXoS01klnvb Received: from adsl-74-226-93-150.mem.bellsouth.net ([74.226.93.150]:49739 helo=BradPC) by authsmtp12.yourhostingaccount.com with esmtpa (Exim) id 1VTeA6-0000pY-GW for lml@lancaironline.net; Tue, 08 Oct 2013 16:45:47 -0400 X-Original-Message-ID: From: "Brad Simmons" X-Original-To: "Lancair Mailing List" References: In-Reply-To: Subject: Re: [LML] Re: Cabin door strut on IV series X-Original-Date: Tue, 8 Oct 2013 15:45:41 -0500 MIME-Version: 1.0 Content-Type: multipart/alternative; boundary="----=_NextPart_000_0108_01CEC43D.718517C0" X-Priority: 3 X-MSMail-Priority: Normal X-Mailer: Microsoft Windows Mail 6.0.6002.18197 X-MimeOLE: Produced By Microsoft MimeOLE V6.0.6002.18417 X-Antivirus: avast! (VPS 131008-0, 10/08/2013), Outbound message X-Antivirus-Status: Clean X-EN-UserInfo: 083c580f26f2276ef4ed2a347163d77c:931c98230c6409dcc37fa7e93b490c27 X-EN-AuthUser: brad@airframesinc.com X-Original-Sender: "Brad Simmons" X-EN-OrigIP: 74.226.93.150 X-EN-OrigHost: adsl-74-226-93-150.mem.bellsouth.net This is a multi-part message in MIME format. ------=_NextPart_000_0108_01CEC43D.718517C0 Content-Type: text/plain; charset="iso-8859-1" Content-Transfer-Encoding: quoted-printable Shane, we have bonded in bushings, pieces of aluminum plate, etc. It = just depends on the thickness of what you are starting with and how you = trimmed out the back side of the door frame. You are limited by the = thread depth on the ball stud. I can tell you that just floxing up the = hole won't last, though... If you have the depth to put an area washer on the stud, that would be = good... Brad Simmons Airframes Inc. 39 Airport Rd. Milan, TN 38358 731-686-3610 731-686-3613 fax www.airframesinc.com ----- Original Message -----=20 From: Shane Bangerter=20 To: lml@lancaironline.net=20 Sent: Tuesday, October 08, 2013 11:22 AM Subject: [LML] Re: Cabin door strut on IV series Brad, the stud on my door looks to be a bit loose. Is there an easy = fix before it completely fails? =20 Shane =20 89GG =20 From: Lancair Mailing List [mailto:lml@lancaironline.net] On Behalf Of = Brad Simmons Sent: Tuesday, October 08, 2013 8:42 AM To: lml@lancaironline.net Subject: [LML] Re: Cabin door strut on IV series =20 John, I could not view your YouTube video; it asked for a log in... =20 Door strut damage is becoming a common item as the fleet ages. We are = seeing problems on probably a 3rd of the planes that we service. There = have also been at least a couple of cracked windows possibly attributed = to the door strut stress placed on the door.=20 Assuming your ball and socket alignment isn't so bad that the range or = motion is exceeded, the other common issue is the stud wallowing out the = hole through the carbon frame. Once it begins to move around, the = threads will quickly open up the hole diameter, and as the assembly = becomes loose, the socket will either pop off, or damage the fingers in = the socket. There's more than one kind of ball and socket floating around out = there, also. Some don't have the same amount of motion as others, so if = your replacement strut did not come from Lancair, make sure that the = similar ends will actually allow the needed rotation.=20 Adding a strap to the door to allow you to cushion the opening is a = good idea also. I still see folks that land, unlatch the door and just = push it up and allow it to open on it's own (and you know who you = are!!!). I can just about guarantee you that the ball studs will be = loose in their composite mounts. =20 Brad Simmons Airframes Inc. 39 Airport Rd. Milan, TN 38358 731-686-3610 731-686-3613 fax www.airframesinc.com ----- Original Message -----=20 From: John Barrett=20 To: lml@lancaironline.net=20 Sent: Tuesday, October 08, 2013 6:55 AM Subject: [LML] Cabin door strut on IV series =20 Hi all, =20 I have to say that my first attendance to a LOBO fly in was awesome = ( to use my children's and their children's cliche). The chance to meet = so many enthusiastic, knowledgeable and fun Lancair folks provided WAY = more benefit than I ever would have imagined. Thank you to the board, = the vendors, presenters and to everyone involved. I loved it and so did = my wife, Anne. =20 =20 I saw some folks examining a IVP door strut on Saturday I think. = The attachment at the frame was very loose so that the ball stud was = flopping around. Close inspection showed that the door frame was = cracked under the stud. I'm not sure whose plane this was but I think = it is the one that vibration measurement equipment had recently been = attached to for studies. =20 The door strut triggered memories of similar occurrence with my = strut a couple of years ago prior to first flight. I would guess the = smart folks who noticed this also figured out the reason for the = failure, but just in case I will share what I found and how I dealt with = it. =20 The problem with the door strut is that the arc described by the = strut during opening and closing exceeds the range of motion built into = the ball stud socket on the lower end of the strut. Therefore the door = frame is wrenched back and forth during door operation when the stud is = attached to the door frame without modification to the frame. There is = a plane you can find by experimentation or by mathematical exercise if = you are so gifted and inclined to pursue (I am not) that will allow the = socket to move within the design limits and therefore not stress the = stud and the door frame. Once this plane is determined, you can use a = small washer of wood, foam or other material to shape the door frame = where the stud penetrates the frame. You'll need to cut out a bit of = the frame to accomplish this. since my frame was broken here it made = that part simple. Super glue or hot glue can hold the form in place. = Then lay up two BID of carbon fibre cloth over the form and remove the = form material when done. Lay up several layers on the back side to = strengthen the mod and to secure it by sandwiching on both sides of = remaining frame.=20 It gets a little more complicated because the back side in my case = was in very tight quarters. When complete I found that the screw stud on = the ball stud part was too short. I was able to go online and find a = replacement at very nominal cost and that had plenty of thread length = for the purpose. I have uploaded a video to YouTube of the way the attachment looks = now. See link below. I hope it helps someone. http://youtu.be/d3sBMgVncMM John Barrett N31VP Sent from my iPad=20 =20 ------=_NextPart_000_0108_01CEC43D.718517C0 Content-Type: text/html; charset="iso-8859-1" Content-Transfer-Encoding: quoted-printable
Shane, we have bonded in bushings, = pieces of=20 aluminum plate, etc. It just depends on the thickness of what you are = starting=20 with and how you trimmed out the back side of the door frame. You are = limited by=20 the thread depth on the ball stud. I can tell you that just floxing up = the hole=20 won't last, though...
If you have the depth to put an area = washer on the=20 stud, that would be good...
Brad Simmons
Airframes Inc.
39 Airport Rd.
Milan, TN  = 38358
731-686-3610
731-686-3613 fax
www.airframesinc.com
----- Original Message -----
From:=20 Shane = Bangerter=20
Sent: Tuesday, October 08, 2013 = 11:22=20 AM
Subject: [LML] Re: Cabin door = strut on IV=20 series

Brad,=20 the stud on my door looks to be a bit loose.  Is there an easy = fix before=20 it completely fails?

 

Shane

 

89GG

 

From: Lancair = Mailing=20 List [mailto:lml@lancaironline.net] On Behalf Of Brad=20 Simmons
Sent: Tuesday, October 08, 2013 8:42 = AM
To: lml@lancaironline.net
Sub= ject:=20 [LML] Re: Cabin door strut on IV = series

 

John,

I could = not view=20 your YouTube video; it asked for a log = in...

 

Door = strut damage=20 is becoming a common item as the fleet ages. We are seeing problems on = probably a 3rd of the planes that we service. There have also been at = least a=20 couple of cracked windows possibly attributed to the door strut stress = placed=20 on the door.

Assuming = your ball=20 and socket alignment isn't so bad that the range or motion is = exceeded, the=20 other common issue is the stud wallowing out the hole through the = carbon=20 frame. Once it begins to move around, the threads will quickly open up = the=20 hole diameter, and as the assembly becomes loose, the socket will = either pop=20 off, or damage the fingers in the socket.

There's = more than=20 one kind of ball and socket floating around out there, also. Some = don't have=20 the same amount of motion as others, so if your replacement strut did = not come=20 from Lancair, make sure that the similar ends will actually allow = the=20 needed rotation.

Adding a = strap to=20 the door to allow you to cushion the opening is a good idea also. I = still see=20 folks that land, unlatch the door and just push it up and allow it to = open on=20 it's own (and you know who you are!!!). I can just about guarantee you = that=20 the ball studs will be loose in their composite=20 mounts.

 

Brad Simmons
Airframes Inc.
39 Airport = Rd.
Milan,=20 TN  38358
731-686-3610
731-686-3613 fax
www.airframesinc.com<= /P>

----- = Original=20 Message -----

From: John = Barrett=20

To: lml@lancaironline.net=20

Sent: = Tuesday, October=20 08, 2013 6:55 AM

Subject: [LML] = Cabin door=20 strut on IV series

 

Hi all,

 

I have to say that my first attendance to a = LOBO fly in=20 was awesome ( to use my children's and their children's cliche). =  The=20 chance to meet so many enthusiastic, knowledgeable and fun Lancair = folks=20 provided WAY more benefit than I ever would have imagined. =  Thank you=20 to the board, the vendors, presenters and to everyone involved. =  I=20 loved it and so did my wife, Anne.  

 

I saw some folks examining a IVP door strut on = Saturday I=20 think.  The attachment at the frame was very loose so that the = ball=20 stud was flopping around.  Close inspection showed that the = door frame=20 was cracked under the stud.  I'm not sure whose plane this was = but I=20 think it is the one that vibration measurement equipment had = recently been=20 attached to for studies.

 

The door strut triggered memories of =  similar=20 occurrence with my strut a couple of years ago prior to first = flight.=20  I would guess the smart folks who noticed this also figured = out the=20 reason for the failure, but just in case I will share what I found = and how I=20 dealt with it.

 

The problem with the door strut is that the arc = described=20 by the strut during opening and closing exceeds the range of motion = built=20 into the ball stud socket on the lower end of the strut. =  Therefore the=20 door frame is wrenched back and forth during door operation when the = stud is=20 attached to the door frame without modification to the frame. =  There is=20 a plane you can find by experimentation or by mathematical exercise = if you=20 are so gifted and inclined to pursue (I am not) that will allow the = socket=20 to move within the design limits and therefore not stress the stud = and the=20 door frame.  Once this plane is determined, you can use a small = washer=20 of wood, foam or other material to shape the door frame where the = stud=20 penetrates the frame.  You'll need to cut out a bit of the = frame to=20 accomplish this.  since my frame was broken here it made that = part=20 simple.  Super glue or hot glue can hold the form in place. =  Then=20 lay up two BID of carbon fibre cloth over the form and remove the = form=20 material when done.  Lay up several layers on the back side to=20 strengthen the mod and to secure it by sandwiching on both sides of=20 remaining frame. 

It gets a little more complicated = because the=20 back side in my case was in very tight quarters. When complete I = found that=20 the screw stud on the ball stud part was too short.  I was able = to go=20 online and find a replacement at very nominal cost and that had = plenty of=20 thread length for the purpose.



I have uploaded a video to YouTube of the way = the=20 attachment looks now.  See link below.  I hope it helps=20 someone.



http://youtu.be/d3sBMgVncMM=


John Barrett

N31VP


Sent from my iPad

 

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