X-Virus-Scanned: clean according to Sophos on Logan.com Return-Path: Sender: To: lml@lancaironline.net Date: Sat, 18 Jun 2011 09:15:13 -0400 Message-ID: X-Original-Return-Path: Received: from elasmtp-banded.atl.sa.earthlink.net ([209.86.89.70] verified) by logan.com (CommuniGate Pro SMTP 5.4.0) with ESMTP id 5024023 for lml@lancaironline.net; Fri, 17 Jun 2011 18:27:07 -0400 Received-SPF: none receiver=logan.com; client-ip=209.86.89.70; envelope-from=colyncase@earthlink.net DomainKey-Signature: a=rsa-sha1; q=dns; c=nofws; s=dk20050327; d=earthlink.net; b=M6nMljPtrw7v8wdJ7YptqTUKDEaQrS/VMcV8pUxRJ2q5jDtqaXKFBg+mWCvextaB; h=Received:From:Mime-Version:Content-Type:Subject:Date:In-Reply-To:To:References:Message-Id:X-Mailer:X-ELNK-Trace:X-Originating-IP; Received: from [66.201.52.88] (helo=[10.71.1.115]) by elasmtp-banded.atl.sa.earthlink.net with esmtpa (Exim 4.67) (envelope-from ) id 1QXhUm-00064D-DB for lml@lancaironline.net; Fri, 17 Jun 2011 18:26:32 -0400 From: Colyn Case Mime-Version: 1.0 (Apple Message framework v1082) Content-Type: multipart/alternative; boundary=Apple-Mail-658--670089762 Subject: Re: [LML] IV Aileron Pressure Box Part 2 X-Original-Date: Fri, 17 Jun 2011 15:26:31 -0700 In-Reply-To: X-Original-To: "Lancair Mailing List" References: X-Original-Message-Id: <5E649F76-F048-49AF-9595-BFE9AB62E0EB@earthlink.net> X-Mailer: Apple Mail (2.1082) X-ELNK-Trace: 63d5d3452847f8b1d6dd28457998182d7e972de0d01da9406df7fa02bd7f2b1af1971eadf5b75962350badd9bab72f9c350badd9bab72f9c350badd9bab72f9c X-Originating-IP: 66.201.52.88 --Apple-Mail-658--670089762 Content-Transfer-Encoding: quoted-printable Content-Type: text/plain; charset=windows-1252 Bill, so when your fuselage puffs out there, what will keep this all lined up = to close tolerance? Colyn On Jun 17, 2011, at 10:46 AM, Bill Wade wrote: > Two pictures show aligning the box to locate the forward = pivot/crosstube supports before bonding the boxes in place. It took a = while to puzzle out the instructions- page 17-22 shows the forward = torque tube tab upwards. It=92s not that way on the ones I got. The = thing I worried about was to make sure there was clearance from the NG = well housing and that the crosstube would be high enough for leg room. = The third picture shows how I went about that. > =20 > I used Clark foam to fill the lower gap, then bonded the box with = Hysol followed by 2 E-glass BID on each side. I gather the bottom needs = to be free for movement during pressurization but I did use a couple of = BID to make a collar through the aileron pushrod hole. My intent is to = make sure the box couldn=92t debond in that area and it=92d remain = sealed during pressurization. The hole needs to be opened out to allow = for the extra material. Also attach the aileron pushrods to the lower = bellcrank and check for clearance through the range of motion to get the = hole sized. > =20 > When all was done I discovered the wing pushrods aren=92t = perpendicular to the aileron torque tube. The lower bellcrank and = intermediate rod end had to be rotated and the shaft holes redrilled = until the bellcrank aligned with the aileron rod end bearing. The = forward hole ended up 0.20 inches closer to the flange face than the aft = one. The phenolic covers mistakes. The holes ended up roughly 0.525 and = 0.555 for the forward, 0.726 and 0.750 for the aft ones; measured from = the face of the box flange. > =20 > I realize this is more than you asked for and probably more than = anyone else wanted to read but I hope it helps. -Bill Wade > <6-12-09 012.JPG><015.JPG>-- > For archives and unsub = http://mail.lancaironline.net:81/lists/lml/List.html --Apple-Mail-658--670089762 Content-Transfer-Encoding: quoted-printable Content-Type: text/html; charset=windows-1252

Two pictures show aligning the box to locate the forward=20 pivot/crosstube supports before bonding the boxes in place. It took a = while to=20 puzzle out the instructions- page 17-22 shows the forward torque tube = tab=20 upwards. It=92s not that way on the ones I got. The thing I worried = about was to=20 make sure there was clearance from the NG well housing and that the = crosstube=20 would be high enough for leg room. The third picture shows how I went = about=20 that.

I used Clark foam to fill the lower gap, then bonded the box = with=20 Hysol followed by 2 E-glass BID on each side. I gather the bottom needs = to be=20 free for movement during pressurization but I did use a couple of BID to = make a=20 collar through the aileron pushrod hole. My intent is to make sure the = box=20 couldn=92t debond in that area and it=92d remain sealed during = pressurization. The=20 hole needs to be opened out to allow for the extra material. Also attach = the=20 aileron pushrods to the lower bellcrank and check for clearance through = the=20 range of motion to get the hole sized.

When all was done I discovered the wing pushrods aren=92t = perpendicular to=20 the aileron torque tube. The lower bellcrank and intermediate rod end = had to be=20 rotated and the shaft holes redrilled until the bellcrank aligned with = the=20 aileron rod end bearing. The forward hole ended up 0.20 inches closer to = the=20 flange face than the aft one. The phenolic covers mistakes. The holes = ended up=20 roughly 0.525 and 0.555 for the forward, 0.726 and 0.750 for the aft = ones;=20 measured from the face of the box flange.

I realize this is more than you asked for and probably more = than=20 anyone else wanted to read but I hope it helps. -Bill=20 Wade
<Aileron Box 001.JPG><6-12-09 = 012.JPG><Crosstube = 003.JPG><015.JPG>--
For archives and = unsub http://mail.= lancaironline.net:81/lists/lml/List.html

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