X-Virus-Scanned: clean according to Sophos on Logan.com Return-Path: Sender: To: lml@lancaironline.net Date: Sat, 18 Jun 2011 20:32:00 -0400 Message-ID: X-Original-Return-Path: Received: from cdptpa-omtalb.mail.rr.com ([75.180.132.123] verified) by logan.com (CommuniGate Pro SMTP 5.4.0) with ESMTP id 5024564 for lml@lancaironline.net; Sat, 18 Jun 2011 11:44:27 -0400 Received-SPF: pass receiver=logan.com; client-ip=75.180.132.123; envelope-from=super_chipmunk@roadrunner.com X-Original-Return-Path: X-Authority-Analysis: v=1.1 cv=SOlsIBN44tkg4MqIq+y2aLZdhoA3kHpmiRsLue6rfnM= c=1 sm=0 a=pMa8p94ZHMUA:10 a=zTVDa7HKqxcA:10 a=35Tvjzvas7lBNn8+H1IYgA==:17 a=Ia-xEzejAAAA:8 a=Psd4dQTOVrS9G0ncYvwA:9 a=4Grzyo_7M8mz8LFtWKYA:7 a=pILNOxqGKmIA:10 a=CVU0O5Kb7MsA:10 a=EzXvWhQp4_cA:10 a=XLEtbLP-mE97sNdB:21 a=YZhgtzBNzc6ehctK:21 a=5Up8faWwAAAA:8 a=U4IGzk4Eg9N1YYNR_xkA:9 a=H2cx5GbE2sNqrXYB2KoA:7 a=RA4776fQhdsA:10 a=v6MMM96S_sUA:10 a=35Tvjzvas7lBNn8+H1IYgA==:117 X-Cloudmark-Score: 0 X-Originating-IP: 69.205.15.200 Received: from [69.205.15.200] ([69.205.15.200:62287] helo=WilliamHP) by cdptpa-oedge01.mail.rr.com (envelope-from ) (ecelerity 2.2.3.46 r()) with ESMTP id 06/0B-15242-8B7CCFD4; Sat, 18 Jun 2011 15:43:53 +0000 X-Original-Message-ID: <7466784D2659485AAF193C07EE82F541@WilliamHP> From: "Bill Wade" X-Original-To: "Lancair Mailing List" References: In-Reply-To: Subject: Re: [LML] Re: IV Aileron Pressure Box Part 2 X-Original-Date: Sat, 18 Jun 2011 11:43:46 -0400 MIME-Version: 1.0 Content-Type: multipart/alternative; boundary="----=_NextPart_000_024D_01CC2DAC.FBDA8A10" X-Priority: 3 X-MSMail-Priority: Normal Importance: Normal X-Mailer: Microsoft Windows Live Mail 15.4.3508.1109 X-MimeOLE: Produced By Microsoft MimeOLE V15.4.3508.1109 This is a multi-part message in MIME format. ------=_NextPart_000_024D_01CC2DAC.FBDA8A10 Content-Type: text/plain; charset="Windows-1252" Content-Transfer-Encoding: quoted-printable Hi Colyn- I hadn=92t thought of that particular aspect. I did use = e-glass rather than carbon so it wouldn=92t be as stiff and might allow = some movement. Perhaps Lancair has a suggestion? :<) The dimensions are = meant as an aid to other builders, not cast in stone. They=92re just = what the CAD program told me or I measured after the fact. I=92ve never dealt with pressurization before and it adds a layer of = complexity that I don=92t always account for. I=92m an airframe mechanic = but not an engineer- my guess would be that the box itself would keep = the bellcrank and torque tube aligned. For the rest there=92s the ball = joints on the rod ends. That=92s why the twist, to keep the rod ends = centered in each bracket for maximum range of movement. Now, if IV-P=92s vary their wing geometry when they pressurize, all = bets are off. One might think the aileron torque tube could be affected as it spans = a longer section of the fuselage and might be compressed to some extent. = It might not hurt to have some flex on one end. -Bill Wade=20 From: Colyn Case=20 Sent: Saturday, June 18, 2011 9:15 AM To: lml@lancaironline.net=20 Subject: [LML] Re: IV Aileron Pressure Box Part 2 Bill,=20 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. 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. 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. 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 ------=_NextPart_000_024D_01CC2DAC.FBDA8A10 Content-Type: text/html; charset="Windows-1252" Content-Transfer-Encoding: quoted-printable
Hi Colyn-
           &n= bsp;  =20 I hadn=92t thought of that particular aspect. I did use e-glass rather = than carbon=20 so it wouldn=92t be as stiff and might allow some movement. Perhaps = Lancair has a=20 suggestion? :<) The dimensions are meant as an aid to other builders, = not=20 cast in stone. They=92re just what the CAD program told me or I measured = after the=20 fact.
 
I=92ve never dealt with pressurization before and it adds a layer = of=20 complexity that I don=92t always account for. I=92m an airframe mechanic = but not an=20 engineer- my guess would be that the box itself would keep the bellcrank = and=20 torque tube aligned. For the rest there=92s the ball joints on the rod = ends.=20 That=92s why the twist, to keep the rod ends centered in each bracket = for maximum=20 range of movement.
 
  Now, if IV-P=92s vary their wing geometry when they = pressurize, all=20 bets are off.
 
  One might think the aileron torque tube could be affected as = it=20 spans a longer section of the fuselage and might be compressed to some = extent.=20 It might not hurt to have some flex on one end.  -Bill Wade
 
From: Colyn Case
Sent: Saturday, June 18, 2011 9:15 AM
Subject: [LML] Re: IV Aileron Pressure Box Part = 2
 
Bill,=20
 
so when your fuselage puffs out there, what will keep this all = lined up to=20 close tolerance?
 
Colyn
 
On Jun 17, 2011, at 10:46 AM, Bill Wade wrote:
  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=20 a 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=20 be 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=20 001.JPG><6-12-09 = 012.JPG><Crosstube=20 003.JPG><015.JPG>--
For archives and = unsub http://mail= .lancaironline.net:81/lists/lml/List.html
 
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