Fuselage - Velocity Aircraft Marking Key. 6.1.2 - Forward Keel ... There are two rectangular access holes to cut in the top of the ... either have a small taper or filet to provide

06 - Fuselage

April 2006 06-EGR Page 6-1

Fuselage

06 - Fuselage

Page 6-2 06-EGR April 2006

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06 - Fuselage


Contents6.0 - Chapter Preface ....................................................................................6-4

6.0.1 - Parts List ................................................................................................... 6-46.0.2 - Tools List .................................................................................................. 6-46.0.3 - Supplies List ............................................................................................. 6-56.0.4 - Glass List .................................................................................................. 6-56.0.5 - Process Overview .................................................................................... 6-5

6.1 - Keel ......................................................................................................6-66.1.1 - General ..................................................................................................... 6-66.1.2 - Forward Keel Access Hole ...................................................................... 6-66.1.3 - Aft Keel Access Holes .............................................................................. 6-76.1.4 - Fitting the Keel ......................................................................................... 6-76.1.5 - Keel Hard points ....................................................................................... 6-8

6.2 - Seats and Hardpoints ..........................................................................6-96.2.1 - Fuselage Hardpoints ................................................................................. 6-96.2.2 - Seat Belt Hardpoints ............................................................................... 6-106.2.3 - Front Seats .............................................................................................. 6-106.3.4 - Rear Seats ............................................................................................... 6-13

6.3 - Keel Controls .....................................................................................6-156.3.1 - Keel Control Assembly Locations .......................................................... 6-156.3.2 - Forward Aileron Torque Tube Bearing................................................... 6-166.3.3 - Rear Aileron Control Bracket ................................................................. 6-176.3.4 - Mid-bearing Support ............................................................................... 6-186.3.5 - Control Stick Assembly .......................................................................... 6-196.3.6 - Keel Installation...................................................................................... 6-206.3.7 - Keel Stiffening Lay-ups .......................................................................... 6-21

6.4 - Forward Fuselage Treatments ............................................................6-226.4.1 - Nose Access Cover ................................................................................. 6-22

6.5 - Pedal System / Brake Cylinders .........................................................6-236.5.1 - Mount Master Cylinders ......................................................................... 6-236.5.2 - Assemble Rudder Pedals ........................................................................ 6-256.5.3 - Mount Pedals .......................................................................................... 6-256.5.4 - Install Nylaflow Tubing for Rudder Cables ............................................ 6-26

6.6 - Instrument Panel ................................................................................6-276.6.1 - Locate Panel ........................................................................................... 6-276.6.2 - Install Panel ............................................................................................ 6-27

6.7 - Installing Main Spar ...........................................................................6-286.7.1 - Spar Positioning...................................................................................... 6-286.7.2 - Spar Installation ...................................................................................... 6-296.7.3 - Lay-ups ................................................................................................... 6-296.7.4 - TRIAX Reinforcement ............................................................................ 6-30

6.8 - Canard Reinforcements .....................................................................6-356.8.1 - Canard Attachment Reinforcement .......................................................... 6-356.8.2 - Canard Top Attachment Points ................................................................ 6-36

6.9 - Overhead Fresh air Duct ....................................................................6-41

06 - Fuselage


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6.0 - Chapter Preface

6.0.1 - Parts List

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6.0.2 - Tools List

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06 - Fuselage


6.0.3 - Supplies List

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6.0.4 - Glass List

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6.0.5 - Process Overview

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6.1 - Keel

6.1.1 - General

The keel comes to you as a one piece structural member that does several things:* It indexes and supports the nose gear system.* It houses the control system.* It houses the RG hydraulic system.* It carries the actuator for the speed brake if used.

The keel has a substantial flange built all around it so as to hold shape while fitting itinto position.

Note: The keel has a number of markings on it. Some show the size and shapeof cutouts and others show drilling positions only. Do not cut the keelwithout knowing exactly what should be done.

A - B - C - D - E - F - G - H - I - J - K -

Front Keel access coverDump Valvle Mounting Location (RG) Wood Hardpoint LocationLarge access hole for nose gearGas Spring Hardpoint Location (RG)Control Stick Hole Control Stick Access HolesAccess Hole for Nose Cylinder Mount (RG)Main gear cylinder access cover

Location of Keel Bulkhead StiffenerAccess Hole for Torque Tube

Co-Pilot Side

Pilot Side

AD

F

I

J

K

A

C

F

G

I

J

K

B

E

E

H

H

C

G

(RG)

Figure 6-1. Keel Marking Key.

6.1.2 - Forward Keel Access Hole

There are two rectangular access holes to cut in the top of the keel. They are pre-marked on your keel at the factory.

___ Cut the access covers on the marked lines and sand the outside faces.

___ Duct tape around the outside of the hole on the keel itself, hot glue the cover back onlightly, and glass a flange around the hole with four BID tapes 1” onto the cover and1” onto the tape.

___ Add one more layer of BID covering the whole plate and the other BID tapes.

___ Cut out the oval hole in the middle of the cover plate. This is used for the elevatortorque tube. Figure 6-2 shows the cutout and placement of screws and nutplates forthe forward holes.

___ Attach the rear cover plate with eight evenly spaced nutplates around the perimeterand one in the top of the keel bulkhead stiffener that will be installed later.

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Keel

0"16.25"

14.125"

8.875"

2.25"

.5"

½" radius in (4) places

Elevator push-pull tube openning

Canardbulkhead

¾" flangeall around

CL of flangeCL of flange0" .75" 5" 10.5"

Hole pattern forAN526C-1032R8 screws.RivetMS21047-3 nut plates on keel.

Figure 6-2. Forward keel access hole.

6.1.3 - Aft Keel Access Holes

There is a premarked 6” diameter hole on the copilot side of the keel 23” aft of thefront of the keel. This is for accessing the nose gear cylinder.

___ The cover plate, p/n VKAC-01, is supplied in the kit. Cut it out and attach with sixevenly spaced #10 nutplates.

Other 4” access holes can be added to the rear of the keel to access the main gearcylinder and aileron torque tubes. The cover can be made using the same techniqueswe used above.

6.1.4 - Fitting the Keel

Note: The keel must be in the center of the aircraft.

___ At the same time you fit the keel you must fit the canard bulkhead. (Refer to Chapter4) Make sure you check the distance from the side of the fuselage to the top of thekeel in several locations to make sure it is in the center. The keel should fit againstthe canard bulkhead.

___ When satisfied with the fit, drill and cleco the bulkhead and keel in position. Keepthe 1/8" holes close to the side of the keel. Remove the keel and canard bulkhead forfurther work inside.

Note: If you installed the speed brake, you will need to trim the keel in the areaof the speed brake to allow the keel to lay flat on the fuselage floor.

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6.1.5 - Keel Hard points

There are three pieces of 1/4” plywood that get installed into the keel. The keel isfactory marked and Figure 6-3 shows the locations. All of these pieces are installedto the inside of the keel with EZ-Poxy mixed with Cabosil to make it sticky. Coverthe plywood with four piles of BID, lapping 1” to 2” onto the keel. They shouldeither have a small taper or filet to provide a smooth transition for the glass. To holdthe hardpoints in place while curing you can brace them to the other side of the keelwith a small piece of dowel rod.

___ Cut out one piece of plywood to dimensions shown at the top of Figure 6-4. This isthe hardpoint that the forward aileron torque tube bearing attachment and overcenterlinkage.

4"

5"

8"

5 .5 "

5 .5 "

17.0"

Gas spring hardpoint¼" plywood, 2" x 2"pilot side only - inside

Overcenter linkage hardpoint¼" plywood, co-pilot side only - inside

¼" plywood, pilot side only - inside

5.75"

Figure 6-3. Keel hardpoints.

___ Cut a 2” x 2” piece of plywood to install 17” aft of the canard bulkhead. 17” is thefront of the hardpoint. This is the hardpoint for the nose gear gas spring. Thisposition is marked on the outside of the keel.

___ Install the piece as shown in the upper right of Figure 6-4 in the position marked inthe keel. This is the hardpoint for the overcenter linkage.

When installing the aileron bearing bracket cut a hole that will allow the bolt head torest against the inside glass of the keel as shown in figure 6-3a.

Inside4 BIDWood Hardpoint

Foam Core When installing Front bearingcutout holes to allow bolt head to rest on inside skin

Figure 6-3a. Strengthening of attach point - top view.

* * *

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6.2 - Seats and Hardpoints

6.2.1 - Fuselage Hardpoints

___ Install front seat hardpoints in the floor. All eight are measured from the fuselagecenterline and from the aft face of the canard bulkhead. The inboard hardpoints canbe installed on the surface and covered with two plies of Bid. The outboard hardpointsare embed in the floor with Micro-Glass or Flox and cover with two plies BID.This keeps the seat level.

The rear seat hardpoints are provided in the kit. We do not show a location for thembecause this depends on how a builder decides to do their back panel in the airplane.Your rear seat rail are predrilled in the mounting locations. Use the rear seat rails toposition you hardpoints and install them as you did the front seat hardpoints.

35“

45“

14.25“

13.75“

6.75“

6.25“

2 plies BID

.25" x 2" x 2" aluminum

Alphapoxy / Flox

Canard bulkhead

- Aluminum hardpoints for seat rail mounting - 2" x 2" x .25" (VSH-01)

Figure 6-4. Fuselage hardpoints.

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6.2.2 - Seat Belt Hardpoints

Locations of the hardpoints are shown in Figures 6-5,6,7 and 9. You can tap thehardpoints prior to installation, but you will still have to drill and re-tap the holes.

___ Structural Adhesive/ Flox or Veloci-Poxy Micro-Glass the hardpoints into posi-tion, transition the edge with the same goo, and glass over with three layers of BIDand EZ-Poxy. It is permissible to lay-up the EZ-Poxy before the Veloci-Poxy iscured.

___ After cure, drill and tap the hardpoints as required. When drilling and tapping, becareful not to go through the outer skin. When you feel the drill going through,ease up on the drill and you will finish in the foam. Be careful with your tap as wellor you will put a bump in your outer skin.

___ The shoulder harness for the rear seats can be bolted to the angled bulkhead with awide area washer on the bottom side.

6.2.3 - Front Seats

Position and install all eight seat hard points (2" x 2" x 1/4" aluminum) according toplans.

___ Position the seat rail appropriately over the hard points and 2" from the rail to thecenter console. It is important that the seat rail is parallel to the sides of the keel toeliminate pinching when the seat is moved fore and aft.

___ You have already installed your inboard seat hardpoints on top of the inside glass tohelp give you a level seating position. If needed you can also use 1/4” washers toshim up seat rail to give you a level position. Measure washer thickness and make apermanent spacer out of aluminum.

06 - Fuselage


.875"in front ofbeam onfuselage

1.25"in front ofkeel fin(bothhardpoints)

26"

1.125"

Keel

Cana

rd b

ulkh

ead

Keel w

all Outside keel

3 plies BID 4" x 5"

3 plies BID 4" x 5"

Hardpoint

.187" x 2.25" x 1.25"hardpoint

Fuselage floor

Bolt CL

Fuselage floor

Microglass

Microglass

Hardpoint details:

1.125"

Hard point on keel shouldbe directly across from outboard hardpoint

Figure 6-5. Seat belt hardpoint installation.

___ Drill and tap hard points for 1/4"-20 rod. The 1-4"-20 rod with nuts can be pur-chased at any hardware store. Be very careful when drilling and tapping theseholes as you can go right through the fuselage.

___ Screw the rods into the tapped holes, measure and cut off for proper height (remem-ber to add a little for carpet). Install the rails and check for proper fore/aft move-ment.

To complete the seat-to-rail installation, it is best to have the seat-tilt side supportsattached and the seats upholstered. If you prefer to install prior to upholstery, it willbe necessary to have the bottom back tilt plates installed and to do this, you will needto simulate the thickness of the upholstery.

___ The side plates can be installed by first installing the bottom plate. This is done byplacing the seat bottom on a flat surface and setting the side plate so that the angledportion of the plate matches the angled portion of the seat. This angle on the seat isthe area that would normally rest on the fuselage side ducts. Once set, drill and tapfor 10/32 screws (two per side).

___ When both seat bottom side plates are attached, set the seat backs in place and installwith two 10/32 machine screws. The seat back plates will need to be cut off justwhere the taper begins.

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3 plies BID 4" x 5"

Duct

Duct

Microglass

.875"

Carb

on be

am

Looking out ofcopilot 's door

Forward

Figure 6-6. Seat belt hardpoint detail.

Duct

Carbon

beam

4"8.25"

1"

Shoulder harness bolt26" above duct measuredvertically

3 plies Bid

Figure 6-7. Seat belt inertial reel hardpoint.

We have previously installed aluminum hard points in the seats to accept the 10/32tapped holes. Remember to allow for the upholstery when installing these plates.

If you have purchased our interior kit upholstered seats, the process is the same.

Seat bot t omRecess

A t hird hole may bedrilled. Make sure itgoes t hrough hardpointin seat back

Figure 6-8. Seat side plates.

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___ To install the seats to the rails, first move the seat position to full aft. It will also benecessary to install spacers along the front and rear portions of the seat bottomswhere they attach to the rails. The spacers are made of strips of 1/4" plywood.These spacers are used to bring the seat to proper height. Shorter pilots/co-pilots,will need about a 1-1/2" spacer front and rear, tall pilots/co-pilots may need only 1/2" inch spacer. These may later be adjusted (fine tuned) to your exact needs.

___ Place the spacers over the seat rails and set the seat over the spacers. Move the seatto the full aft position (front of seat approximately 2" in front of attach bracket). Thisshould place the seat back just in front of the carbon door stiffeners. Once satisfiedwith the fit, reach under the seat and mark the position using a felt pen.

___ Remove the seat and seat rails. Drill through the seat and rail in four places. An inchor so in from each end will work. Attach the seat to the rail with (4) AN3 bolts andnuts. Use AN970-3 washers on the seat (cushion) side. Attach the spacers to the seatwith 1 layer of BID.

Final seat back position (lean) can be changed by adding to or sanding away thealuminum stop blocks.

___ If you have purchased our interior kit, the row of staples attaching the center sectionof the upholstery to the leading edge of the seat will need to be removed and thecenter section lifted up to gain access to the bolts used in attaching the bottom seat tothe seat rails.

6.3.4 - Rear Seats

Attach the rear seat backs to the seat pans using the side hinge pivots in the same waythat you assembled the front seats in the previous section.

___ Using the templates, cut 3/8" or 1/2" foam to make two of each support bulkhead. Cutthem oversize then sand them to fit the contour of the floor.

___ Temporarily attach the supports to the seat bottoms with hot glue using the dimen-sions shown in Figure 6-9. The outboard one is shorter because the aft outboardcorner of the seat pan rests on the wiring duct.

___ Place the seat in the desired position in the fuselage. Sand the bottoms of the bulk-heads until the seat sits firmly on the wiring duct and the floor. A good method is toset it in position and slide a marker along the floor, drawing on the bulkhead. Thiswill mark the bulkhead with the contour of the floor.

___ Mark the position of the supports on the seat bottom and remove the supports. Glassthem with one layer of TRIAX on each side. After cure, trim them and reattach themto the seat with two BID on each side of the support.

1-½"

Recess inseat pan

4-½"

Support bulkheadsShown in posit ion forright seat .Reverse posit ionsfor left seat

Aluminumangles

VRSA-01

4-¼"

Out board

Forward

Figure 6-9. Rear seat support bulkheads.

An optional method is to leave them on the seat after the initial fitting and apply oneply BID to the face of the support. Then apply two more plies BID to the face of thesupport, allowing them to lap onto the seat bottom.

___ After cure, trim the excess glass. Glass the exposed edges on the support by recess-ing the foam slightly, fill the cavity with Micro-Glass, and cover with one layer ofBID.

06 - Fuselage


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___ Each support gets a hardpoint in the floor centered 4-1/2" back from the front of thesupport and even with the inside of the support. Install it as you installed the otherseat hardpoints in Chapter 6.

___ Center the aluminum angles 4-1/2" back from the front of the supports and even withthe bottom of the support. Attach each angle with two AN3-10A bolts, MS21042-3nuts and an AN970-3 washers. Drill a 1/4" hole centered in the horizontal portion ofthe angle. Set the seat back in position and mark the floor hardpoints through the holein the angle or use a right angle drill to drill a hole in the hardpoint.

___ Drill a #7 hole in the hardpoint and tap for a 1/4"-20 stud. We used a 1/4"-20threaded rod from the hardware store to make a 1" stud.

You can secure the seat with a regular nut or use a wing nut for faster removal. Youcould also add another hardpoint that would give you two positions for the seat.

06 - Fuselage


6.3 - Keel Controls

6.3.1 - Keel Control Assembly Locations

___ There is a location marked on the top centerline of the keel, approximately 11" aft ofthe instrument panel. Drill a 3-1/8" hole. This is where the control stick exits.Dimensions on Figure 6-10 are approximate and are for reference only.

___ Also marked on the sides of the keel at this same 11" distance aft of the panel, areholes to be cut for access for assembling the stick mechanism.

Aft sid

e o

f pa

nel

Forwa

rd

10-11"

2"

1" hole

- left sid

e o

nly.

1" hole

- bo

th side

s.

3-1/8" hole

in top

ce

nter (stic

k exits he

re)

Kee

l

Aileron torque tub

e C

Positions marked on keel

Diagram is for reference purposes only

Ce

nter o

f be

aring

is ap

pro

x.1" b

elow

top

of ke

el

Figure 6-10. Keel and control stick layout.

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6.3.2 - Forward Aileron Torque Tube Bearing

You will need to install the front torque tube bearing to the aileron torque tube.Clamp the aileron torque tube in a bench vise . There is an aileron torque tuberetainer that comes to you inserted in the front of the aileron torque tube taped inplace. Remove the retainer and install it through the aileron torque tube bearing.Refer to 6-11 to make sure the bearing is facing the right direction. With the retainerinstalled tight up to the aileron bearing you will need to drill a 3/16” hole for the boltto hold the retainer. This hole is located 3/4” behind the bearing. Make sure thebushings for the control stick are perpendicular to the hole you are drilling.

3/16“ hole drilled perpendicularly to control stick bushings

Control StickBushing

Insert torque tube retainerthrough aileron bearing intotorque tubeAFT

Inside ofKeel

Bushings for the control stickwill be centered in the hole whenfont bearing is in the correct position

Figure 6-11 Torque tube retainer installation

Forward Aileron Cont rol Bracket

Qt y. Descript ion Part Number

1 Bracket , Front Aileron Torque Bearing VFAB-01

1 Cont rol Torque Tube, Aileron (End wit hret aining sleeve t o front of aircraft ) VATT-XL

3 Bolt AN3-7A

6 Washers (use as shims if necessary) AN960-10

3 Locknut s MS21042-3

___ The front aileron torque bearing bracket is mounted flange forward on the pilot sideof the keel. The extreme front end of the bearing itself is 18-1/4" aft of the frontflange of the keel. The center of the bearing is 12-1/2" above the bottom keel flange.The control stick bushings will be in the center of the hole you cut for the control stickwhen the front bearing is in the correct position. See Figure 6-11. Use (3) AN3-7Abolts, AN960-10 washers, and MS21083N3 nuts. For now, install it with just onebolt so that you can adjust the angle as you install the rear aileron control bracket.Counterbore the foam in the keel to allow the head of the bolt to be flush with the keelinner skin.

06 - Fuselage


6.3.3 - Rear Aileron Control Bracket

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___ Mount this assembly against the aft side of the keel fin with the center of the bearing1" below the top of the inside of the keel. See Figure 6-7 for bearing orientation.Use (4) AN3-5A bolts, AN970-3 washers, and MS21042-3 locknuts. Using the holesin the bracket as a guide drill through the fiberglass holes to attach the roll trim motorand shaft. Install the roll trim motor and pulley to the rear control bracket by insertingthe studs on the motor through the plate and securing with two 3/16” locknuts. Youwill have to open up holes in the fiberglass to allow all the bolts except the fourmounting bolts to tighten up against the aluminum control bracket.

Install the rear of the keel onto the front keel section. Install the aileron torque tubeand insert it into the aileron torque tube bellcrank. It will be a little long and need tobe trimmed. Measure the gap between the rear aileron section and the front section.Trim this amount off of the aileron torque tube. This will assure the aileron torquetube is tight up against the rear aileron torque tube bearing.

Locate the aileron torque tube bellcrank . Drill two 1/8" holes 2" up from the bottomtip of the bellcrank, 3/16" in from each side, for the trim spring attachments. Theseholes can be moved up or down to achieve the desired trim action.

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nk: V

ABC

-01

Ca

ble

, Pus

h-p

ull

Cla

mp

and

shi

m,

cont

rol c

ab

le, a

ilero

nVC

CC

-01

Bra

cke

t, a

ilero

n co

ntro

l sys

tem

VBAC

-01

AN3-

5A

MS2

1042

-3 lo

cknu

ts (4

)AN

970-

3 w

ide

are

a w

ash

ers

(4)

AN4-

12A

AN96

0-41

6M

S210

42-4

AN3-

11A

MS2

1042

-3

Rod

end

, ¼-2

8, fe

ma

le: M

W4

Ca

ble

cla

mp

shi

m

No

te: C

ut c

lea

ranc

e ho

le in

ke

el fi

nfo

r bo

lt/nu

ts o

n re

ar a

ilero

n b

rack

et

MS2

1042

-S (2

)

AN97

0-41

6(S

afe

ty W

ash

ers)

AN97

0-41

6(S

afe

ty W

ash

ers)

Figure 6-12. Aft aileron control assembly.

6.3.4 - Mid-bearing Support

With the aileron tube temporarily installed and aligned with the bearing in the rearbracket, measure the distance from the side and top of the keel to the center of the tubeat the factory-marked position of the keel bulkhead stiffener rib (VKBS-01). Nowdrill a 1" hole in the rib at that location.

___ Remove the torque tube and sand the area of contact for the rib to keel.

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___ Install the rib with the flange forward of the locator line on the keel with StructuralAdhesive.

___ Reinstall the torque tube and verify that the tube passes through the center of the hole.If not, file the hole to get enough clearance for the intermediate bearing (VIB-01).When satisfied, install the bearing, flange forward, with Structural Adhesive.

1".25"

3"

2"3.25"

1.5"1"

12.5"18.25"

18.25"

Top view

Front bearing support

Aileron torque tube

Mid-bearing support

Mid-bearingsupportVKBS-01

From canard bulkhead tofront side of bearing

Front aileronbearing bracket

Aft keel fin

Aileron torque tube

Center of bearing is approx1" below top of keel

Optional rivets

Intermediate bearinggoes here

Figure 6-13. Aileron torque tube installation in keel.

___ Now install the other two bolts into the front aileron bracket.

___ Reinstall the torque tube to the front bracket.

6.3.5 - Control Stick Assembly

___ Assemble the control stick to the torque tube. The hole in one side of the stick istapped for the threaded portion of the stick pivot bolt. The nut locks it in place. Donot drill this hole out by mistake.

Keel Cont rol Assemblies, Hardware List

Qt y. Descr ipt ion Part Number

1 Cont rol St ick Assembly VCSA-0 1

1 Cont rol Torque Tube, Aileron VCTT-0 1

1 Elevat or Push Rod Assembly VEPR-0 1

2 Rod End, 1/4-28 Male MM4

2 1/4"-28 Nut BI1428

1 Bolt AN4-15A

1 Bolt AN4-17A

4 Bolt AN3-10 A

4 Washer, Thin AN9 6 0 -416 L

2 Locknut MS210 42-4

4 Locknut MS210 42-3

Not e: Some bolt s may come assembled t o t he st ick andt ube assemblies

___ Insert the bellcrank into the torque tube. With the control stick up and the bellcrankdown, i.e. each pointing in opposite directions and their centerlines parallel to eachother, drill a 3/16" hole horizontally for an attaching bolt about 3/4" from the end ofthe torque tube through both pieces holding both in the above alignment. There aretwo circles premarked at the rear of the keel to cut holes for access to your torquetube.

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___ Remove the bellcrank and control stick from the torque tube. Reinsert the torque tubeinto the keel and permanently install the front torque tube retainer.

___ Install the two roll trim springs into the attachment holes of the bellcrank. Tie the lineto the left spring, route the line clockwise around the pulley, wrap around the trimmotor shaft (two complete wraps) and tie to the right spring. Be sure there is suffi-cient tension on the springs with no slack. If the motor shaft slips during operationmore tension is required.

___ Locate the two aileron control cables and thread on the (2) 1/4" rod ends. Screwthem on about halfway to ensure adequate threads for adjustment. Be careful duringfuture adjustment that you have at least 3/8" of the cable threads in the rod end anduse the locknuts provided on the cables.

___ Install the cables as shown in Figure 6-12 using the proper bolts, nuts, washers,shims, and spacers. This step can be done later, but make a note as to where to locatethis information.

AN3-

10A

Aile

ron

Torq

ueTu

be R

etai

ner

¼-2

8 Ja

m n

ut¼

-28

Jam

nut

Con

trol s

tick

Aile

ron

torq

ue tu

be

AN4-

21A

AN96

0-41

6L

Rear

bea

ring

brac

ket

Eleva

tor p

ush-

pull t

ube

AN3-

10A

AN3-

11A

Drill

and

fast

en b

ellcr

ank

to a

ilero

n to

rque

tube

with

cont

rol s

tick s

traig

ht u

p an

dbe

llcra

nk st

raig

ht d

own,

cent

erlin

es p

arall

el.

AN4-

21A

(2) A

N960

-416

LM

S210

42-4

Trim

fron

t por

tion

with

ele

vato

r fai

red

/ neu

tral

and

cont

rol s

tick v

ertic

al.

Faste

n wi

th 3

/16"

har

dwar

e.

Enga

ge th

read

sat

leas

t ½"

Enga

ge th

read

sat

leas

t ½"

AN4-

15A

(2)A

N960

-416

MS2

1042

-4 lo

cknu

t(1

)AN9

70-4

16 Sa

fety

Was

her

Figure 6-14. Control stick assembly.

6.3.6 - Keel Installation

Before permanently installing the keel make sure you have done the following:* Make sure the nose gear has been prepared as described in chapter 6.* Complete installation of gear hydraulic system as much as possible

(chapter 6).

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* Control system components have been installed in the keel.* Canard bulkhead and keel have been checked for fit.

On the bottom front of your keel there are two 1/4” holes for your nose gear. You needto space this apart so that the nose gear will fit properly. Cut a piece of 1/2” PVCtubing (or aluminum) 4-3/4” long. Using two 1/4-20 nuts and a length of 1/4” all-thread bolt the PVC tubing in place between the two holes.

It has come to our attention from one of our builders that the hydraulic fluid from thegear system can seep into the foam through the skin if allowed to sit for a period oftime. Before the keel is installed, the floor inside the keel area should be coated andsealed with epoxy to prevent this from happening. You can also coat the inside sur-face of the bottom cowling, floor of the nose section around the brake system, battery,hydraulic pump and plumbing, and any area that could be exposed to oil or hydraulicfluid.

Bond the keel in place using Structural Adhesive as shown in Chapter 4. Glass theinside of the keel from the front back about 24" with 2 layers of Bid 3” wide. Removethe piece of 1/2” PVC after the keel has cured.

6.3.7 - Keel Stiffening Lay-ups

After the keel and canard bulkhead are installed, you need to do all of the reinforcinglay-ups.

2 plies TRIAX per sideover plywoodalternate major axis

2 plies TRIAX per sideover plywoodalternate major axis2" overlap onto floor, keel andcanard bulkhead

Inside keel reinforcements:

2 plies TRIAX9" x 13"

6 plies TRIAX3" x 11"

Double arrows show major axis

Figure 6-15. Keel stiffening lay-ups.

___ Install the TRIAX stiffeners as shown in the Figure 6-15.

___ In the RG, there are holes predrilled in the plywood inserts. Make sure the holes arekept open while you are glassing by making some 1/4” pins that you wax and theninsert into the holes after glassing. When the glass is cured, you may remove the pins.

___ Each side of the keel gets two small and two larger TRIAX layers. The last twoplies lap onto the floor and canard bulkhead as well as lapping the wood stiffener.

___ The inside gets:* Two 9" x 13" layers of TRIAX from one side of the keel onto the

canard bulkhead, and onto the other side of the keel.* Six layers of TRIAX, 3" x 11" centered 6" above the pivot bolt holes.

Observe the major fiber orientation as shown in the diagram.

* * *

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6.4 - Forward Fuselage Treatments

6.4.1 - Nose Access Cover

This cover is a molder part, p/n VMAP-01.

The flange recess is molded into the fuselage top.

___ On the fuselage top, mark a line around the perimeter of the hole, 5/8” inside the edgeof the molded recess cut out to this line. This will become the flange for the cover.

___ Drill countersunk holes for #10 screws at the four corners of the cover, through thelip, and install 10-32 nutplates with 3/32” pop rivets.

___ Install the cover with (4) MS24693C-272 screws.

Nose access cover

Access cover

MS21047-3 nutplate

AAC-3-4 rivets

3/16“ Hole

5/8“

Figure 6-16. Upper fuselage reinforcement for canard installation.

* * *

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6.5 - Pedal System / Brake CylindersRubber Pedal / Brake Cylinder Inst allat ion Hardware List

Qt y. Descript ion Part Number

2 Mast er Brake Cylinder VMBC-01

1 Brake and Rudder Pedal Assembly VBRPA-02

4 Brake and Rudder Pedal VBRP-01

1 Brake Pedal Mount , Left VBML-01

1 Brake Pedal Mount , Right VBMR-01

2 Brake Push Tube VBPT-01

2 Brake Pedal Push Block VBPB-01

2 Roll Pin, 1/8: x 1", Brake Push Tube VPTRP-01

2 Fit t ing, 1/8", brake line VFBL-01

4 Bolt AN3-7A

5 Bolt AN3-10A

1 Bolt AN3-11A

4 Bolt AN5-10A

4 Washers- Thin AN960-516L

4 Locknut s MS21083N5

14 Washers- Thin AN960-10L

14 Locknut s MS21042-3

1/4" Drill Bit

1/8" Drill Bit

3/16" Drill Bit

1-1/2" Hole Saw

6.5.1 - Mount Master Cylinders

___ Measure and mark horizontal and vertical centerlines on the molded brake box on thefront face of the canard bulkhead (when finding the vertical centerline, do not includethe portion that is angled in your measurements - just use the portion that is parallel tothe bulkhead face).

___ Drill two 1-1/2” holes, centered 1/2” above the horizontal centerline and 2-1/4” outfrom the vertical centerline. Using the master cylinder as a guide, drill four 5/16”holes for mounting. See Figure 6-17.

___ Mount the master cylinders with (4) AN4-10A bolts, (4) AN960-516L washers, and(4) MS21083N5 nuts.

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AN5-10A bolt

AN5-10A bolt

AN5-10A boltAN5-10A bolt

Drill four 5/16“ holes using master cylinder as a guide.(Typ)

Drill 3/8" hole in center

Center

2-1/4“

Figure 6-17. Master cylinder mounting locations on brake box.

Ma

ster

cyl

ind

erMa

ster

cyl

ind

er b

ox

(mol

ded

into

ca

nard

bul

khe

ad

)

Adju

sta

ble

pus

h b

lock

Ped

al a

ttach

bra

cket

Push

tub

e (2

)Pedal arm

90º

1/8"

x 3

/16"

tub

e fit

ting

Nyl

aflo

w tu

bin

g

Push

rod

Loc

knut

4" to

top

of P

ed

al

MS2

1042

-4AN

960-

16L

Dril

l hol

es

as

ma

rked

on

box

mo

lded

into

ca

nard

bul

khea

d.

Dril

l 1-½

" ho

les

for

bra

ke p

ush

tub

es.

AN5-

10ACa

nard

bul

khea

d

Cot

ter

Pin

Feru

le

Bra

ke li

ne In

sert

Figure 6-18. Brake master cylinder assembly.

* * *

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6.5.2 - Assemble Rudder Pedals

___ Install the pedals into pedal arms with (4) AN3-7A bolts, (4) AN960-10L washers,and (4) MS21042-3 nuts. Multiple holes can be drilled in pedals for adjustment.

Figure 6-19 Rudder pedal to pedal arm assembly.

___ Install push tube and push tube stop bolts to the pilot’s pedal arms with (4) AN3-10Abolts, (4) AN960-10L washers, and (4) MS21042-3 nuts.

___ Install rudder actuator arms to assembly using (1) AN3-11A bolt on pilot’s side, (1)AN3-10A bolt on the co-pilot’s side, (2) AN960-10L washers, and (2) MS20142-3nuts. Make sure to put the mounting blocks on each side first.

Figure 6-20. Brake push tube to pedal arm attachment.

6.5.3 - Mount Pedals

___ Position the rudder and brake pedal assembly centered against the bulkhead approxi-mately 4" below the top of the canard bulkhead, or spaced just above the keel.

___ Drill #21 pilot holes through the bulkhead using the attach brackets as a guide. Re-move these brackets and tap them with a 10-32 tap. You don’t have to tap the wholeblock, but you need enough threads to fully engage your bolts. Enlarge the holes inthe bulkhead to 3/16". Install the assembly with (4) AN3-11A bolts.

___ Install two 1/8", 90 degree fittings (use Permatex #2), and brake lines as shown iffigure 6-18. Run the brake lines down the pilot’s side duct, exiting the duct under thegear in front of the firewall, and leading down the appropriate gear leg.

Do not make these lines too short! Length should be approximately 15’ right and12’ left. At the rear of the plane you can install a union in the brake lines before theygo down the gear leg. This will allow you to remove the gear leg. The adjustments ofthe push block and the installation of the lock nut will be done when the brakes areinstalled and the fluid is added.

Do not use anything but Dot 5 brake fluid. Aircraft brake fluid will ruin theToyota master cylinders and automotive brake fluid will mess up the aircraft brakes.DOT 5 brake fluid is the only type you can use.

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Figure 6-21. Rudder / brake pedal assembly.

6.5.4 - Install Nylaflow Tubing for Rudder Cables

___ Drill a 3/16" hole through the firewall 5" from each side, just below the centersection spar. Also drill a 3/16" hole through the gear bulkhead just inboard of thetransverse bulkhead, 8" above the duct.

___ Cut two lengths of the 3/16" Nylaflow tubing provided, to run from the back of thefirewall (protruding slightly) to within 6" of the canard bulkhead. Route the tubingwith a smooth curve, with the forward end at the same height as the cable attach pointon the rudder pedal arm. The tubing will have to pass through the bottoms of bothcarbon beams at the door.

Hot Glue the tubing to the fuselage sides. Using one layer of bid glass the tubing inplace the entire length except for the last 6 inches on each end.

Transverse Bulkhead

1 ply BID

Up

Forward

Side View(Inside Looking Out)Rudder Cable in Nylaflow tubing

The rudder passes throughBase of Carbon Beam

Figure 6-22. Rudder cable fuselage conduit.

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6.6 - Instrument Panel

6.6.1 - Locate Panel

The instrument panel aft face (in front of the pilot) is located 21” from the front of thecanard bulkhead. ( If you are installing a yoke system the dimension from the canardbulkhead is different. Refer to your Control System Chapter.) The bottom flat hori-zontal part of the panel should be 17” off the floor on each side and level. You willneed to trim the center of the panel to obtain this.

6.6.2 - Install Panel

The instrument panel is installed so that you may remove it in the future for mainte-nance if needed. After the panel has been trimmed to fit duct tape the outside backedges where the panel meets the fuselage and the bottom where the panel meets thekeel. Install the panel using hot glue or bondo in the position you want it. Lay-up 5layers of bid 4 inches wide down each side of the panel so that 2 inches are on boththe fuselage and the panel. Lay up 5 bid 4”x4” patch between the top of the keel andthe panel. After this glass has cured and before removing the panel mark and drill thepanel for screws to hold it in. Lay out your pattern so the screws are equally spaceand you are far enough in from the fuselage to use a screwdriver to remove them.Also make sure that you are on the flange that you just made and that you leave enoughroom for nutplates. After you have drilled you holes you can remove the panel. Trimthe flanges to give them a smooth edge.

**** Many builders make a small removable insert in there panel for there throttle mixtureand prop controls. This allows these controls to stay in the airplane if the panel isremoved. After you have trimmed and fit your panel lay-out where you will wantyour throttle mixture and prop to go . Draw two cut lines around your control loca-tions. Keep in mind that there are large nuts to hold these cables in and leave enoughroom for them. Cut out the bottom pilots side of the panel along your lines. Duct tapethe back of the instrument panel along your cut out. Lay your instrument panel flat ona table and hot glue back in the piece you just removed. Make sure that the front of thepanel and the cutout are flat against the table. Now you can lay up a 5 bid flange fromthe back of the panel onto the duct tape. Mark out your screw locations and drillbefore separating the pieces.

Screw and nutplate locations

Center will need to be trimmed to clear the keel

Figure 6-23. Instrument panel / keel joint.

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6.7 - Installing Main Spar

6.7.1 - Spar Positioning

___ Level the fuselage fore and aft and side to side along the premolded gear pockets. Cutout a 3” wide hole 9” high from the top of the premolded gear pockets up right againstthe firewall.

Fire

wa

ll

Spar

Spar

Leve

l fus

ela

ge

Fore

to A

ft an

d sid

e to

sid

e

Be s

ure

sin

gle

ha

rdp

oin

tis

at t

op

2 p

lies

BID

No

tch

the

fuse

lag

e fr

om

the

pre

mo

lde

d

po

cke

ts u

p 9

“ a

nd 3

" ahe

ad

of t

he fi

rew

all.

(a) A

dju

st s

pa

r end

s to

be

plu

mb

.

(b) A

dju

st s

pa

r end

s to

be

eq

uid

ista

nt fr

om

no

se

(c)

Ad

just

sp

ar e

nds

to e

qua

l he

ight

usin

g th

e w

ate

r le

vel.

No

se

(c)

(c)

(a)

(a)

(b)

(b)

Sing

le h

ard

po

int

at t

op

Figure 6-24. Aligning spar for installation.

___ Center the spar in place with the inboard single hardpoint up top.

___ Using a marker draw a line where the spar meets the firewall top and bottom. Alsomark where the back of the spar meets the firewall.

___ Sand 2” above the top line and 2” below the bottom line. Sand the firewall 4” infrom the fuselage on both the front and the back side where you made the cutoutearlier. Sand the top of the premolded gear pockets. Sand the bottom of the sparwhere it will sit on the gear pockets. Sand the top and bottom spar cap where it willmeet the firewall. Sand the back of the spar about 4” inside the lines you drew on itearlier.

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6.7.2 - Spar Installation

Make sure your fuselage is level fore and aft and left to right before installing. Put thespar in place with the center of spar aligned with the fuselage centerline.

___ Spar plumb: With a level on the outboard hard points, shim the spar to be plumb. Ifthey differ, split the difference. See Figure 6-24 (a).

___ Spar sweep: Adjust the spar ends to have the same distance from the nose bolt holeto the plumbed level on the outboard hard points. Be consistent with your measuringreference points at each end. Slip bolts into the outboard hardpoints to use as aguide. See Figure 6-24 (b).

___ Spar level: Use the water level to set the spar ends at the same height. Measure fromthe same place on the outboard hard points. Do a dry run first with your spar to seehow it will fit. Find out where you may need shims so when you go to bond in the sparit will go smoothly.

___ You will need to mix up about 1 cup on Structural adhesive with flox in order to bondin the spar.

Spread a bed of Structural Adhesive on top of the gear pockets where the spar willgo. On the back side of the spar spread Structural Adhesive 3” in from the lines youdrew earlier. Now, with some help reinstall the spar. Re-level the spar as you didabove. When satisfied with the level of the spar leave it alone until it cures.

6.7.3 - Lay-ups

Note: Don’t forget to sand before applying your lay-ups. BID is always cut on a45 degree bias. Unless noted, TRIAX major axis is on the long dimen-sion. Pre-wet multiple layers of TRIAX on plastic. Precutting the pliescalled for in this chapter will make your work go much easier.

___ Micro-Glass a radius along the firewall to spar line. Apply two plies of 3" x 41"piece of BID along the engine bulkhead to spar line, top and bottom Figure 6-25.

Spar

2 plies 3" x 41” BIDover micro-balloon radius

2 plies 3" x 41” BIDover microglass radius

Cut

Off

Figure 6-25. Spar to firewall joint.

___ Apply two plies of 3" x 9" BID, lapping the aft sides of the firewall and spar. Figure6-26. Cut off fuselage behind firewall even with bottom of spar.

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Spar

Aft face of Firewall

(2) plies3" x 9” BID

Figure 6-26. Aft spar to firewall reinforcement.

Spa

r

6.25“ x 9" x 3/8" PVC foam fit from top spar cap diagonallyto gear bulkhead

Premolded Gear Pocket

Figure 6-27 Foam inserts for main gearbox- firewall reinforcements.

___ Cut two pieces, one for each side, of 3/8" dyvinicel foam, 6-1/4" wide by about 9" tofit between the top forward edge of the spar cap angling down onto the gear bulkhead. Taper these pieces to fit. See Figure 6-27.

6.7.4 - TRIAX Reinforcement

The section of the airplane that takes the most regular abuse is the section from thegear bulkhead back to and including the firewall. These sections need to be rein-forced to be very durable. This is done with TRIAX. The cutting schedule below isenough TRIAX to do all of these lay-ups. They all can be wet out on visqueen andallowed to get tacky (about 1-2 hours depending on temperature and humidity) Be-forehand. Peel ply will help to keep the TRIAX from draining once installed.

06 - Fuselage


___ Cut 4 plies, 2 for each side, of 6.25" x 8" TRIAX and apply to the top of the spar andup the firewall. See Figure 6-28.

___ Cut 4 plies, 2 for each side, of 6.25" x 22" TRIAX and apply to the firewall about 7-1/2" above the spar, across the top of the spar, down the angled foam and onto thegear bulkhead about 2". See Figure 6-28.

___ Cut 4 plies, 2 for each side, of 6.25" x 32" TRIAX and apply over the previous lay-up and on down to the fuselage floor. See Figure 6-28.

___ Cut 4 plies, 2 for each side, of 4" x 12" TRIAX and apply, crossed, over the gear bolthole area on the gear bulkhead, one lapping onto the fuselage side and one lappingonto the conduit and floor. See Figure 6-30.

___ Cut 4 plies, 2 for each side, of 4” wide BID. Install from top of slant bulkhead downto the gear bulkhead. This attaches the slant bulkhead to the fuselage. It can be in-stalled before or after the TRIAX.

The last lay-up is four plies of BID that extends from the underside of the top sparledge, down across the inside surface of the angled piece, onto the gear bulkhead,and across the top of the horizontal bulkhead onto the lower spar ledge. It also lapsaround about 1" onto the transverse bulkhead. See Figure 6-28.

-itnauQyit eziS noitacoL

4 "8x"52.6 daehkluBtnalS/rapS

4 "22x"52.6 daehkluBraeG/daehkluBtnalS/rapS

4 "23x"52.6 daehkluBraeG/daehkluBtnalS/rapS

8 "81x"6 rapSfopoTstnemecrofnierediS

4 "21x"4 elohtloBraeG

4 "8x"6 retneCpoT

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(2) plies 6.25" x 22” TRIAX

(2) plies 6.25“ x 8" TRIAX

(2) plies 6.25" x 34” TRIAX

(4) plies BID

Figure 6-28 Upper spar to bulkhead ties.

___ Cut eight 6" x 18" . Pre-wet these out on plastic in sets of two. Starting above thespar lay 6” onto the firewall and 12” onto the fuselage. One set of the two will passbelow the window while the other will go above the window. Refer to figure 6-29.

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Spar

FirewallWindow

12"6"

(2) 4" x 4" TRIAXto aft top sidecenter of firewall

Figure 6-29. Firewall reinforcements.

___ Cut four 6" x 8" pieces of TRIAX, axis lengthwise install them on the top of thefirewall as shown in figure 6-29. Also apply two 4" x 4" plies of TRIAX on the aftside top center of the firewall (opposite the lay-up on the front).

All these pieces serve to tie the firewall and upper fuselage together and reinforcethe upper engine mounting points.

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Spar

Forward face of firewall

DuctGear Bulkhead

Gear pivotbolt holelocation

(1) ply TRIAXlap onto fuselage side.

(1) ply TRIAXlap onto duct.

Figure 6-30. Main gear bolt hole pad.

___ Cut four plies, two for each side, of 7" x 8" BID and apply, centered, over the ductbetween the gear bulkhead and the firewall, lapping each bulkhead slightly. SeeFigure 6-27.

___ Join fuselage-to-spar line, inside and out, with two 2” wide strips of BID over afinger radius of Micro-Glass.

€ Make sure you have not forgotten the 7” x 33” one ply TRIAX reinforcement on thefuselage floor between the firewall and gear bulkhead. See Chapter 4.

€ Check all the lay-ups to be sure they are not pulling away from the corners. Let cure.

06 - Fuselage


6.8 - Canard Reinforcements___ Level and plumb the fuselage.

Using the template found at the end of this chapter follow the instructions to cutoutthe doghouse. Open up the front and aft cutout before you precede by using 80 gritsand paper. Make sure you keep the gap no greater than 1/8”. After you cut the coverout groove a little bit of the foam around the edge of both the fuselage and the cover.Fill with micro and cover the exposed foam with 1 layer of Bid.

___ Using a level and your incidence block, get the canard level right, left, fore, and aft.Also make sure that it is perpendicular to the fuselage by measuring back to theoutboard hardpoints in the main spar from the trailing edge of the canard. If yourcanard is not level left to right shim the canard so that one side is touching the canardbulkhead. The gap between the canard and the bulkhead will be filled when youinstall your canard bushings. You will need to get the canard lift tabs as close to thecanard as you can. You may have one lift tab that is not perfectly flat against thecanard. When the bushings are installed we will be able to take care of this also.

6.8.1 - Canard Attachment Reinforcement

___ Pre-cut eight pieces of 8" x 18" TRIAX, axis lengthwise. Trim to fit as shown in thesketch lapping 4" below the canard cutout, 4" above and below the fore and aft sidesof the opening, and 5" onto the canard bulkhead.

Figure 6-31. Forward fuselage treatments.

___ After cure of the reinforcements, trim them back to the edges of the canard cutout.Square up and straighten any cut lines with a sanding block, remove 1/8" foam behindthe inner and outer skins. Fill the recesses with EZ-Poxy Micro-Glass, and apply 1ply of BID on a 45 degree bias. Let cure.

___ Reinstall the canard and check to make sure that it is set in position-

* level - Left to right using a level. After that stand at least 10 feet in front of theairplane and sight the top of the canard and the spar and make sure they are levelwith each other. Refer to Figure 6-32.

* centered - Left to right lining the center line of the airplane with the center line ofthe fuselage

* Proper Incidence - using you canard incidence gauge

*Straight - Making sure that the distance from the canard tips to the center spar tipsare equal.

Using the predrilled holes in the lift tabs as guides, drill 1/4” pilot holes in the canardbulkhead. Remove the canard and open these holes up to 1" to accept bushings usinga hole saw.

___ Enlarge the holes in the lift tabs to 3/8" so they will accept the attach bolts. As a dryrun, put the bushings in, put the canard back in place, and fit the bolts.

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Make sure the top ofthe canard is level withthe top of the spar

Figure 6-32 Leveling Canard with Center Spar

If your canard has a small gap on one side between the bottom of it and the bulkheadwhen level we will fill that when we install the bushings. Run one layer of duct tapeon the bottom side of the canard from left to right where it meets the bulkhead. Makea bed of EZ-poxy and Micro-balloon along the top of the bulkhead. Install the bush-ing using Structural adhesive mixed with flox . Put your canard in place. Install thenuts and bolts tight as shown in figure 6-33. Put a little vaseline on the washers sothey will not stick. Re-level and center you canard and check your incidence. Checkit twice. Shim as needed to keep it in place. You may have one bushing that sticks outin front of the canard slightly farther than the other because the canard bulkhead wasinstalled slightly crooked. This should not affect anything. Now go back and cleanoff any extra Micro that has squeezed out between the bulkhead and the canard.

Canard

Lift tab

AN363-624 locknut

AN970-6 large washer

Forward

AN960-616 washer

AN6-16A boltBulkhead

Lift tab installedon of canard bulkhead

forward side

Figure 6-33. Canard mounting tabs.

6.8.2 - Canard Top Attachment Points

___ The next section shows how to build TRIAX tabs that attach to the top of the strake.We show building these lay-ups so that you have tabs front and aft on top of thecanard. This is how it is done in the XL’s. The standard Velocities do just fine with asingle tab on the aft side of the canard. You have the option of only installing the backtabs. If you opt to do this the lay-ups shown in figure 6-35 that are 20 inches long andextend to the front of the canard to make the second tab can be left 12 inches long andjust used on the aft tab.

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Install your canard in position in your airplane. Duct tape the bottom inside of yourdoghouse cover on each side 3”. Install your doghouse cover. Trace a line on yourcanard where the doghouse sits. Your doghouse will need to be trimmed to fit thecanard before you do the next step. When you are satisfied with how your doghousesits on the canard hot glue or Bondo it to the canard on the outside of the cover.Remove you canard from the airplane carefully. Use scrap wood or Dyvinicel tomake backer boards to layup 3" x 3" TRIAX pads on the aft and front sides of thecanard just above the trailing and leading edges. Put duct tape on the backer boardswhere the pads will be laid up. Hot glue the boards onto the trailing edge of thecanard cover just above the trailing edge of the canard. Hot glue the front boards onso they but up to the top of the leading edge. Make sure the backer boards are largeenough to lay a 3”x3” pad onto.

Canard

Use duct tape on boardsto prevent adherence.

Canard cover

3“3“

1. Cut ( 8) 3“ x 20” pieces of TRIAX2. Cut ( 4 ) 3“ x 12” pieces of TRIAX3. Wet the 3“ x 20” pieces out 2 at a time4. Add one 3“ x 12” piece to each lay-up so the 3” x 12” is at the back5. First install the horizontal lay-up over the canard and up onto the front and rear boards6. Install the vertical lay-up letting about 1“ of the lay-up overlap onto the canard.

Backer BoardsFigure 6-34. Canard torsion tabs.

A small piece of wood with duct tape on it will have to be placed between the backerboards and the trailing edge of the canard to span the gap and support the TRIAXuntil it cures. Make sure it does not sag. If the TRIAX is too low, it will interferewith the operation of the elevators.

___ Sand all areas on top of the canard.

___ Cut eight 3” x 20” pieces of TRIAX (major axis lengthwise) and wet out two at atime on some visqueen. Cut four 3” x 12” pieces of TRIAX and lay one on top ofeach lay-up of 3” x 20” . The aft pad is thicker than the front pad so have the 3” x12” lined up with the trailing edge of the lay-up. On each side place one of theselayups so it starts on your front backer board and finishes on your rear backer boardcreating the 3” x 3” pads. The first layup has 2” of its width on the canard and 1”overlapping onto the doghouse. The second layup has 2 “ on the doghouse and 1”overlaping onto the canard. Work the coners ot make the glass conform to them asbest you can. This forms a six-ply 3" x 3" pad at the aft side and a four-ply 3” x 3”pad at the front side. Put aside and let cure. Refer to figure 6-34 and 6-35.

Once cured mark three equally spaced holes 1” off the canard along the doghouse.Drill three 3/16” holes through the doghouse and the TRIAX. Refer to figure 6-36.You can now remove the doghouse. You can now install MS21047-3 nutplates on theTRIAX flange where you drilled your three holes on each side. Now the doghousecan be held in place with three 10-32 screws on each side. Pop the doghouse backoff and run one layer of duct tape along the outside of the lift tab so it will be underthe edges of the doghouse. Reinstall the doghouse and secure it on the inside with alittle hot glue. Now you can fill the radius between the doghouse and the canard withEpoxy and Flox and cover with one layer of bid. Make this a smooth transition. Thebottom edge that you just filled and glassed will need to be trimmed.

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Figure 6-35 Canard Tab Lay-up Schedule

On the fuselage, prepare an area for mating the 3" x 3" pads you just made on thecanard. Sand the inner skin for about 12" aft and 12" below the pad area at the rear ofthe canard cutout. Forward of the canard cutout sand a 12” x 12” area. Duct tape theoutside of the tabs that you just made on the canard. Instead of using scrap wood wewill lay-up our tabs for the fuselage right onto these tabs. Reinstall the canard with-out the doghouse. Install the bolts through the tabs and the canard bushings.

Fuse lage

Approximately 1“ ofVertical triax layup under doghouse over-lapsonto the canard

Before removing doghouse drill3 equally spaced 3/16“ holesfor attach screws

Install wood so that it is an extensionof the pad

***Remember to duct tape both the tab and the extension. If you don’t you will glass you canard in permanently

Figure 6-36. Fuselage mate for canard torsion tab.

___ With the canard in place we will need two 3” x 8” pieces of scrap wood (for the aftside) and two 3” x 6” scraps of wood ( for the front side) all with one side coveredwith duct tape. These need to be installed under the canard so they are an extension ofthe pad we just laid up. Refer to figure 6-36.

Cut six pieces of 6" x 12", and six pieces of 3" x 12" TRIAX. Pre-wet three plies ata time on some visqueen. The 6" x 12" are installed vertically with 3" on the tab andscrap wood and 3" on the fuselage. Install the 3" x 12" horizontally onto the side ofthe fuselage, with 3" overlapping your canard tab. This forms a six-ply pad that mateswith the one on your canard .

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___ Cut four pieces of 6" x 8", and four pieces of 3" x 8" TRIAX. Pre-wet three plies ata time on some visqueen. The 6" x 8" are installed vertically with 3" on the tab andscrap wood and 3" on the fuselage. Install the 3" x 8" horizontally onto the side of thefuselage, with 3" overlapping your canard tab. This forms a four-ply pad that mateswith the one on your canard .

___ Once cured, remove the wood, square up the edges on both pads, and taper the verti-cal portion of the pad on the fuselage from 3" wide at the top back to the fuselage skinat the bottom.

___ Reinstall the canard, file away any interference, and bolt in place. Drill a 1/4” holethrough both pads. Using 1/8" pop rivets, attach a 1/4” nutplate to the front side of thefront tab and back side of the back tab through a 1/4” wide area washer. Lightly sandthe back of the washer and the back of the pad. Spread Structural Adhesive be-tween the pad and the washer.

Fuselage tab

Canard tabMS21047-4 nutplate

1/8“ pop rivets

AN970-4 washer

AN970-4 washer

Structural AdhesiveAN4-7A bolt

Figure 6-37. Aft canard attachment cross-section detail.

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06 - Fuselage


6.9 - Overhead Fresh air DuctThis installation may be easier with the airplane upside down. You will be flippingyour airplane over when you get to the end of the fuel strake installation so you maywant to do this installation then.

The overhead vents comes to you extra long so that you can trim them to fit. The ductextends from about 6” in front of the firewall to a comfortable distance from the frontwindshield. The front position of the duct is up to you.

You will first need to install the small NACA scoop in the top of the fuselage. Drawa center line down the top of the airplane. Using the NACA scoop as a guide mark,cut the hole for the scoop about 11” from the cowling cut line centered on your line.The NACA scoop is installed with the pointed end facing forward. Slide the scoopdown into position and file the hole until it fits nicely. Remember to have the bottomof the front of the NACA scoop flush with the outside surface of the fuselage. Theback of the NACA scoop should be about 1” deep. You will have to trim off some ofthe scoop since it will extend above the surface of the fuselage once fit.

At the rear of the scoop cut the inside skin of the fuselage 3/4” back from the rear ofthe scoop. Bevel the foam back to this cut line. The will open the scoop up more andimprove airflow. Remove a little foam around the edges, and glass over with onelayer of bid. Do not try to wrap the bid around the corners. Wait until after it hascured then cut the bid flush to the fuselage skin with a razor blade.

Sand the exterior of the NACA scoop where it touches the fuselage. Install the NACAwith FLOX and EZ-poxy. Glass the inside of the scoop to the fuselage with a 1”wide layer of BID. There is no need to glass the NACA scoop on the exterior.

Now the fresh air duct can be installed. Decide where you are going to terminate youduct at the both ends and mark these locations. The rear location is approximately11” forward of the cowling cut line. The rear of the duct must be far enough forwardto allow access to the top engine mount bolt and not have any interference with theOC-link on the RG airplanes.

Bid the duct to the fuselage using a 1-1/2” wide piece of bid followed by a 1” widepiece of bid. Lay up a 5” x5” piece of 3 Bid on a flat table on plastic. Cut out endcaps for your duct from this cured glass and install with 2 Bid.

Holes can now be drilled for vent installation. Our typical installation places thefront two vents about 10” aft of the windshield. The rear vents are located about 40”aft. Many people install lights in their ovehead vent. If lighting is mounted in theoverhead vent the wiring runs out the back of the duct. Keep the exit hole high at therear of the duct.

The last thing that you will have to do is to drill a 3/8” hole in the rear lowest corner.Insert a 3/8” aluminum tube flush with the inside surface, flox around the tube andglass with one bid. This tube should be long enough to extend down through the floorflush with the outer skin. Route the tube so it doesn’t interfere with the landing gear.Your duct is typically upholstered before the headliner as a separate piece

Documents

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