glasair 2-1

RUDDER ASSEMBLY

TABLE OF CONTENTS

PAGE

A. RUDDER HINGE LAYOUT AND REINFORCEMENT . . E-3

B. RUDDER HINGE ATTACHMENT . . E-S

C. RUDDER RIB CONSTRUCTION AND INSTALLATION .. E-IO

D. RUDDER CLOSEOUT . . E-17

~ STODDARDHAMILTON

AIRCRAFT. INCORPORATED

MODEL ASSEMBLY NAME

GLASAIR TD RUDDER ASSEMBLY REVISION DATE VOLUME

II PAGE

E-l

RUDDER ASSEMBLY

INTRODUCTION

The rudder is made from a right and left shell half. The rightshell half has the forward shearweb built into the panel. The left shell half's leading edge curves inward in a similar manner, as do the flaps and ailerons. Construction and installation of the rudder assembly is very similar to the flap and aileron assemblies. The rudder is hinged on the right hand side with extruded piano hinge. Figure E-I below shows the major components of the rudder assembly.

RIGHT RUDDER PANEL

-

RIGHT RUDDER PANEL SHEARVVEB

~ - :: : ~ : : : :---

"- --RUDDER ACTUATOR FITTING

RUDDER ASSEMBLY

FIGURE (E-I)

~ STODDARD-HAMILTON


MODEL ASSEMBLV NAME


II PAGE

E-2

CONSTRUCTION PROCEDURE

Before beginning construction of each alphabetical division in this section, study every step thoroughly to avoid any surprises.

A. RUDDER HINGE LAYOUT AND REINFORCEMENT

STEP A-I

HINGE LOCATIONSrT--r=-_~

FUSELAGE

SIDE VIEW OF RUDDER AND VERTICAL FI N

FIGURE (E-2)

Layout the hinge locations onto the right trailing edge of the vertical fin and the right rudder panel as shown in Figure E-2.

~ STODDARCJ.HAMILTON


MODEL

GLASAIR TD ASSEMBLY NAME

RUDDER ASSEMBLY REVISION DATE VOLUME

II PAGE

E-3

STEP A-2

From the supplied .025" thick 2024-T3 aluminum sheet cut two pieces1" x 8" . R.emove any sharp burrs and sand both . ' for bonding. s~des w~th 60 gra t sandpaper. Cut (4) pieces of fiberglass cloth 2" x 9" on the 45 0 bias.

STEP A-3

RIGHT RUDDER PANEL

.025" 2024 -T3 ALUM INUM

~~-2"x 9" (2) LAYER LAMINATE

SECTION A-A

FIGURE (E-3)

The rudder requirea reinforcement at the hinge attach locations. It is reinforced in the same manner as the aileron and flaps.

Lay up one layer of the 2" x 9" cloth at each hinge location on the inside corner of the right rudder panel, as shown in Figure E-3. Let cure. Bond the 1" x 8" aluminum reinforcements to the inside of the shearweb on the right rudder panel with body putty, as shown in Figure E-3. Once the body putty hardens, lay up the remaining 2" x 9" cloth pieces over the aluminum strips as shown. Let cure.

NOTE: Make sure the aluminum strips are bonded flush against the shearweb so no air bubbles will be present in the laminate.

COMPLETED 0

~ STODDARD-HAMILTON

AIRCRAFT, INCORPORATED

MODEL



II PAGE

E-4

B. RUDDER HINGE ATTACHMENT

STEP B-I

Cut two 8" lengths of MS20001-P4 hinge. Do not cut the hinge pin at the same time. Cut the MS20253-P2 hinge pin 9" long. Deburr and file any saw cut roughness smooth.

Put a 90 0 bend in each hinge pin about 3/4" from one end. This will act as a "handle" and keep the pin from falling out.

STEP B-2

_--e:::""'"" 1

...-RIGHT RUDDER PANEL I

\:0

LFUSELAGE -MS20001-P4 HINGE

CROSS-SECTION OF RIGHT RUDDER PANEL

FIGURE (E-4)

~ STODDARD-HAMILTON


MODEL ASSEMBLY NAME


II PAGE

E-5

Measure the thickness of the right trailing edge of the vertical fin at the hinge locations, as indicated by Flag #1 in Figure E-4 and Figure E-5. C-clamp the hinge halves to the rudder shearweb at a distance from the corner equivalent to the thickness of the right trailing edge of the vertical fin.

NOTE: Rudder travel is 250 to the right and 18 0 to the left. The two hinges must be in line with each other or the rudder will bind when rotated. Make sure the surfaces that the hinges are riveted to are flat, and that the hinge line is straight. Check the hinge line straightness by sighting down the hinges. Check the inside surface of the right trailing edge with a straightedge to check for flatness at the two hinge locations. Build up the areas with fiberglass laminates, if needed, to make them flat and in line with each other.

VERTICAL FIN RIGHT TRAILING EDGE THICKNESS c::::rJ

RIGHT RUDDER PANEL SHEARWEB

MS20001- P4 HINGE

FIGURE (E-5)

Layout the hole pattern shown in Figure E-5 onto the rudder hinge halves . Space the rivets 1" apart, 1/2" from the ends. Drill through the hinge halves and the shearweb of the rudder with a #30 drill bit at the end hole locations, only, of each hinge half. Insert a cleco clamp into each hole after drilling to hold the hinge halves in place. Remove the C-clamps.

NOTE: Only drill the end holes in each hinge half to start with. Make sure everything fits and rotates freely before drilling the remaining holes and riveting. Do not do any riveting in this step.

~ STODDARD-HAMILTON


MODEL ASSEMBLY NAME


II PAGE

E-6

NOTE: Before riveting the lower hinge half to the rudder shearweb, SO:me material may need to be removed from the hinge half to allow the rudder actuator fitting to be installed correctly. Check the 2" dimension in view A-A of Figure E-13 for agreement. Remove material from the hinge half for the actuator fitting, if needed.

STEP B-3

~--AN426AD4-5 RIVET

RIVET

TYPICAL CROSS-SECTION OF RIGHT RUDDER PANEL IN NEUTRAL AND FULL RIGHT POSITION

FIGURE (E-6)

A gap is required between the right trailing edge of the vertical fin and the rudder shearweb to allow 25° of right rudder travel as shown in Figure E-6. The gap is approximately 1/8". (See Flag#1, Figure E-6.) .

With two of the hinge halves c1eco clamped to the rudder shearweb, install the other two hinge halves with the hinge pin. Layout a similar hole pattern onto the outside surface of the right trailing edge of the vertical fin E-2, E-5, and E-6.

at the hinge locations,· as shown in Figures

~ STODDARD-HAMILTON

AIRCRAFT. INCORPORATED MODEL ASSEMBLY NAME


II PAGE

E-7

Have a helper hold the rudder at 25° right travel, flush against the vertical fin as shown in Figure E-6. He will also have to hold the hinge against the inside surface of the trailing edge while drilling. Drill through the trailing edge of the vertical fin and the hinge with a #30 drill bit. Drill the end holes to start with, and make sure the holes are 3/8" from the edge as shown in Figure E-6. Insert a cleco into each hole after drilling to hold the rudder in place.

NOTE: It is kind of tricky holding the rudder in the right angular position while providing adequate back-up on the hinge half when drilling. A third person would be helpful. Check the rudder movement to see if it binds when rotated. If, upon checking for fit and free movement, and finding that a rivet hole must be redrilled, fill the incorrect hole in the laminate with mill fiber mixture and redrill it. The rudder should not bind when rotated.

With the right rudder panel and hinge cleco clamped to the vertical fin and rotating freely, drill the remaining holes in the vertical fin, hinge halves, and rudder shearweb.

Countersink the holes in the vertical fin for the flushhead AN426AD4-5 rivets. Proceed to rivet the hinge halves to the vertical fin and rudder shearweb, using the AN426AD4-5 and AN470AD4-5 rivets, respectively.

STEP B-4

Rotate the right rudder panel until the shearweb contacts the left trailing edge of the vertical fin. Make a line on the shearweb along this edge. (See Flag #2, Figure E-6.) Make another line parallel and inboard to the first, the approximate thickness of the left rudder panel. Measure the thickness of the left panel to determine the placement of the other line.

Remove the right rudder panel by removing the hinge pins. Trim the shearweb to the outermost line. The inboard line will be used as a reference to sand to, when fitting the left rudder panel to the right one.

NOTE: Large heavy duty scissors or aircraft shears work well for cutting the shearweb. Be very accurate when trimming the shearweb.

Reinstall the right rudder panel to the vertical fin with the hinge pin.

~ STODDARD-HAMILTON


MODEL



II PAGE

E-8

STEP B-5

VERTICAL FI N

FULL LEFT NEUTRAL POSITION

RIGHT RUDDER PAN EL

TYPICAL CROSS-SECTION OF RUDDER IN NEUTRAL AND FULL LEFT POSITION

FIGURE (E- 7)

With a long sanding block, sand the rudder shearweb down just enough so that the left rudder panel is flush with the vertical fin in the neutral position. (See Flag #1, Figure E-7.) Left rudder travel is l8 G

• There should be no surface mis-match between the left rudder panel and vertical fin when the shearweb is properly sanded.

NOTE: The left trailing edge of the vertical fin must be beveled ana-shortened at about a 20 G angle to allow full left rudder. (See Flag #2, Figure E-7.) Use a long sanding block to accomplish this. Approximately 1/4" must be removed from the vertical fin at Flag #2 in Figure E-7.

COMPLETED 0

~ STODDARD-HAMILTON

AIRCRAFT. INCORI'ORATED

MODEL



II PAGE

E-9

-- --------

C. RUDDER RIB CONSTRUCTION AND INSTALLATION

STEP C-l

~ ~IRUDDER RIB TEM PLATEt----__~-( 1~" FOAM)I

I

1_-------

ACTUATOR _ REI N[~~MENT _

TEMPLATE

IRUDDER RIB CLOTH I ...------------1, TEMPLATE 11--------..-.1

FIGURE (E-8)

Cut out the rudder rib from 1/4" thick foam, as shown full size in Figure E-8. Also, cut out (4) pieces of cloth on the 45° bias for the actuator reinforcement and (4) pieces for the rudder rib, using the full size templates shown in Figure E-8.

NOTE: The template given for the rudder rib is only approximate. rne-rib will have to be custom fit to the left and right rudder panels.

~ STODDARD-HAMILTON


MODEL ASSEMBLY NAME

GLASAIR TD RUDDER ASSEMBLY REVISION IDATE

VOLUME

II PAGE

E-10

STEP C-2

[1~

RIGHT RUDDER PANEL

FIGURE (E-9)

Fi t the 1/4" foam rib to the right and left rudder panels in the location shown in Figure E-9. This will require several sequencesof putting the foam rib in place, installing the left panel.checking for fit, and then removing the left panel to sand the rib.

STEP C-3 ~"DIA.

DOWEL

Q CELL .---tiM IXTURE

VIEW A-A

FIGURE (E-lO)

~ STODDARD-HAMILTON


MODE~

GLASAIR TD ASSEMB~Y NAME

RUDDER ASSEMBLY REVISION DATE VO~UME

II PAGE

E-ll

Mix up a small batch of wet Q-cell mixture and apply a thin coating to both sides of the foam rib. Let cure. Mix a small thick Q-cell mixture for bonding the rudder rib in place. Apply a bead of this mixture to the right and forward edge of the rib and press into place in the right rudder panel. Use a 1/4" dowel to radius the excess Q-cell mixture as it oozes out from below as shown in Figure E-IO. Remove any excess mixture so that only a 1/8" radius fillet of Q-cell mixture remains in the corners. Let cure.

2 LAYER RIB STEP C-4 LAMINATE

1 LAYER ACTUATOR REI NFORCEMENT LAMINATE (TYP.)

TRIM EXCESS CLOTH HERE FLUSH TO RIB

VIEW A-A

FIGURE (E-ll)

~ STODDARD-HAMILTON


MODEL



II PAGE

E-12

Lay up two layers of rib cloth on each side of the rudder rib as shown in Figure E-ll. Use standard laminating procedures. Lay up 1 layer of actuator reinforcement cloth on each side of the rib, also, as shown. Let the cloth extend a little beyond the foam so it can be trimmed with a sharp knife when in the green cure state. Trim and let final cure. (See view A-A, Figure E-ll.).

NOTE: Laying up the rudder rib is very similar to the flap ribs.

DIA. (TYP.)STEP C-5 316

~6 (TYP.)

315 RAD.

,.,.->"",,~ .... ,.

.... " " ,. ,. " ,... "...... ,. .... ,. " " .... " ,. ..

--+--~..... ,,"'--_-+ -!-_-I,.

FIGURE (E-12)

~ STODDARD-HAMILTON

AIRCRAfT. INCQRIlClRATED

MODEL ASSEMBLY NAME


II PAGE

E-13

Pictured in FIGURE (E-12) is the rudder actuator fitting. The (2) flanges for the bearing attach points are at a 600 angle to the base. Drill (4) 3/16" diameter holes in the base of the fitting, as shown. Also drill the 3/16" diameter hole through the flanges of the fitting as shown in FIGURE (E-12).

STEP C-6

Clamp the rudder actuator fitting to the rudder shear web as shown in FIGURE (E-13). Using the fitting as a drill guide, drill the 3/16" diameter actuator mounting holes through the rudder shear web.

NOTE: One of the holes under the lower flange on the fitting rs-Inaccessib1e with a drill while the fitting is in place.Mark its location with a pencil, remove the fitting, and drill the hole.

~ STODDARD-HAMILTON


DATE VOLUMEMODEL ASSEMBLY NAME REVISION IPAGEII~LASAIR TD RUDDER ASSEMBLY I E-14

AN3-4A BOLT

RUDDER ACTUATOR FITTING

AN3-11A BOLT AN364-1032A NUT F3416M ROD END BRG

3

Kl000-3 NUTPLATE (TYPJ

VIEW A-A

FIGURE (E-13)

~ STODDARD-HAMILTON


MODEL ASSEMBLY NAME


II PAGE

E-IS

STEP C-7

Install the rudder actuator fitting to the rudder shearweb with the AN3-4A bolts, and KIOOO-3 nutplates as shown in Figure E-13. The nutplates are "glassed" in place with mill fiber mixture and the reinforcement cloth pieces rather than rivets. With the actuator fitting bolted to the rudder, the nutplates are held in the proper position for bonding.

NOTE: Make sure to wax the threads of the nutplates and bolts to prevent the resin from sticking to them.

STEP C-8

Mix up a small batch of mill fiber mixture and spread on the nutplates, filling any sharp corners. Use the remaining actuator reinforcement cloth pieces to lay up over the nutplates. Punch two holes in the cloth pieces for the nutplates to protrude through. Let cure and then remove the fitting.

NOTE: Fill the holes flush with modeling clay after removing the fitting to prevent them from being filled with resin when laying up the following laminates.

COMPLETED 0

~ STODDARD-HAMILTON


MODEL ASSEMBLY NAME


II PAGE

E-16

D. RUDDER CLOSEOUT

STEP D-l

RI GHT RUDDER PANEL

SECTION A-A

FIGURE (E-14)

Using a foam router tool, route the foam rib on the rUdder as shown in Section A-A of Figure E-14. A knife and sandpaper also work well for this.

NOTE: Make sure to remove all the foam from the inside surfaces of ~laminates on the rib as indicated by Flag #1 in Figure E-14.

The left and right rudder panels curve inward to the center of the rudder at the top and bottom mating edges. Sand these edges with a sanding block until tte flange lip disappears and the two panels fit flush together. (See Flag '112, Figure E-14.) Al.so , sand the rudder shearweb in the area where there is no gelcoat present. This is in preparation for the following E-15.)

laminates. (See Flag #1, Figure

~ STODDARD-HAMILTON


MOOEL ASSEMBLY NAME


II PAGE

E-17

STEP D-2

B

--~ -. ... .-. ----.-.- ... ~-- --. --- --.- .. --.-.- -- ----•• t..Ci B C~~ o ~

~ RUDDER ASSEMBLY

RUDDER TRIM TAB

2 LAYER~-----lLAMINATE

SECTION A-A SECTION B-B

FILL WITH MILL FIBER MIXTURE

2 LAYER LAMINATE

SECTION C-C SECTION D-D

FIGURE (E-15)

~ STODDARD-HAMILTON


MODEL ASSEMBL Y NAME


II PAGE

E-18

To closeout the rudder, the procedure is a little like bUilding a ship in a bottle being that the top, bottom, and aft seams are bonded together on the inside of the rudder.

Cut cloth strips on the 45° bias to the following quantities and dimensions:

QUANTITY: (2) 1-1/2" x 9-1/4" (for top seam)

(2) 1-1/2" x 19" (for bottom seam)

(2) 1-1/2" x 46-1/2" (for shearweb seam)

STEP D-3

Tape the bottom seam of the two rudder panels together with masking tape. Use plenty of tape so that no resin can seep through the seam. This seam is referenced by Section A-A in Figure E-15. The masking tape not only acts to hold the seam together, but also acts as a hinge when the panels are propped apart.

With the right rudder panel on a flat workbench, prop the left panel up with a stick so that the bottom seam is easily accessible. Lay up the two 1-1/2" x 19" pieces of cloth on this seam. Also, at this time, mix up a small mill fiber mixture and fill the trough in the rudder rib with it. The trough should be overfilled somewhat, so a good bond occurs between the rib and the left rudder panel. With the rib filled with mill fiber mixture and the bottom seam freshly layed up, remove the stick prop and close the rudder halves together.

NOTE: Be careful when closing the two halves together,that the z-Layer laminate on the bottom seam doesn 1t shift.

Now, tape the top and aft seams together with masking tape.

NOTE: These seams will be bonded together later.

Turn the rudder over on it's left side and proceed to lay up the two 1-1/2" x 46-1/2" pieces of cloth onto the shearweb and curved portion of the left panel. (See Section B-B in Figure E-15.) Weight the rudder on a flat workbench to make sure the halves are held flush together while the laminates are curing. Make sure the left panel is bonding tightly to the rib. Let cure.

~ STODDARD-HAMILTON


MODEL ASSEMBLY NAME


II PAGE

E-19

STEP D-4

From .025" thick 2024-T3 aluminum sheet, cut a piece 5-5/8" by 2" as shown in Figure E-15A. This .025" thick piece is defined as the rudder trim tab. File any saw cut roughness smooth and deburr. Round the corners as shown. Pre-bend the tab to a 15° angle. Sand the area to be bonded with rough grit sandpaper and drill a series of holes as shown.

NOTE: The angle given in Figure E-15A is only approximate and may differ from plane to plane. Only after flight testing can this angle be finalized. We recommend adjusting the trim tab so that no rudder pedal pressure ~s required during optimum cruise speeds (about 180 to 190 MPH lAS). If left rudder pedal pressure is needed, then the tab needs to be Bent to tli.e right and vise versa for the opposite condition.

When bending the trim tab once the tab is bonded to the rudder make sure to support the trailing edges of the rudder while bending or the tab will break loose.

BEND UP 15°

rlTH1S AREA TO BE rBEND LINE

I _t

\13/4 0,-

\ -

2

r

\ ,BONDED TO RUDDER

I0 0 o - ------- - -------+

~----------55/8--------~ FIGURE (E-15A)

~ STODDARD-HAMILTON


MODEL ASSEMBLY NAME


II PAGE

E-20

STEP D-S

Remove the masking tape from the trailing edge of the rudder and prop it open with small wooden braces. The braces should be about 1-1/2" to 2" long. This is the only way to gain access to the top seam for laminating. The trailing edge readily spreads apart for access into the inside of the rudder.

Lay up the two 1-1/2" x 9-1/4" pieces of cloth on the top seam of the rudder as shown in Section C-C of Figure E-lS. The brush extension works well for this area. Check for bubble~ with a flashlight.

Once the top laminate i.s complete, mix up an adequate amoun t of mill fiber mixture for bonding the trailing edge together. Apply a generous bead of this mixture to the inside of the trailing edge on one of the panels. Insert the rudder trim tab between the trailing edges of the rudder at the location shown in Figure E-15. Apply a generous amount of mill fiber mixture around the trim tab so that the trim tab is securely bonded to the inside surfaces of the trailing edges of the rudder. Remove the braces. Squeeze the panels together, wiping up the excess mill fiber mixture as it oozes out. Lay the rudder on a flat workbench and weight the trailing edge so that it cures straight. Let cure. Do not upset the trim tab location when removing tne oraces.

MOTE: Position the trim tab so that the tab is angled to the right when bonding it in place. The reason for this is that the side hinged rudder tends to float to the right during flight.

~ STODDARD-HAMILTON

AIRCRAFT. INCORPORATED MODEL



II PAGE

E-2l

STEP D-6

TRIM HERE

DRILL ~161 DRAIN HOLE

FIGURE (E-16)

To allow installation of the rudder actuator fitting and clearance for the actuator linkage, the curved portion in the locality of the fitting on the rudder needs to be trimmed. Cut out this portion as shown full size in Figure E-16.

Reopen the holes for the actuator fitting that were covered when laminating the rudder shearweb. Be careful not to damage the nutplates when drilling.

~ STOODARD-HAMILTON


MODEL ASSEMBLY NAME


II PAGE

E-22

Install the actuator fitting to the rudder and then install the rudder to the fuselage with the hinge pins. Check the operation of the rudder. Make any final adjustments.

NOTE: The curved portion on the left leading edge of the rudder may need to be sanded to allow the full 18 0 of left rudder travel. This is done to clear the vertical fin shearweb.

WARNING: Especially check the left rudder travel when the elevator is in the full up position. Relieve the curved leading edge of the left rudder panel, if necessary, to eliminate interference between the rudder and the elevator linkage arm when the elevator is deflected fully upwards and the rudder is full left.

STEP D-6

Remove the rudder from the fuselage. Sand all seams flush (fill with body putty if needed) and gelcoat. Also, sand the trailing edge of the rudder straight and smooth with a long sanding block. The rudder is now complete and ready to be hooked to the control linkages. Paint the trim tab white after the correct angle is found through flight testing.

NOTE: Drill a 3/16" drain hole just aft of the rudder shearweb as-5hown in Figure (E-16). This hole will also vent the interior of the rudder, preventing damage to the structure caused by pressure changes during climbs or descents.

COMPLETED 0

~ STODDARD-HAMILTON


MODEL ASSEMBLY NAME


II PAGE

E-23

Date post:	28-Apr-2015
Category:	Documents
Upload:	donzqw8194
View:	85 times
Download:	5 times

glasair 2-1

Documents