Fuselage construction: updated October 16, 2000
Fin and Ribs Assembly
|Epoxy in the fin spar and Fin ribs. Locations of the ribs are not critical.|
|Epoxying on the Gussets. Use a little cabosil in the epoxy to fill gaps and prevent runs. Use spring clamps to get an even pressure on the bond.|
Mount the hinges on the fin spar.
|Drill for Lower hinge and install with bolts and full size nylocks.|
|Start with the Control stick installation. Align carefully.|
|The control stick installed|
Install Belcrank triangles M170 with Aileron/Elevator belcranks M 130G. The 1/4" hole for the belcrank shaft is shown by a mark in the fuselage. Drill this mark with a 1/4 "drill. Do not drill oversize. Place the triangle with the Bolt screwed in that hole mounted from the outside of the fuselage so you can drill the other 3/16th holes in the fuselage. The 1/4: bolt needs to have its threads extended with a 1/4" -28 die. cut the threads to within 3/4" of the bottom of the head.
Belcrank shafts: measure their lengths fro the fuselage just to be sure then are correct to the fuselage.
For the Aileron Belcrank at the central sick I used a plastic tube with a 1/4" ID for a spacer between the belcrank and the fuselage.
Remember there is a nut on one side of the inside of the fuselage on all belcrank shafts to hold the shaft secure so it will not rotate in the fiberglass.
Install the Rear Spar fuselage attachment #M185 with 3 AN4-6a bolts with nuts and washers
Install rear Aileron drive bracket M132G.
Install Aileron Drive Belcrank on Aileron Drive shaft. Fit so that a nut can be fitted on the inside of the fuselage at the first front aileron drive Pivot M142.
Install all pushrods temporarily to check sizes etc.
Take your time and fit carefully, your life depends on these pushrods working well.
Drill all holes for Belcrank shafts
Mount root fittings on front of fuselage
Aileron pushrod shaft installation.
The rubber boot I used to hide the control stick was a Boot and plate cover for a gearshift from Autozone. Part #9648, from Mr Gasket Co.
The release mechanism mounted on the fuselage.
|Note that the Nut on the bolt attached to the release arm is tight against the release arm so that the locked bolt rotates in the fuselage/release mechanism. The original way this is designed is to have the release arm rotating on the bolt which has the nut down tight against the fuselage/release mechanism. The latter requires a lot of precision to get this correct.
Note also the Release handle is not notched but just bolted on the side.
The bolt that holds the tow release trigger does not get tightened down hard, other wise the trigger will not release.
|The spring is attached to the trigger and then anchored to the fuselage with a pop rivet.|
|Make sure the wheel well has all of the belcranks well out of the way of the wheel cover. On one installation I had the Belcrank rubbing against the wheel cover, it wore through and caused a block in the aileron movement which was very disconcerting in my preflight.
Drill the axle holes carefully, measure twice!
|The Wheel installed!|
|The bucket seat is not bonded in with my installation so as I can take the seat off to do control adjustments. I waxed the seat then bonded a flange on to the side of the fuselage, then drilled the seat and flange for bolts.|
|The skid is made up of two 1/4" pieces of oak glued together correct shape is obtained with wood blocks set at the correct height in in this photo..|
Mating the wings to the fuselage
|It is a good idea to check the mating of the wings to the fuselage|
Seat Belt Installation:
|On this particular glider I chose to attach the shoulder straps to the side of the fuselage. Note the cutouts in the seat for the lap belts.|
|The seat belt is attached to the fuselage below the seat with an aluminum bar (3 " x 1/4" x 3/4"), rounded on the corners and attached with an-4 bolts to the fuselage.|
Rudder Cable Installation
|Rudder cable installation, checking the pulleys and cutting the cable to length.|
|Cable guides hold the hard nylon tube covering the rudder cables, installed on fuselage with pop rivets.|
|The rudder cable guides hold the nylon guides in place. On this particular location I adjusted the guide down so as to miss touching the elevator in its full down position.|
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