Winglet/Rudder Construction |
Date: January 2003 |
Chapter: 3.0 Winglets/Rudders |
Section: Wings |
Section 3.1 Winglet
Pre-2002 - Chapter
3.1.1
- "Core Preparation"
FB
This section was completed by the factory as part of the "Fast Build Wings" option.
Pre-2002 - Chapter
3.1.2
- "Glassing Inboard Surface"
FB
This section was completed by the factory as part of the "Fast Build Wings" option.
Pre-2002 - Chapter
3.1.3
- "Communications Antenna"
FB
This section was completed by the factory as part of the "Fast Build Wings" option.
Pre-2002 - Chapter
3.1.4
- "Glassing Outboard Surface"
FB
This section was completed by the factory as part of the "Fast Build Wings" option.
Pre-2002 - Chapter
3.1.5
- "Winglet Trimming and Preparation"
FB
This section was completed by the factory as part of the "Fast Build Wings" option.
Section 3.2
Winglet Attachment
FB
Pre-2002 - Chapter 3.2.1 - "Setup and Alignment"
This section was completed by the factory as part of the "Fast Build Wings" option.
Pre-2002 - Chapter
3.2.2
- "Winglet Attachment Lay-ups"
FB
This section was completed by the factory as part of the "Fast Build Wings" option.
Section 3.3 Rudders
Pre-2002 - Chapter
3.3.1 - "Rudder Cut-Outs"
FB
This section was completed by the factory as part of the "Fast Build Wings" option.
Pre-2002 - Chapter
3.3.2
- "Rudder and Rudder Wells"
FB
This section was completed by the factory as part of the "Fast Build Wings" option.
January, 2002 - Chapter
3.3.3
- "Rudder Hinge Installation"
First the hinge locations needed to be established. The lower hinge is 6" above the rudder opening, and the upper is 6" below the top of the rudder well, with the remaining 4" hinge spaced evenly between them. With the locations established, 3/16" notches were Dremeled for each hinge and chamfered, and the winglet sides were drilled for 3/16" clecos the same as on the wings. Again the hinge alignment was checked with my 6' straight edge, and then the hinges were 5 minute epoxied to the rudder.
Rudder Hinging
Next the travel is checked, and interferences are sanded away (it turns out that the inside of the rudder tends to rub on the outboard section of the winglet). Once it swings properly the rudder side of the hinges are microglassed and riveted with counter sunk rivets that will be later covered.
Ruder Hinge Installation
January, 2002 - Chapter
3.3.4
- "Bellcrank Installation"
Next the bellcranks needed to be installed. These levers attach to the rudder cable and actuate the rudders. The standard installation is to mount these outboard of the winglet where they can be seen. This isn't very pretty so we opted for the option internal bell cranks. First a notch is made in the rudder to accept the lever, and the lever was ground to fit inside the rudder. Next the rudder was reattached and checked for fit, to see if the bellcrank interfered with the travel and that the end of the bellcrank was aligned with the rudder conduit internal to the wing. Once this was satisfactory the bell crank was roughened and potted in microglass.
Here's the bushing that mounts to the rudder horn. When either rudder pedal is pressed, the pedal pulls this inward and deflects the rudder outboard. The return springs bring the rudder to neutral when released. You need to configure the system to get 4" of travel outboard before the brakes engage.
Rudder Cable Installation
January, 2002 - Chapter
3.3.5
- "Rudder Return Spring"
Finally the rudder return springs were installed. These "center" the rudders once you release rudder pressure. The springs are mounted in 1" cylinders about 18" above the bottom of the rudder well. A 1" hole is drilled in the winglet side, favoring the wing side, and is mounted in microballons.
Rudder Return Spring
Next the anchor for the return spring is mounted in the rudder opposite the spring. It's a l bracket that's potted in microballoons.
Rudder Return Spring Anchor
~ End of Chapter ~ End of Section ~