EGR-Contents. Standard Retractable Gear Contents. June 2005 EGR-Contents Page 1

Transcription

1 Standard Retractable Gear Contents June 2005 EGR-Contents Page 1

2 EGR-Contents Chapter 1 - Introduction Overview Description Getting Started Video Tapes Contents of Manual Getting Help While Building Modifications Materials Epoxies Glass Cloth Fillers Glues Foam Plywood Hardware O.E.M. Equipment Machined Parts Construction Techniques Mixing Epoxy Cutting Cloth Sanding Glassing Foam Using Hot Glue, Bondo or 5-Minute Epoxy Glassing Cloth Filling Attaching / Joining Hardware Work Habits Patching Foam Use of a Level Micro-Glass / Micro-Slurry Peel Ply Tapping Fluid Lines and Fittings Countersinking Quality Assurance Quality Control Mindset of a builder Tools Water Level Benches Necessary Tools Nice To Have Tools Page 2 EGR-Contents June 2005

3 Chapter 2 - Wings / Winglets Chapter Preface Parts Tools List Supplies List Glass List Process Overview Wing Core Joining Leading Edge Wing Cores to Spar Joining Trailing Edge Wing cores to Spar Navigation (VHF) Antenna Wing Skins Lower Skin Wing Leading Edge Rib Wing Root Ribs Glassing Rudder Conduit Installation Top Wing Skin Wing Attach Bolt Access Holes Winglets Preparing Winglets for Glassing Glassing Inboard surface Glassing Outboard Surface Winglet Marking Wingtip Trimming Winglet to wing attachment Overview of Winglet to Wing Attachment Winglet and Wing Preparation Set-Up and Alignment Winglet Attachment Lay-Ups Filling and Sanding Wings and Winglets Ailerons Aileron Cutouts Aileron Wells Glassing Aileron Well and Ribs Aileron Construction Torque Tube and Hinge Backing Plates Hinge Installation Rudders Rudder Cut-Outs Rudder and Rudder Wells Rudder Hinge Installation Rudder Horn Installation Rudder Return Spring Winglet Bottom Prepare Winglet Bottom Attaching Winglet Bottom to Wing June 2005 EGR-Contents Page 3

4 EGR-Contents Chapter 3 - Canard / Elevator Chapter Preface Parts List Tools List Supplies List Glass List Process Overview Critical Dimensions Reference list Canard Core Preparation Installation of Lift Tabs Foam Cores Preparation for Skinning Glassing the Canard Canard Lay-up Schedule Canard Lay-up # Canard Lay-up # Canard Lay-ups #3 and # Elevator Construction Assemble Cores Lay-up Procedure - Side One Lay-up Side Two Elevator to Canard Fit Elevator Hinge Installation Hinge Arm Installation Canard Final Preparation for Elevators Positioning the Elevator Positioning torque / counterweight arms Elevator Balancing Chapter 4 - Bulkheads Chapter Preface Parts List Tools List Supplies List Glass List Process Overview Bulkhead Preparation Locate Bulkhead Placement Install Bulkheads Preliminary Fitting of Parts Bonding Procedures Glassing Bulkheads Engine Bulkhead Engine and Gear Bulkheads Cowl Canard Bulkhead Battery Shelf Landing Light Page 4 EGR-Contents June 2005

5 Chapter 5 - Doors and Windows Chapter Preface Parts List Tools List Supplies List Glass List Process Overview Windows Window Cutouts Fit Windows Install Windows Fuselage Top Installation Door Cutout Fuselage Door Hole Treatment Door Hinge Installation Install Door with Hinges to Fuselage Latches Install Door Latch Mechanism Latch Base Assemblies Pilot Door Security Lock Installing Door lock Install Windows in Doors Install the Latch Pin Tubes in Fuselage Carbon Beams Install Carbon Beams Install Door Seal Finishing the Doors Install Door Gas Springs Chapter 6 - Fuselage Chapter Preface Parts List Tools List Supplies List Glass List Process Overview Keel General Forward Keel Access Hole Aft Keel Access Holes Fitting the Keel Keel Hard points Seats and Hardpoints Fuselage Hardpoints Seat Belt Hardpoints Front Seats Rear Seats June 2005 EGR-Contents Page 5

6 EGR-Contents Keel Controls Keel Control Assembly Locations Forward Aileron Torque Tube Bearing Rear Aileron Control Bracket Mid-bearing Support Control Stick Assembly Keel Installation Keel Stiffening Lay-ups Forward Fuselage Treatments Nose Access Cover Pedal System / Brake Cylinders Mount Master Cylinders Assemble Rudder Pedals Mount Pedals Install Nylaflow Tubing for Rudder Cables Instrument Panel Locate Panel Install Panel Installing Main Spar Spar Positioning Spar Installation Lay-ups TRIAX Reinforcement Canard Reinforcements Canard Attachment Reinforcement Canard Top Attachment Points Chapter 7 - Landing Gear Chapter Preface Parts List Tools List Supplies List Glass List Process Overview Nose Gear Door Installation Nose Gear Door Cutout Nose Gear Installation Nose Gear Bushings Overcenter Linkage Sequence Valve Gas Spring Nose Gear Guides Nose Gear Templates Main Gear Preparation Gear Leg Preparation Gear Leg Torsional Reinforcement Page 6 EGR-Contents June 2005

7 7.4 - Fuselage Preparation Gear leg cut out Drilling Holes for Main Gear Bushings Transverse Bulkhead Install Installation of Main Gear Bushings Main Gear Cables and Cylinder Pulley Assembly Main Gear Overcenter Linkage and Sockets Hydraulic Cylinder Cables Installing the Main Gear Gear Legs Brake Lines Main Gear Doors Hydraulic System Hydraulic Power Pack and Nose Gear Door Cylinder Plumbing Pressure switch adjustment Electrical Final System Adjustments Emergency Extension Basics Nose Gear Safety Stick Chapter 8 - Wheels / Axles Chapter Preface Parts List Tools List Supplies List Glass List Process Overview Wheels and Axles Install Main Gear Axles Nose Wheel Installation Chapter 9 - Fuel System Chapter Preface Parts List Tools List Supplies List Glass List Process Overview Transfer Template Transfer Template June 2005 EGR-Contents Page 7

8 EGR-Contents Lower Fuel Strake Wheel Well Measurements Preparation Lower Strake Alignment Cut out Lower Baggage Access Openings Lower Strake Half Glassing Internal Strake Structures Fitting Wheel Well Baffles and Bulkheads Install Strake Baffles Bulkhead Fuel Fittings Fuel system venting Upper Strake Half Fuel Cap Installation Fitting the Upper Strake Half Upper Strake Half Installation Outboard End Strake Reinforcement Sump Tank and Fuel Lines Fuel lines Install the Sump Tank Cover Install Mounting Tabs Sump Tank Installation Wing Strake Cutout Wing Strake Cutout Wing Strake to Beam Support Installing Leading Edge of Strake onto Door Fuel System Plumbing Solid fuel line Installation Chapter 10 - Control System Chapter Preface Parts List Tools List Supplies List Glass List Process Overview Elevators Introduction Installing Control Stick Push-Tube Assembly Elevator Trim Aerodynamic Trim (Sparrow Strainer) Rudders Rudder Cable Installation Ailerons Rigging of the Roll System (Ailerons) Page 8 EGR-Contents June 2005

9 Chapter 11 - Fairings Chapter Preface Parts List Tools List Supplies List Glass List Process Overview Cowl Treatments Relocating Upper to Lower Cowl Joint Wing Root Fairings Premolded NACA Scoop Installation Oil Access Door Canard Tips Installation Counterweight Fairings Chapter 12 - Engine / Propeller Chapter Preface Parts List Tools List Supplies List Glass List Process Overview Engine Installation Introduction Engine Mounts Fluid Lines Aluminum Oil Lines Fuel Plumbing Controls, Cooling and Prop Throttle, Mixture, and Prop Controls Pressure Checking Fuel System Fuel Sight Gauges Cooling Plenum Chamber Propeller Nose Mounted Cooler Chapter 13 - Electrical / Instrumentation Chapter Preface Parts List Tools List Supplies List Glass List Process Overview June 2005 EGR-Contents Page 9

10 EGR-Contents Antennas Introduction Glideslope Antenna Marker Beacon Transponder GPS ELT Instrument Panel Instrument Panel Engine Instruments Electrical System Completion Introduction Basic Electrical System Trim, Speed Brake, & Speed Brake Warning Switches and Circuit Protection Avionics P-Leads Pitot - Static and Vacuum Instruments Vacuum System Static Port Pitot Tube Chapter 14 - Final Assembly and Finishing Chapter Preface Parts List Tools List Supplies List Glass List Process Overview Final Assembly Procedures Canard / Elevators Aircraft Tie Downs Wings to Aircraft Ailerons Control System Rudder Pedals, Cables, Vortilon Installation Brake Bleeding Landing Gear, Wheels, Brakes, Fairings Fuel System Powerplant / Propeller Pitot / Static System Electrical System Alternator Vacuum Pump System Chapter 15 - Interior Chapter Preface Parts List Tools List Supplies List Glass List Process Overview Page 10 EGR-Contents June 2005

11 Materials Headliner Carpet Upholstery Seat Foam Glue for Installation Trim and Weather-stripping Installation Fuselage Headliner Window Frames Carpeting Side Panels Interior Door Cover Glare shield Rear Cover Panel Chapter 16 - Flight Testing Chapter Preface Parts List Tools List Supplies List Glass List Process Overview Final Preparation Placarding and Markings Inspections Pilot Qualifications True Story Testing Taxi Testing High Speed Taxiing High Speed Taxi Nose Wheel Liftoffs Runway Hops First Flight Envelope Expansion High Speed Flight Envelope Expansion Flying the Velocity Crosswind Landings June 2005 EGR-Contents Page 11