Chapter 5: Building the Elevators, June and July 1997
The elevator construction was reasonably straightforward. The manufacturing techniques started to develop now. Also I started to evolve into a true kit plane builder, as deviations from the manual are now a matter of course. The important lessons are:
Mounting nut plates onto separate pieces of glass, which are subsequently bonded to the spar (or whatever) is MUCH easier than riveting them directly onto the spar (or whatever).
Mounting the trim tab hinge after closing out the elevator results in a compromise in folly. We (Cal Brabandt, an RV builder with 10 zillion rivets behind him, and I) landed up using blind (Pop) rivets as it is impossible to fit a squeezer, or bucking bar, into the gap of the trim tab.
The simple solution to this problem is to mount the hinge prior to closing out the elevator. Another idea is to mount the mini-spars at the same time. To try and fit them into the small gap is a real pain and again results in compromises. The credit for the early mounting of the mini-spars goes to
Another exercise in masochism is the recommended method of making the trim tab gap seal, i.e. to shape a piece of foam to a small, but changing radius, and then cover with 1 BID. Carsten, of Lancair, subsequently mentioned that he had made a mold out of a dowel and formed a 1 BID seal over it. Sounded like a much better solution. Also
Terry Pickering’s web site-- describes yet another solution.A slightly bigger access panel for the servo would make life easier when mounting the servo. A group of ES builders suggested this in their web site:
http://www.edlevine.com/lancair/index.htm.Closeout was uneventful. It took more Hysol than I had imagined it would, almost a quart per elevator. The picture shows me proudly holding up the workbench. Also shows the straight edge clamped against the trailing edge of the elevator. The trailing edge is actually sandwiched between the straight edge and the angle iron in the jig. This ensured a dead straight trailing edge.
The balancing of the elevators resulted in 3 lbs. 0 oz. in the left elevator and 2 lbs. 10 oz. in the right. The left elevator weight is heavier owing to the trim tab and servo.
The final touch was to build a small cover for the trim crank.
Now onto the big plastic parts of this 1:1 scale "Revell" kit.
(Since I have avoided all construction, there is little I can add to the process. Except that Burns's word are constantly ringing in my inner ears, that things continue to "gang agley.")
Chapter 6: The Rudder