--FUSELAGE ASSEMBLY TABLE OF CONTENTS PAGEA. WING ATTACH AND STABILIZER FUSELAGE REINFORCEMENTS D-3 B. BELLY PANEL CONSTRUCTION D-4 C. FUSELAGE SHELL CONSTRUCTION . D-8 D. LANDING GEAR SUPPORT RIB CONSTRUCTION AND INSTALLATION . . D-17 E. FIREWALL CONSTRUCTION AND INSTALLATION D-24 F. FIREWALL RIB CONSTRUCTION AND INSTALLATION D-27 G. FUSELAGE REFERENCE LINE DETERMINATION D-31 H. LANDING GEAR CONSTRUCTION AND INSTALLATION D-34 J. ENGINE MOUNT SUPPORT STRUCTURE FABRICATION AND INSTALLATION . D-49 K. WHEEL AND BRAKE INSTALLATION D-58 L. ENGINE MOUNT INSTALLATION . D-63 M. FIREPROOFING THE FIREWALL D-65 N. WHEEL PANT INSTALLATION D-69 P. CANOPY AND WINDSHIELD INSTALLATION D-82 Q. CANOPY FRAME FABRICATION D-98 R. CANOPY LATCH FABRICATION AND INSTALLATION D-124 S. HORIZONTAL STABILIZER INSTALLATION D-147 T. RUDDER PEDAL FABRICATION AND INSTALLATION D-167 U. ENGINE C O ~ ~ I N G INSTALLATION '. D-177 V. LANDING GEAR STRUT FAIRING FABRICATION D-203 ~ STODDARD-HAMILTON AIRCRAfT. INCORPORATED MODEL ASSEMBL Y NAME GLASAIR TD FUSELAGE ASSEMBLY REVISION DATE VOLUME I PAGE D-l FUSELAGE ASSEMBLY INTRODUCTION The fuselage consists basically of two fuselage halves, a belly panel, firewall, and various ribs and bulkheads. The two fuselage halves are bonded together first, then the belly section is bonded in place. Seaming the fuselage shell together itself is a relatively simple task and takes only a small portion of the time required to construct the whole fuselage assembly. The majority of the time required for construction is spent on what is installed and attached to the fuselage such as controls, landing gear, engine, cowling, wing, instruments, canopies, horizontal stabilizer, etc. ELEVATOR HORIZONTAL STABILIZER LEFT FUSELAGE HALF BELLY LANDING GEAR STRUTSECTION FIGURE (D-1) STODDARD-HAMILTON MODEL GLASAIR TD ASSEMBLY NAME FUSELAGE ASSEMBLY REVISION DATE VOLUME I PAGE D-2 NOTE: Every step builds onto the preceding one. It is important in the beginning to get the fuselage shell jigged properly so that the cowling, wing, and stabilizer will each match the contoux of the fuselage. Pay careful attention to this. All ribs and bulkheads are made from the supplied foam and fiberglass stock. Full size templates are supplied where needed. A simple fuselage jig is required to hold the fuselage shell to the proper alignment while seaming it together. Figure D-I shows the major components of the fuselage. CONSTRUCTION PROCEDURE Before beginning construction of each alphabetical division in this section study every step thoroughly to avoid any surprises. A. WING ATTACH AND STABILIZER FUSELAGE REINFORCEMENTS STEP A-I 6 LAYERS(4- DIA'> CANOPY AREA FIGURE (D-2) ~ STODDARD-HAMILTON AIRCRAFT, INCORPORATED MODEL GLASAIR TD ASSEMBLY NAME FUSELAGE ASSEMBLY REVISION DATE VOLUME I PAGE D-3 The fuselage halves require reinforcements at the wing attach and stabilizer points. These areas are outlined in red on the fuselage halves. Cut the cloth on the 4S-bias for both halves as shown in figure D-2. NOTE: The rear wing attach points require 2 large layers (outlined in red) and then (6) 4" diameter layers of fiberglass cloth centered over the 40 LB foam insert. The 40 LB foam insert will be a darker color than the regular foam core. STEP A-2 Lay up the cloth on the inside of each of the fuselage halves as shown in Figure D-2, using standard laminating procedures. A squeegee works well for saturating the cloth. NOTE: Check the fuselage halves to see if they require prep sanding. Completed 0 B. BELLY PANEL CONSTRUCTION STEP B-1 In order to install the wing to the fuselage, the belly section requires a removable panel. There are two troughs in the belly section where there is no foam core. (See Flag 111, figure D-3) Sand any surface irregularities in these troughs smooth and flush to insure a flat hinge line. ~ STODDARD-HAMILTON AIRCRAFT. INCORPORATED MODEL GLASAIR TD ASSEMBLY NAME FUSELAGE ASSEMBLY REVISION DATE VOLUME I PAGE D-4 ~ H E R E < : D ---. -BELLY PANEL CM PLAN VIEW (BELLY SECTION) HINGE lGAP' SECTION A-A FORWARD HINGE AFT HINGE FORWARD HINGE AFT HINGE HALF HALF HALF I +I I+ +II I I I I I I __ J + L__ J + L__ PANEL CUT PANEL CUT LINE LINE HALF DETAIL B DETAIL C FIGURE (D-3) ~ STODDARD-HAMILTON AIRCRAfT. INCORPORATED MODEL ASSEMBLY NAME REVISION DATE VOLUME PAGE GLASAIR TD FUSELAGE ASSEMBLY I D-S STEP B-2 The belly panel is fastened to the belly section via 2 extruded hinge sections. See Section A-A and detail views B & C in Figure D-3. The supplied MS2000l-P4 hinge stock comes in 6 foot lengths. There is more hinge pin than hinge half supplied. Cut two sections of hinge, one 38" and one 37-1/2" long. NOTE: Do not cut the hinge pin while cutting the hinge halves. Being that the hinge stock comes in 6 foot lenghts, only one length can be obtained from a 6 foot length. The shorter pieces of hinge stock will be used for the cowling and control surfaces. Cut the (2) hinge pins 39.5" long, allowing 1-1/2" excess. Deburr any sharp edges or corners. NOTE: These pins can be cut in half to make pin insertion easier. T'Fi'e38" hinge is used for the forward edge of the belly panel, and the 37-1/2" length is for the aft edge. STEP B-3 -- .50 ~ ~ 1 . 0 0 - -c: ~ + + + -I I I -r-u I -. I, ~ + + + +> La -~ . 2 5 FIGURE (D-4) Layout the hole pattern on each hinge section as shown in Figure D-4. Center punch each hole location prior to drilling. NOTE: Do not hit the aluminum hinge too hard when centerpunching, causing the thin flange to dish or bend. Centerpunch lightly. using a small hammer. The hinge pin can be inserted into any hinge halves with smooth gradual contours, but any sharp turns or irregularities will not allow pin insertion. It is, therefore, important not to bend the hinge stock or to have any surface irregularities on the surface where the hinge is. attached. Sand any surface irregularities smooth where the hinge halves attach. ~ STODDARD-HAMILTON AIRCRAFT. INCORPORATED MODEL GLASAIR TD ASSEMBL'( NAME FUSELAGE ASSEMBLY REVISION DATE VOLUME I PAGE D-6 STEP B-4 Center the fully assembled hinges in each trough of the belly section and C-Clamp in place. Using a #30 drill bit and drill motor, drill a few holes on one end only of each hinge through the hinge and belly section. Insert cleco clamps into these holes. At least 20 clecos will be required for holding each hinge in place while drilling. NOTE: Drill 5 holes and then insert a cleco clamp. The drilling sequence is as follows. Drill one end, then the center, the other end, and then the remaining holes in between. The reason for this is to keep the center section of the hinge from p,ulling away or lifting off of the belly panel. With the center 'pinned" down second this problem is alleviated. Do not remove any of the cleco clamps until all the holes are drilled. Also, before completely removing the hinges and clecos, the panel cut lines need to be marked. (See Figure D-3, Details B and C.) To mark the rear panel cut line remove the forward hinge half and leave the-a!t hinge half cleco clamped in place. The panel cut line is aft of the hinge pivot line in this case. NOTE: To remove the hinge pin, a notch will have to be cut in the belly section. (See Flag #2, Detail C.) With the forward hinge half removed, make scribe marks along the hinge inbetween the hinge pivot point tangs. (See Flag #3.) To mark the forward panel cut line, the procedure is the same except that the panel cut line is forward of the hinge pivot line in this case. A notch will also have to be made to remove the hinge pin. With the panel cut lines now referenced, remove the remaining hinge halves and deburr if required. There will now be two dotted lines where the belly panel is to be separated. Complete these lines, using a long flexible straightedge. With a saber saw and sharp fine tooth blade, cut out the belly panel along these lines. Remove any rough edges or corners.' NOTE: Be careful not to deviate from the panel cut lines while cutting. STEP B-5 Countersink the holes on the outside gelcoat surface using the machine stop countersinking tool and then rivet the hinges in place with the supplied AN426AD4-5 rivets. Refer to the riveting procedures in the fabrication section. Completed 0 ~ STODDARD-HAMILTON AIRCRAFT. INCORPORATEO MODEL GLASAIR TD ASSEMBLY NAME FUSELAGE ASSEMBLY REVISION DATE VOLUME I PAGE D-7 C. FUSELAGE SHELL CONSTRUCTION STEP C-l SANDING BLOCK ~ EEfP.!iijt , 1 CORRECT INCORRECT FIGURE (D-S) Using a long sanding block and 60 grit sandpaper sand all edges of the 3 fuselage sections until the flange lip just disappears. (See Flag #1, Figure D-S.) NOTE: The fuselage sections will require very little sanding (noiiiO're than 1/16") to remove the flange lips from the edges of the parts. Be ~ a r e f u l not to sand too much or to sand unevenly, causing gaps or cracks along the joints where the parts are butted together. STEP C-2 DETAILeD FIGURE (D-8) From the 50" wide cloth cut strips on the 45 bias to the following dimensions: QUANTITY (1) 3 ~ x 22" (for B to C) (6) 3-! x 70" (for B to C) (4) 3-! x 18" (for A to B) (4) 2 x 55" (for C to D) NOTE: Organize the cloth strips into separate piles and then separately roll the 70" strips up into small cylinders. This will keep the edges from fraying and also prevent undue stretching of the cloth strips when laminating. STEP C-7 Tape the fuselage halves together at point E where they join (approximately 4") as shown in Figure D-8. Remove any PVA if present first. NOTE: Do not laminate at point B as shown in Figure D-8. Leave a 174" unlaminated area to ~ l l o w proper skin thickness for windshield ins tallation. (See Detail r., Figure D-8.) ~ STODDARD-HAMILTON AIRCRAfT. INCORPORATED MODEL GLASAIR TD ASSEMBLY NAME FUSELAGE ASSEMBLY REVISION DATE VOLUME I PAGE D-ll The seam from points A to D requires a 4 layer laminate which is done in various segments. Laminate segment BC first, segment AB second, and segment CD last. Point E will be laminated with the belly section later. Laminate segment BC in the sequence shown in Figure D-8. Use 100 to 200 gram batches of resin as required. Wet the trough to be laminated first to aid in saturation of the cloth. Use standard laminating procedures. Three of the 70" strips used for this segment will cuLting. This creates staggered overlaps. NOTE: Overhead laminates are not exactly "fun". Surgical gloves are recommended to keep the resin off the hands as it runs down onto the handle of the brush. Be careful not to stretch the cloth strips too much in the canopy trough area causing them to be too narrow. The full width is required in this area to fully cover the exposed foam core. (See Figure D-6.) Overlap each lay-up 1" as shown in Figure D-8. Stagger the overlaps su there no Lay up segment AB using standard laminating procedures. Start at point B and work forward to point A, which is the firewall location. Trim any excess cloth after curing. Do not laminate at point B where the windshield is installed. Use the 18" long strips for this segment. FIGURE (D-9) STODDARD-HAMILTON AIRCRAFT. INCORPORATED MODEL TD ASSEMBLY NAME FUSELAGE ASSEMBLY REVISION DATE VOLUME I PAGE D-12 Segment CD is laminated in somewhat the same procedure as the leading edge of the horizontal stabilizer. Lay up the four 2" x 55" strips as shown in Figure D-9. Make a 2\' long brush extension by fastening a 2\ foot long stick to a \" varnish brush. Use this brush extension to aid in saturating segment CD, which is the vertical fin. To lay-up the vertical fin (segment CD) it is recommended that 2 people participate. Have one person crawl to the aft of the fuselage and hold the cloth at point C (See Flag #1) while the other person holds the cloth at point D. NOTE: Make sure to overlap the layers of cloth for segment CD onto segment BC 1" at point C. With the 2\' brush extension push the strip into the upper corner of the fin. (See Flag #2). Be sure to wet the area to be laminated first with resin. With the first layer stuck in place continue to saturate the cloth using the 2\' brush extension. Lay up the following 3 layers in the same manner. Trim any excess cloth at point D after it has cured. NOTE: Try to avoid getting resin on the inside sidewalls of the fin while laminating. This will make positioning the cloth much easier. Allow the fuselage upper seam to cure 24 hours before joining the belly section. STEP C-8 To hold the fuselage shell to the proper contour while bonding a s m a ~ l "jig" is required. ,On a flat garc:ge floor or the eq';1iva1ent, s t r Lke a 150" base chal.kl.tne . T'Iiei1 str:Lke 40" reference l ~ n e s perpendicular to the baseline at stations 0, 82, 93, 106, and 122 as shown in Figure D-10. From the supplied full size fuselage jig templates, cut the four supports from \" plywood. Nail a 2 by 4 to each support as shown in Figure D-10. Place each support at the previously marked reference lines in the appropriate location. Lay an old blanket or pad on the garage floor to protect the right side of the fuselage as shown in Figure D-10. Insert a 39 3/4" long stick inbetween the fuselage halves for support while placing the upper fuselage on its right side on top of the blanket and supports. With the fuselage on the supports, place a sandbag or the equivalent at the firewall location to keep it from sliding off the supports. ~ STODDARD-HAMILTON AIRCRAFT, INCORPORATED MODEL GLASAIR TD ASSEMBLY NAME FUSELAGE ASSEMBLY REVISION DATE VOLUME I PAGE D-13 PLAN VIEW F 93 106 122 SIDE VIEW G F FIGURE (D-IO} NOTE: Make sure the supports fit flush to the right fuselage half. Shim if necessary. To laminate the belly section in place a person must climb into the fuselage shell. The jig must be stable enough to sustain the weight of a person without the fuselage halves deflecting. ~ STODDARD-HAMILTON AIRCRAFT. INCORPORATED MODEL ASSEMBLY NAME GLASAIR TD FUSELAGE ASSEMBLY REVISION DATE VOLUME I PAGE D-14 Check points H, E, and D along the centerline to see if they are all equidistant from the floor, especially point D, at the vertical fin tip. Prop with a stick if this point droops below the fuselage centerline. With the supports aligned and shimmed, nail two 2" x 4" boards lengthwise on both sides connecting all the supports together. This will insure no movement during bonding. STEP C-9 At this point the belly sections and panel need to be taped to the bottom of the fuselage. Clean any PVA coating off the ge1coat side of the seams, if present and tape the belly section to the fuselage in the same manner as in step C-4. Start taping at the firewall on the top seam and work to the tail. NOTE: Assemble the belly section prior to taping it in ~ l a c ~ . Make sure the hinge pins are protruding out from tne left side of the belly panel so they won't get bent during installation. Temporarily insert a couple of props under the right side of the fuselage to allow access to the bottom seam while taping. Tape the bottom seam from the firewall to the tail. Tne belly sections are now ready to be bonded in place. NOTE: Check the jig stability by having a partner watch the seam joints while crawling aromld inside the fuselage. If the fuselage is supported properly, the joints should remain f1usn. Adjust if necessary. STEP C-10 From the 50" wide cloth cut strips on the 45 bias to the following dimensions: QUANTITY (8) 3 ~ " x 16" (for segment HG) (10) 3 ~ " x 70" (for segment FE) (2) 3 ~ " x 35" (for segment FE) This is enough cloth for both the top and bottom seam. ~ STODDARD-HAMILTON AIRCRAFT. INCORPORATED MODEL GLASAIR TD ASSEMBLY NAME FUSELAGE ASSEMBLY REVISION DATE VOLUME I PAGE D-15 STEP C-ll @ --~ --- ~ @ FIGURE (D-ll) NOTE: Do not boud the belly panel in place. It is a removable panel ana-is in place at this time to insure proper hinge line up. Be careful not to drip any resin onto the hinge. Mask the hinge, if needed. Lamination of the 4 belly section seams is similar to the upper fuselage seam. Each seam requires a 4 layer laminate. Lay up the two HG segments first, using the 3 ~ " x 16" strips (4/side). Then layup the FE segments in a similar manner to segment BC, using the 3 ~ " x 70" and 3 ~ x 35" strips as shown in Figure D-ll. NOTE: At point E the two belly section seams overlap, causing &1 eight layer thickness. This is required to give strength for the tailwheel attachment. CAUTION: Use a vapor mask while laminating inside the fuselage due to the small enclosed area. A ventilation fan and light are recommended. Allow the seams to cure 24 hours before disturbing; then remove the masking tape. Completed 0 ~ STODDARD-HAMILTON AIRCRAFT. INCORPORATED MODEL GLASAIR TD ASSEMBLY NAME FUSELAGE ASSEMBLY REVISION DATE VOLUME I PAGE D-16 D. LANDING GEAR SUPPORT RIB CONSTRUCTION AND INSTALLATION STEP D-l -------------I I I - DETAILeD /vENTILATION AND ILIGHT CUTOUT FIGURE (D-12) Remove the belly panel from the fuselage and place the fuselage on two sawhorses as shown in Figure D-12. The fuselage jig is no longer required. With a saber ~ a w and drill, cut out two ventilation and light holes (one on each side) in the canopy area as shown by the dotted lines in Figure D-12. NOTE: Do not cut into the foam core surrounding the canopy area, thereby ruining the canopy frame. ~ STODDARD-HAMILTON AIRCRAFT. INCORPORATED MODEL GLASAIR TD ASSEMBL V NAME FUSELAGE ASSEMBLY REVISION DATE VOLUME I PAGE D-17 STEP D-2 The landing gear support ribs are located forward of the belly panel cutout as shown in DETAIL I. of Figure D-12. It is important that the layout and location of these ribs be very accurate. Measure back 12" aft of the firewall and draw a line parallel to it on the inside of the belly section. This is the forward edge of the aft foam rib. Measure forward 6-1/8" from the 12" line and draw another line parallel to the firewall. This is the aft edge of the forward foam rib. Continue these lines 10" up the sides of the fuselage,also parallel to the firewall. NOTE: The critical measurement is the 6-1/8" dimension. The Ianaing gear attach brackets are pre-bent to closely fit inside this dimension, once the laminations have been added. STEP D-3 Each rib is made in two pieces to make fit-up easier. The two rib halves are spliced in the middle upon installation. From the full size supplied templates, cut the four rib halves from ~ " thick foam. NOTE: The dotted areas on the templates require a dense 20 lb. foam to take bearing loads. T h e ~ " thick 20 lb. foam is light brown in color. Cut four pieces of ~ " thick 20 lb. foam to fit the dotted areas on the templates (2/rib). Trace the outline of the 20 lb. foam inserts onto the regular foam ribs at their appropriate locations. Cut out these outlines. With a small amount of body putty, bond these inserts in place, making sure they are flush to the surface of the ribs. Fit these rib halves to the previously layed out lines. Some sanding will be required. Round the top edges of the foam ribs with a \" radius as shown in DETAIL 1., Figure D-12. Remove any sanding dust with a vacuum cleaner. STEP D-4 Mix a wet 100 gram Q-cell mixture. Apply a thin coating of this mixture to the exposed surfaces of the landing gear ribs (all surfaces except those in contact with the inside of the fuselage). Sand any surface irregularities flush after the Q-cell mixture has cured. STEP D-5 Bond each rib half in place with small dabs of body putty every 2". Install one rib half in place at a time. Remove any excess body putty that oozes out while pressing in place. Join each half rib in the center with body putty. Sand any exposed body putty flush. NOTE: Be very accurate in placement of each rib half, paying close attention to the 6-1/8" dimension. ~ STODDARD-HAMILTON AIRCRAFT. INCORPORATED MODEL GLASAIR TD ASSEMBLY NAME FUSELAGE ASSE}ffiLY REVISION DATE VOLUME I PAGE D-18 STEP D-6 Mix a thick 75 gram Q-cell mixture and place a bead of this mixture in all the corners where the ribs and fuselage meet. (See Flag #1, Detail 1., Figure D-12.) With a 3/8" dowel radius the Q-cell bead in the corners and remove any excess Q-cell mixture. STEP D-7 Cover the forward belly panel hinge with masking tape to protect it from resin spillage. STEP D-8 Cut two sets of landing gear rib cloth from the supplied full size templates on the 450 bias. Each rib half is covered with 10 layers of cloth. The first five layers on each rib half are the same size and overlap approximately 4" in the center. Layers 6 through 10 are consecutively shorter in length, creating a tapered thickness as shown in Figure D-13. NOTE: Use the loose weave style cloth for this lay up, not the weave style. The gear support ribs and the firewall use this style of cloth. QUANTITY (10) forward rib (layers 1 through 5) (2) forward rib (layer 6)(2) forward rib (layer 7)(2) forward rib (layer 8)(2) forward rib (layer 9) (2) forward rib (layer 10) QUANTITY (10) aft rib (layers 1 through 5)(2) aft rib (layer 6) (2) aft rib (layer 7) (2) aft rib (layer 8) (2) aft rib (layer 9) (2) aft rib (layer 10) STEP D-9 Prior to lamination, trial fit one of the 1-5 layers to the aft rib to become familiar with how the cloth stretches over the ribs. There will be no second chances during lamination, so it is a good idea to practice with the cloth dry. Also, during lamination the cloth will stretch and change shape from the original pattern. Therefore, a centerline drawn on each piece of cloth with a felt tip pen is required. This centerline coincides with the top of the rib and gives a frame of reference while laminating, if the cloth shifts. -Ir STODDARD-HAMILTON AIRCRAFT. INCORPORATED MODEL GLASAIR TD ASSEMBLY NAME FUSELAGE ASSEMBLY REVISION DATE VOLUME I PAGE D-19 STEP D-IO .. 1 . 2 ~ -1. ~ '----HINGE FIGURE (D-13) NOTE: Laminating the landing gear support ribs is a demanding job. x-cnair, vapor mask, ventilation fan, and good lighting are a must. Mix resin in 100 gram quantities as required. Wet the entire area on the rib to be laminated with resin first before applying the cloth. This will aid in saturation of the cloth. When laminating layers 1 through 5 on the ribs, alternate from side to side creating an overlap region in the center of the rib. Start laying each layer down at the outermost curved portion of the ribs, working to the center. Gently stretch the cloth width-wise and work it down along the side of the rib to the corners on each side. Stretch the cloth width-wise while working to the center, creating a l \ " - l ~ " border (see Flag 112) behind the aft rib. This border does not need to be accurate as long as it doesn't cover the hinge half. ~ STODDARD-HAMILTON AIRCRAFT. INCORPORATED MODEL ASSEMBLY NAME REVISION DATE VOLUME PAGE I GLASAIR TD FUSELAGE ASSEMBLY D-20 Laminate the aft rib first, then the forward rib in the order shown in Figure D-13. Lay up the first two layers and let them cure before laying up layers 3-10 on each rib. This will make the following layers saturate easier by giving a hard curved surface to laminate to. NOTE: Saturation of these ribs will be tricky. Air bubbles will saturate and then seem to come back from nowhere. Be on the watch. There can be no air bubbles in the 20 LB foam area. Any air bubbles in this area will create added thickness causing the landing gearbrackets to not fit. When laminating the forward rib the sequence and procedure is the same, except the cloth will have to be cut at the sidewall of the fuselage so it will lay flat. Cut the cloth at the top of the rib and corners and overlap. (See Flag 11, Figure D-13.) STEP D-ll LANDING GEAR RIB REINFORCEMENT TEMPLATE (FULL SIZE) FIGURE (D-14) Cut 8 pieces of standard weave style cloth 6" x 6" on the 45 bias. Cut 16 pieces of standard weave cloth to the full size pattern in Figure D-14. ~ STODDARD-HAMILTON AIRCRAfT. INCORPORATED MODEL GLASAIR TD ASSEMBLY NAME FUSELAGE ASSEMBLY REVISION DATE VOLUME I PAGE D-2l STEP D-12 ~ - - 6 x 6 " LAY-UP (4 LAYERS/SIDE) RE IN FORCEMENT A(4 LAYERS) t--LANDING GEAR SUPPORT RIBS SECTION A-A FIGURE (D-15) Lay up the 6" x 6" pieces of cloth inbetween the landing gear ribs on both sides as shown in Figure D-15. Use standard laminating procedures. STEP D-13 Lay up the 16 reinforcement patches (4/lamination) on the outside of each rib in the 20 LB foam areas as shown in Figures D-15 and D-16. This means only the forward side of the forward rib and the aft side of the aft rib. ~ 5TODDARD-HAMILTON AIRCRAFT. INCORPORATED MODEL GLASAIR TD ASSEMBLY NAME FUSELAGE ASSEMBLY REVISION DATE VOLUME I PAGE D-22 AFT RIB FORWARD RIB FIGURE (D-16) NOTE: Do not laminate inbetween the ribs. Make sure the layersrre-flat in these areas. Let cure. Completed 0 ~ STODDARD-HAMILTON AIRCRAFT. I N C ~ A T E D MODEL GLASAIR TD ASSEMBLY NAME FUSELAGE ASSEMBLY REVISION DATE VOLUME I PAGE D-23 E. FIREWALL CONSTRUCTION AND INSTALLATION STEP E-l I---FIREWAl..1.. STATION,FUSELAGE PANEL T '-- FUSELAGE FLANGE TYPICAL CROSS-SEC TION FIGURE (0-17) At the firewall station trim the flanges on the fuselage down to a 5/8" width as shown in Figure 0-17. STEP E-2 The firewall bulkhead panel is constructed from "scratch" and only the raw materials to build it are supplied. To fabricate the firewall bulkhead panel the outside contour of the fuselage at the firewall location needs to be scribed onto 1/2" thick foam. The firewall is roughly 30" x 41". The 1/2" foam stock comes in 2' x 8' sheets and is therefore too narrow for the firewall to be made from one piece of foam. It is necessary to splice two pieces of foam together, making approximately a 30" x 41" rectangle. Use small dabs of body putty to accomplish this. The orientation of the splice is not important. Once the body putty has cured, place the foam against the fuselage at the firewall location and trace the fuselage outline onto the foam. Cut out the firewall foam core from the traced outline. NOTE: Before cutting the 1/2" foam for the firewall bulkhead make sure the firewall is the proper contour by measuring diagonally from corner to corner and equating the distances. Also, check the upper cowling area of the firewall with the full size firewall upper cowling template to make sure the firewall is the proper contour. Measuring diagonally from corner to corner and equating the distances insures that the engine mount will fit properly to the firewall. STEP E-3 Mix a wet 200 gram Q-cell mixture. Apply a thin coating of this mixture to the forward side only of the foam bulkhead with a squeegee. Let cure. STODDARD-HAMILTON AIRCRAFT. INCORPORATED MODEL GLASAIR TD ASSEMBL Y NAME FUSELAGE ASSEMBLY REVISION DATE VOLUME I PAGE D-24 STEP E-4 Lay the foam firewall on a flat surface and use it as a template to cut 4 pieces of fiberglass cloth on the 45 bias 1" larger radially than the firewall bulkhead. Lay up 2 layers of this cloth onto the Q-celled side of the foam bulkhead, using standard laminating procedures. NOTE: Do not wet the surface to be laminated first before laying down the cloth. Over saturation of the cloth will result if this is done. Approximately 300 - 400 grams of resin will be used for this step. When the 2 layers have green cured, trim them back flush to the edge of the foam core with a sharp knife. Let cure. STEP E-5 /F CORE SA ND ....\,,' --- -- -, - - - - - - - -1 I CUT I . I 1.5 2 LAYER LAMINATE FIGURE (0-18) Turn the partially complete firewall over and remove the foam core along the edgeband of the panel as shown in Figure 0-18. A chisel, knife, and sandpaper work well to accomplish this. NOTE: Make sure to remove all the foam core from the flat surface with sandpaper to insure a good bonding surface. (See flag #1, Figure 0-18.) STEP E-6 Mix a wet 200 gram Q-cell mixture. Apply a thin coating of this mixture to the other side of the foam core of the firewall panel. Let cure. NOTE: Do not get any Q-cell mixture on the flat edgeband surface preventing a good bond. We suggest masking this area with masking tape prior to applying the Q-cell mixture. STODDARD-HAMILTON AIRCRAFT. INCORPORATED MODEL GLASAIR TD ASSEMBLY NAME FUSELAGE ASSEl1BLY REVISION DATE VOLUME I PAGE D-25 STEP E-7 Lay up the other 2 pieces of fiberglass cloth cut in step E-4 onto the aft surface of the firewall panel. Use standard laminating procedures. Trim the excess cloth from the edge when it reaches green cure. The firewall panel is now ready for installation. STEP E-8 J ~ 1 1 ~e J_ 1 I 1 - - ' : : : ~ - 3 LAYERS LAMINATE FIREWALL PANEL SECTION A-A FIGURE (D-19) Position the firewall panel against the fuselage and check for fit. To allow the engine cowling to butt up flushly against the fuselage the e dgeban d of the firewell paneL needs to be relieved 1/8" as shown in Section A-A, Figure D-19. With the firewall panel properly held in place drill (4) 1/8" diameter holeE in each corner through the firewall panel and fuselage flange. Insert 4 cleco clamps to hold the paneL in place. Then scribe the 1/8" trim line on the panel edgeband. Trim the panel, using a saber saw and sand any saw cut roughness smooth. ~ STODDARD-HAMILTON AIRCRAFT. INCORPORATED MODEL GLASAIR TD ASSEMBLY NAME FUSELAGE ASSEMBLY REVISION DATE VOLUME I PAGE D-26 STEP E-9 Reinstall the firewall panel with the 4 cleco clamps. Check to see if the panel lifts off the fuselage flange in any areas. If the panel does lift off in any areas secure these areas with more cleco clamps by drilling holes first, and then inserting cleco clamps. Remove the panel, sand the fuselage flange with 80 grit sandpaper, and put a small dab of body putty on the fuselage flange every 3". Quickly reinstall the firewall panel and hold it in place with the cleco clamps. Let the putty harden and then remove the cleco clamps. Mix a thick Q-cell mixture and fill the corner where the firewall panel and fuselage flange meet. (See Flag II, Figure D-19.) STEP E-IO From the 50" wide cloth cut 6 strips of cloth 3" wide by 70" long on the 45 bias. Lay up these strips 3 layers thick in the inside corner of the fuselage flange and firewall panel as shown in Figure D-19, Section A-A, using standard laminating procedures. Overlap the strips I". Lamination is similar to the fuselage seams. Make sure to stagger the overlap areas so that there is no buildup of overlaps. NOTE: The fuselage should be up on two sawhorses. The builder will need a light, good ventilation, and have to sit on a chair in the belly panel area to gain access to this lamination. (See Figure D-12.) Completed 0 F. FIREWALL RIB CONSTRUCTION AND INSTALLATION STEP F-l From " thick foam cut out (2) firewall rib halves, using the full size template. Make these slightly oversize to allow some material for fit up. The firewall rib construction and installation is similar to the landing gear support ribs. ~ STODDARD-HAMILTON AIRCRAFT. INCORPORATED MODEL GLASAIR TD ASSEMBLY NAME FUSELAGE ASSEMBLY REVISION DATE VOLUME I PAGE D-27 STEP F-2 ......,.----40# FOAM REWALL RIB =17 "'----I+-FI REWALL FIREWALL AFT VIEW FILL WITH '--------' MI LL FI BER MIXTURE --- 40# FOAM ---I l--,----,, I I I SECTION A-A (HALF SIZE) DETAIL @ (FULL SIZE) FIGURE (D-20) STODDARD-HAMILTON AIRCRAFT. INCORPORATED MODEL GLASAIR TD ASSEMBLY NAME FUSELAGE ASSEMBLY REVISION DATE VOLUME I PAGE D-28 Make a line 17" above the bottom of the fuselage flange at the fuselage centerline as shown in Figure 0-20. This line references the bottom of the firewall foam rib. NOTE: The line should be perpendicular to the fuselage halves just above the 40 LB foam inserts as shown. NOTE: The 40 LB foam inserts are darker brown in color and protrude slightly above the regular foam surface. STEP F-3 Fit the two foam rib halves to the firewall and splice together with body putty. Round the exposed edge in a similar manner as the landing gear support ribs. the firewall rib. Use the line drawn in Step F-2 to reference STEP F-4 Mix a wet 50 gram Q-cell mixture and apply exposed portion of the rib. Let cure. a thin coating to the STEP F-5 Apply small dabs of body putty every 3" to the forward non-rounded edge of the foam rib and bond in place. Scrape away any excess body putty as it oozes out of the corners. Mix up a thick Q-cell mixture and radius the corners of the firewall rib in a similar manner as done on the landing gear support ribs. Fill the corner where the rib and 40# foam meet with mill fiber mixture as shown. STEP F-6 Cut (10) pieces of the loose weave fiberglass cloth on the 45 bias to the shape given by the full size firewall rib cloth template. With a felt tip pen, mark the centerline of the cloth in a similar manner as done to the landing gear support ribs. STEP F-7 Lamination of the firewall rib is similar to the landing gear support ribs, except the laminate is only 5 layers thick with approximately a 6" overlap in the center. Use standard laminating procedures. Wet the area to be laminated first before laying down the cloth. Alternate from side to side while laminating. The corners will require cutting to allow the cloth to lay down flat as shown in Figure 0-21, see Flag tl. ~ STODDARD-HAMILTON AIRCRAFT. INCORI'ORATED MODEL ASSEMBLY NAME GLASAIR TD FUSELAGE ASSEMBLY REVISION DATE VOLUME I PAGE D-29 FIREWALL RIB (INSIDE VIEW) FIGURE (D-2l) STEP F-8 Cut (30) 4" x 8" pieces of fiberglass cloth on the 450 bias. These pieces of cloth are used to reinforce the upper landing gear attach points (40 LB loam location) in the corners made by the firewall, firewall rib, and fuselage halves. (See Flag #2, Figure D-2l.) There are 15 pieces per side. ~ STODDARD-HAMILTON AIRCRAFT. INCORPORATED MODEL GLASAIR TD ASSEMBLY NAME FUSELAGE ASSEMBLY REVISION DATE VOLUME I PAGE D-30 STEP F-9 "----tf-FI REWALL RI B FIGURE (D-22) To lay up the corners made by the firewall, firewall rib, and fuselage halves, a specific laminating sequence must be followed. The area to be laminated is equivalent to 3 sides or faces of a 4" square cube. (See Figure D-22.) Fifteen pieces of cloth are layed up in each corner. By following the sequence described below, the total thickness on each face should be 10 layers thick. Laminate in this sequence. First wet the area to be laminated. Then lay up one 4" x 8" piece of cloth on surfaces 1 and 2. Follow this by laying up a second 4" x 8" piece on surfaces 2 and 3, overlapping the fiEst piece on surface 2. Then lay up a third piece of cloth on surfaces 3 and 1, overlapping the previous two pieces of cloth on surfaces 3 and 1. The first set of 3 pieces of cloth is complete. Repeat this same overlapping sequence 4 more times until all fifteen pieces of cloth are used. Do the same on the other side of the fuselage in the opposite corner. Completed 0 G. FUSELAGE REFERENCE LINE DETERMINATION STEP G-l At this point reference lines must be drawn for jigging the landing gear struts, wing, horizontal stabilizer, and the incidence angle of the wing. Prop the fuselage on two sawhorses or the equivalent. The front end of the fuselage should be at least 30" from the ground level to allow landing gear strut clearance. ~ STODDARD-HAMILTON AIRCRAFT. INCORPORATED MODEL GLASAIR TD ASSEMBLY NAME FUSELAGE ASSEMBLY REVISION DATE VOLUME I PAGE D-3l NOTE: Protect the gelcoat surfaces on the fuselage belly section from point loading by placing towels or the equivalent on the edge of the sawhorses. STEP G-2 The fuselage needs to be leveled along the wing axis of the plane at this point. Place a carpenters level on the side of the fuselage in the flat vertical area at the windshield location 30" aft of the firewall. Check bo th s ides to see if the s ides are vertical. Adjust the fuselage with wood shims, if necessary, to make it level. NOTE: The fuselage sides may not be parallel. If this is the case, average the distmlce between the bu6bles on the carpenters level and use this measurement to level the fuselage. STEP G-3 t r I ~ I T FIRErALL 18.9, 1 T 18.9 LEVEL I FIGURE (D-23) Place a level on the bottom of the fuselage at the firewall centerline as shown in Figure D-23. With the level "level" measure up 18.9" and make a mark on each side of the fuselage as shown. NOTE: Make sure the 18. 9" me as irrement s are made parallel to the firewall. ~ STODDARD-HAMILTON AIRCRAFT. INCORPORATED MODEL GLASAIR TD ASSEMBLY NAME FUSELAGE ASSEMBLY REVISION DATE VOLUME I PAGE D-32 STEP G-4 WATER INT 18.9 ~ FIGURE (0-24) In the same manner as in Step G-3 measure up 4.6" along the aft face of the vertical fin. The line connecting the 18.9" and 4.6" measurements is defined as waterline 100 and is the centerline of thrust for the airplane. This line is used as a baseline for jigging various parts as mentioned previously. (See Figure 0-24.) STEP G-5 To draw waterline 100, fasten a 8 foot straightedge onto the firewall at the 18.9" measurements. The straightedge should stick out about 2 feet on each side of the fuselage. Next, fasten a length of string to the aft vertical fin surface at the 4.6" mark. Pull this string tight from the 4.6" to the 18.9" mark, sliding the string along the straightedge until it presses against the side of the fuselage. Have a helper make marks about every foot or so, remove the string, and connect the marks. Use a soft lead pencil for this. Make another line on the other side of the fuselage in the same manner. Completed 0 ~ STODDARD-HAMILTON AIRCRAFT. INCOQPORATED MODEL GLASAIR TO ASSEMBLY NAME FUSELAGE ASSEMBLY REVISION DATE VOLUME I PAGE 0-33 H. LANDING GEAR CONSTRUCTION AND INSTALLATION STEP H-l FORWARp k2 :: .. ';': I 1 :", .: '.;, '.---- - - -=--- - --t-l .-....--- 381/2 -----:----eool57 y2--------.j SIDE VIEW FIGURE (0-66) Layout Figures a water the windshield, canopy, 0-66, 0-67 and 0-68. soluable felt tip pen. and canopy Use a flat, frame flexiboutlines le straigas hteshown and dge in NOTE: The dimensions called out in Figures (0-66) and (0-67) are only approximate. The important considerations are that the lines be either straight or smoothly curved. The final layout should be as close as possible to these dimensions but will also depend considerably on the builder's judgement as to "what looks right." ~ STODDARD-HAMILTON AIRCRAFT. INCORPORATED MODEL ASSEMBLY NAME GLASAIR TD FUSELAGE ASSEMBLY REVISION DATE VOLUME I PAGE D-85 To layout the upper curved canopy frame lines as indicated by Flag #1 in Figure D-66, the fuselage contour needs to be simulated. Make a template simulating this contour as shown in Figure D-67. Make two reference lines on it coinciding with the canopy frame lines as shown in Figure D-67. Lay the template on it's side so that it is 7/8" away from the plexiglass outline shown in details A and B of Figure D-67. Draw the upper curved canopy frame lines, using the previously made template as shown in Figure D-67. Layout the elliptical corners as shown in Figure D-67. Use either a 30 ellipse template, or freehand the curves in the corners as shown in details A and B of Figure D-67. NOTE: A second person is helpful when laying out these lines; one to hold the straightedge, and one to draw the lines. Make gentle, eye pleasing curves with a minimum 1" radius in the corners, except where noted. STEP P-4 Place the plexiglass windshield and canopy halves on the fuselage over the previously drawn lines. The windshield and canopy halves are drape molded. plexiglass is pulled down over the molds, using large retainer Approximately 1/2" of excess material is provided around the periphery of the plexiglass parts. The retainer rings leave a rough finish on the parts that cannot be used as part of the visible canopy or windshield. Check the Ld.ne s on the fuselage against the plexiglass to see whether they agree so that only "good" plexiglass is visible. Adjust the lines on the fuselage only, if necessary, to get "good" plexiglass. The plexiglass parts are to be 1/4" larger, radially,than the cutouts. STEP P-5 Section A-A and B-B of Figure D-68 refer to the plan view of Figure D-66. Cut out the windshield, using a saber saw and sharp blade along the previously layed out lines. In the areas on the windhield outline where foam core is present, set the saber saw at a 45 angle as shown in B-B of Figure D-68. In the areas on the windshield outline where no foam core is present, set the saber saw at the regular 0 angle. (See Section A-A, Figure D-68.) NOTE: Be careful, and do not rush when cutting out the windshield area. Try not to deviate from the outline. Use the fastest speed on the saber saw to avoid chipping the gelcoat. Hold the saber saw steady while cutting. Do not cut outside of the windshield outline. This would cause the windshield frame to be too narrow and the windshield plexiglass to be too small. Make sure to leave a 1/4" lip at the base of the windshield as shown in Section A-A of Figure D-68. STODDARD-HAMILTON AIRCRAFT. INCORPORATED MODEL ASSEMBLY NAME GLASAIR TD FUSELAGE ASSEMBLY REVISION DATE VOLUME I PAGE D-87 SABER SAW BLADE WINDSHIELD SKIN WINDSHIELD OUTLINE L _ ~ . . ) ~ SECTION B-B WINDSHIELD SKIN LOCATION SABER SAW BLADE SECTION A-A FIGURE (D-68) ~ STODDARD-HAMILTON AIRCRAFT. INCORPORATED MODEL GLASAIR TD ASSEMBLY NAME FUSELAGE ASSEMBLY REVISION DATE VOLUME I PAGE D-88 STEP P-6 SAND SQUARE RELIEVE FOAM CROSS SECTION OF WINDSHIELD OUTLINE IN FOAM AREAS FIGURE (0-69) Sand the saw cut edges of the windshield outline smooth and square. The amount of sanding required will depend on how straight the lines were cut. Figure 0-69 is similar to Section B-B of Figure 0-68. After sanding the windshield cutout smooth, carve the foam back 1/4", where present, as shown in Figure 0-69. NOTE: Make sure all the foam is relieved from the inside surface of ~ o u t e r skin so that it is of a uniform thickness. We used a rotary file and drill motor to accomplish this. STEP P-7 Place the windshield plexiglass over the cutout area on the outside of the fuselage. Hold it down flush and centered over the cutout while a helper crawls inside and marks the outline onto the plexiglass. Use a water soluable felt tip pen. NOTE: Make sure that only "good" plexiglass will show when installed. There is excess plexiglass on the top of the windshield, but a minimum amount at the base. This outline on the plexiglass is 1/4" too small. ~ STODDARD-HAMILTON AIRCRAFT. INCORPORATED MODEL LASAIR TO ASSEMBLY NAME FUSELAGE ASSEMBLY REVISION DATE VOLUME I PAGE 0-89 STEP P-8 COTTON CLOTH MASKING TAPE FIGURE (D-70) ~ STODDARD-HAMILTON AIRCRAFT. INCORPORATED MODEL ASSEMBLY NAME REVISION DATE VOLUME PAGE LASAIR TD FUSELAGE ASSEMBLY I D-90 A bandsaw will be required for cutting the plexiglass parts to fit. To protect the parts from being scratched, tape a scrap piece of cotton cloth to the bandsaw table. Lay a strip of masking tape on the table right next to the blade, and make a mark 1/4" from the blade, as shown in Figure 0-70. Use this mark as a reference when cutting the windshield. Position the line on the windshield over the 1/4" mark on the tape so tfiat the plexiglass is cut 1/4" l a r ~ e r , radially, than the previously marked outline. Cut the winds ield out, using the bandsaw. NOTE: Make sure the masking tape with the mark on it doesn't shift WErre cutting. Use a blade that has at least 8 - 12 teeth per inch. Be careful when cutting the plexiglass, because it can easily crack and ruin the windshield. Hold the plexiglass flush against the bandsaw table to avoid chattering. 00 not allow the plexiglass to flex or wind up on the blade while cutting. If it begins to crack while cutting, stop immediately and drill a hole to stop the crack before it enters the "good" plexiglass area. STEP P-9 1 LAYER MASKING TAPE 5 LAYERS OF NEWSPAPER 1 LAYER MASKING TAPE SAND HERE ALL AROUND WINDSHIELD 8 LAYERS OF MASKING TAPE CROSS SECTION OF WINDSHIELD AT FUSELAGE CENTERLI NE FIGURE (0-71) ~ STODDARD-HAMILTON AIRCRAfT. INCORPORATED MODEL GLASAIR TO ASSEMBLY NAME FUSELAGE ASSEMBLY REVISION DATE VOLUME I PAGE 0-91 Trial fit the windshield in place from the inside. Notice that the windshield is too large to fit in place. This is because the outline was traced from the outside radius on the windshield rather than the inside smaller one. The windshield may appear to be as much as 1" larger than needed. Do not be deceived. This is an optical illusion. Fit the windshield to the fuselage cutout as described below. Set the top edge of the windshield in place first, and then gradually trim the sides and base of the windshield to fit. Use a bandsaw for the preliminary trimming, and then use a file or the equivalent for final fitting of the windshield to the fuselage. The windshield should fit flush to the cutout, as shown in Figure D-71. CAUTION: Be patient and only trim a little at a time when fittingthe windshield to the fuselage. A windShield that is trimmed too small is ruined. Follow these directions and not your eyes. STEP P-10 Prior to bonding the plexiglass windshield in place, it must be protected from resin and scratches with newspaper and masking tape. Fit the windshield into place, and with a water soluab1e felt tip pen, mark the windshield border on the outside surface of the p1exiglass windshield. Remove the windshield. Transfer the windshield border onto the inside surface of the windshield, as well. Cover the windshield with about 5 layers of newspaper on both sides, as shown in Figure D-71. Build up an 8 layer "dam" of masking tape on the inside surface of the windshield at the windshield border, as shown in Figure D-71. 'Ihis "dam" provides a solid edge for the following laminates to build up against. It is the only way to obtain a straight, neat border around the Windshield. NOTE: Resin will seep through newspaper if it is only a couple rayers thick. Four to five layers are needed to protect the windshield. STEP P-l1 Sand the 1/4" border on both the inside and outside surfaces of the p1exiglass windshield with rough grit sandpaper as shown in D-71.Ihis is in preparation for bonding of the windshield to the fuselage. STEP P-12 Gather a bunch of small finishing nails or round toothpicks. Turn the fuselage over on it's back and place it on two sawhorses. NOTE: Place the forward sawhorse at the firewall location as far away from the as possible. The fuselage at the base of the windshield deflects readily, because there is no supporting structure beneath it until the windshield and various other components are bonded in place. STODDARD-HAMILTON IAIRCRAFT. INCORPORATED VOLUME MODEL ASSEMBLY NAME REVISION PAGEDATE I D-92GLASAIR TD FUSELAGE ASSEMBLY STEP P-13 TAPE OR WEIGHT Q-CELL HERE HERE TO HOLD IN PLACE MASKING TAPE AND NEWSPAPER FINISHING NAILS OR ROUND TOOTH PICKS CROSS SECTION OF WINDSHIELD AT FUSELAGE CENTERLI NE FIGURE (0-72) Mix up an appropriate of wet Q-ce11 mixture. Coat the outer 1/4" border on both the p1exig1ass and fuselage where the windshield bonds in place, as shown in Figure 0-72. Use a small brush for this. Press the windshield in place and remove any excess Q-ce11 that oozes out. Insert small finishing nails or round toothpicks into the foam core every 2" to 3", where present, to hold the windshield in place. Where there is no foam core present, (such as the base of the windshield), hold the windshield in place with tape or weights. NOTE: If weights are used to hold the windshield against the fuselage during bonding, the fuselage needs to be supported from below so that the fuselage does not deflect due to the additional load. If the fuselage does deflect, the appearance of the airplane will take on a "broken nose" look. Let the Q-ce11 mixture cure and remc,ve the finishing nails or toothpicks. Sand any rough surfaces smooth. __-----------------1 STODDARD-HAMILTON AIRCRAFT, MODEL ASSEMBLY NAME REVISION DATE VOLUME PAGE I 0-93 FUSELAGE ASSEMBLY GLASAIR TO STEP P-14 ---.----2 LAYER LAMINATE Q-CELL FIGURE (D-73) Mix a batch of thick Q-cell mixture. Fill any cracks or corners flush with this mixture, as shown in Figure D-73. Let cure and sand any rough surfaces smooth. NOTE: At the base of the windshield, where no foam core is present, of the windshield is exposed. This corner needs to be filled with a thick Q-cell mixture as shown to allow the following laminates to lay flat. STEP P-15 The windshield is held in place with a two layer laminate as shown in Figure D-73. Cut enough 2" wide cloth strips on the 45 bias to encircle the windshield border twice. NOTE: The edges of the cloth strips should be very straight and not frayed. The cosmetic appearance of the interior cabin area is dependent on how neat this lay up is done. STEP P-16 With the eight layer "dam" in place on the inside border of the windshield, lay up a two layer laminate as shown in Figure D-73. Use standard laminating procedures. STODDARD-HAMILTON AIRCRAFT, INCORPORATED MODEL GLASAIR TD ASSEMBLY NAME FUSELAGE ASSEMBLY REVISION DATE VOLUME I PAGE D-94 CAUTION: The two layer laminate should just butt up against the masking tape "dam." The laminates should not overlap onto the "dam" at all. Be very careful when laying up these strips. To cut glass, all that is needed is a sharp scribe line, and then a quick snap. P1exig1ass works the same way; therefore, it is not advisable to try to trim a ragged edge of the laminate on the p1exiglass surface. The only way to trim the border would be to use a knife which would make scribe lines in the p1exig1ass. This would weaken the windshield, creating potential cracks. Do a good job in the first place and this problem will be avoided. INOTE: Do not overlap the cloth strips when laminating. Butt them up against each other as tight as possible. Make the strips as long as possible in the straight The corners will require a couple of small strips. Stagger the butt joints. Let cure before disturbing the fuselage, and then turn the fuselage over, upright. Sand any surface roughness smooth. STEP P-17 The canopies are installed in much the same way that the windshield was installed. Basically, the only difference is that the canopy has a foam core all the way around it. Figure D-74 shows the installation sequence in brief. The following steps briefly outline the canopy installation sequence. Refer to the preceding steps on windshield installation for details. The numbers in Figure D-74 coincide with the steps below. (1) Place the canopy halves on the fuselage and check the p1exig1ass for agreement with the previously made outline. Adjust if necessary. Set saber saw at 450 angle and cut out window area carefully, following the previously made outline. (2) Sand the window edge smooth and flat. Notch the foam core back 1/4" as shown. Make sure to sand all the foam from the window lip as shown. (3) Place the canopy halves on the fuselage in the proper place so that only "good" glass shows. From the inside of the fuselage, mark the canopy cutout outline onto the p1exig1ass. Cut the p1exig1ass canopy halves 1/4" larger, radially, than the cutout outline. (See Step P-8, Figure b-70.) Trial fit them in place. Begin trimming the canopy halves to fit the fuselage. Start at the bottom and work to the top. NOTE: The canopy p1exig1ass will again appear too large. Do not be deceived. Cut a little at a time until the canopies just fit the fuselage. With the canopy halves in place, mark the border on both the inside and outside surfaces. Remove the canopy halves and cover with newspaper. Build up an eight layer "dam" on the inside surface. Sand the 1/4" border on the p1exig1ass on both sides. STODDARCJ.HAMILTON AIRCRAFT. INCORPORATED MODEL GLASAIR TD ASSEMBLY NAME FUSELAGE ASSEMBLY REVISION DATE VOLUME I PAGE D-95 SAND LIP MASKI NG TAPE AND NEWSPAPER WINDSHIELD OUTSIDE GELCOAT SURFACE OF FUSELAGE CD SAND HERE @ INSTALLATION SEQUENCE FIGURE (D-74) ~ STODDARD-HAMILTON AIRCRAFT. INCORPORATED MODEL ASSEMBLY NAME GLASAIR TD FUSELAGE ASSEMBLY REVISION DATE VOLUME I PAGE D-96 Brush a wet Q-cell mixture onto the outside 1/4" border of the plexiglass and fuselage window lip. Pin the canopy halves in place and let cure. Wipe up the excess Q-cell mixture as it oozes out. (4) Sand the inside surface smooth and fill any cracks or sharp corners with a thick Q-cell mixture. Let cure and. sand smooth. Cut 2" wide cloth strips on the 450 bias. Be careful to make the edges as straight as possible. Lay up these strips, butting them up against the "dam", creating a two layer laminate as shown. Be as neat as possible. (5) Sand the rough edge along the dam and any cloth that "accidently" crept up on it during lamination. NOTE: Over a period of about three months the masking tape aanesive will react with the plexiglass parts, leaving permanent marks on the plexiglass surfaces. Heat or exposure to sunlight will speed up this process. We recommend removing the masking tape from the plexiglass surfaces after they have been bonded in place. Re-cover the inner and outer surfaces of the plexiglass parts with newspaper, taping the newspaperdown to the fuselage surrounding the plexiglass. Do not let any masking tape contact the plexiglass parts. The purpose of the newspaper is to protect the windshield and canopy from scratches and dust. COMPLETED 0 ~ STODDARD-HAMILTON AIRCRAFT. INCORPORATED MODEL GLASAIR TD ASSEMBLY NAME FUSELAGE ASSEMBLY REVISION DATE VOLUME I PAGE D-97 Q. CANOPY FRAME FABRICATION STEP Q-l Recheck the canopy frame outlines that were drawn in Step P-3 of this section. Adjust if necessary. NOTE: The canopy outlines should be such that there is only "good"plexiglass showing. ~ STODDARD-HAMILTON AIRCRAFT. INCORPORATED MODEL GLASAIR TD ASSEMBLY NAME FUSELAGE ASSEMBLY REVISION DATE VOLUME I PAGE D-98 STEP Q-2 ~ B --------L..B - CANOPY FRAME CUTOUT - INSI DE SKIN -HINGE0:: c n ~w-C\Jcno::_ L~ - - - - - - - - -I I Ig;+ ,II 0 I ~ Iu, I I I I \ \ \ \ ) --: -,II I rn ~ I-W ~ ~ ~ ~ :::>2V)w(91zI ~ I -0 W.:.J IIlU I I ~ - - - -_/ .......... FIGURE (D-124) ASSEMBLY NAME FUSELAGE ASSEMBLY ~ STODDARD-HAMILTON AIRCRAFT. INCORPORATED REVISION OATE VOLUME I PAGE D-168 On a clean, waxed, flat aluminum plate lay-up a (2) layer laminate large enough to make (3) bearing support ribs as shown full size in FIGURE (D-124). These laminates are used to give a hard surface to laminate to. Cut all cloth on the 45 bias. Once the laminate cures, separate from the plate and cut out (1) bearing support ribs as shown full size in FIGURE (D-124). Cut out (18) pieces of bearing support rib cloth on the 450 bias as shown full size in FIGURE (D-124). This is enough cloth for the (3) ribs (6/rib). STEP T-2 The bearing support ribs are located between the firewall and the forward landing gear support rib as shown in FIGURE (D-125). The bearing support ribs consist of an (8) layer laminate, two of which are "pre-made" and bonded in place with body putty. The rudder pedal bearings are bolted to the bearing support ribs as shown in FIGURE (D-125). Fit the bearing support ribs to the fuselage, firewall, and forward landing gear support ribs as shown in FIGURE (D-125). Sand the smooth surface on these (2) layer laminates until the surface is completely dull and rough for laminating. Hold the ribs in place with small dabs of body putty. Radius the corners where the putty oozes out. Lay up (3) pieces of the bearing support rib cloth on each side of the (2) layer laminates, creating an (8) layer rib. Cut the cloth in the corners, if needed, to make the cloth lay flat. The cloth should extend beyond the corners, creating about a 1" border, tying in the fuselage belly section, forward landing gear support rib, and firewall. Use standard laminating procedures. Trim the cloth when in the green cure state flush to the (2) layer laminate. Sand if needed. The (2) layer rib laminate gives a hard surface to laminate to for the following (6) layers. NOTE: If dual pedals and brakes are desired, duplicate the left nana side as shown in FIGURE (D-125). Extra rudder pedals are available. The rudder pedal assemblies are shown mounted in front of the forward landing gear support rib in FIGURES (D-123) and (D-125). However, we recommend mounting the rudder pedalassemblies between the landing gear support ribs unless most passengers will be over 6 feet, 1 inch tall. If most passengers will be under 6 feet, 1 inch tall, mount the rudder pedal assemblies between the landing gear support ribs. The distance from the seat back to the firewall is 51". Decide which location is desirable before installing the bearing support ribs. The only change will be the shape of the bearing support ribs and the rudder control spring 1eneth. Spring extensions can be made from aluminum plate, if needed. ~ STODDARD-HAMILTON AIRCRAFT. INCORPORATED MODEL ASSEMBLY NAME GLASAIR TD FUSELAGE ASSEMBLY REVISION DATE VOLUME I PAGE D-169 STEP T-3 From the supplied 3/4" UHMW polyethylene, fabricate (1) A bearing, (2) B bearings, and (1) C bearing as shown full size in FIGURE (D-126). NOTE: Bearing B is split in (2) pieces down the middle. Cut the bearing in half and bolt or clamp together before drilling the 7/8" diameter hole. The hole will end up too small otherwise. Use a bandsaw or the equivalent to cut out the Use a regular flat 7/8" diameter drill bit to drill the 7/8' holes. It works fine and is much cheaper than a regular drill bit or hole saw. Use a high speed when cutting or drilling the UHMW material. STODDARD-HAMILTON AIRCRAFT. INCORPORATED MODEL GLASAIR TD ASSEMBLY NAME FUSELAGE ASSEMBLY REVISION DATE VOLUME I PAGE D-17l --- ----5~ 6 DRI LL THRU CENTER 316" HOLE -1--- ~ - - - - t ...--- '6 DIA.(TYP.) 1 ~ BEARING A BEARING B RUDDER PEDAL BEARINGS FIGURE (0-126) ~ STODDARD-HAMILTON AIRCRAFT. INCORPORATED MODEL DATE VOLUME PAGE ASSEMBLY NAME REVISION I 0-172FUSELAGE ASSEMBLY GLASAIR TO STEP T-4 Mount the right rudder pedal we1dment first, then the left assembly, as shown in FIGURE (D-12S). Use the supplied AN3-12A, AN3-20A, AN3-17A bolts, AN960-D10L washers, and AN364-1032A nuts as shown. The AN3-17A bolts hold the split B bearings together. The one AN3-20A bolt ties both the C and B bearings together on the right side as shown in FIGURE (D-12S). NOTE: It is very important that the right assembly be mounted as close to the forward landing gear support rib as possible. Radius the corners of the UHMW bearings in the corners, as indicated by Flag #1 in FIGURE (D-12S) to accomplish this. Slide the bearings onto the we1dments as shown, and position the we1dments as shown. Make marks on the bearing support ribs for mounting the bearings to the ribs. Use the bearings as templatesby inserting a nail or the equivalent into the holes in the bearings and scribing marks onto the ribs. Remove the assembly and drill the 3/16" diameter mounting holes. A right angle drill will be required for this operation. With the right assembly in place, proceed to mount the left assembly. The left assembly should be mounted parallel and as close as possible to the right assembly. NOTE: The AN3-20A bolt is common to both bearing blocks on the right hand side. The ribs may require some trimming to allow free rotation of the tubes. STEP T-S Drill and deburr 3/16" diameter holes in the (4) master cylinder attach links. Use the pilot holes in the attach links to locate the holes. Drill a 3/16" diameter hole 3/8" from the corner of the (2) flanges on each rudder pedal as shown in FIGURE (D-127). This is the rudder pedal pivot hole, so make them in line and accurate. Mount the (4) master cylinder attach links to the rudder pedals, using the supplied AN3-SA bolts, AN364-1032A nuts, and AN960-D10L washers, as shown in FIGURE (D-127). Drill 3/16" diameter holes in the right flange of the left rudder pedal and in the left flange of the right rudder pedal for mounting the attach-rInks. This allows alignment of the master cylinders for mounting to the bearing support ribs. NOTE: An attach link is fastened on each side of each of the ruacrer pedal flanges where the 3/16" mounting holes were drilled, forming a (2)-pronged fork for the upper attach point on the master cylinders. ~ STODDARCJ.HAMILTON AIRCRAFT. INCORPORATED MODEL GLASAIR TD ASSEMBLY NAME FUSELAGE ASSEMBLY REVISION DATE VOLUME I PAGE D-173 AN3-5A BOLT AN960-DIOL WASHER AN364-I032 NUT (TYP. 4 PLACES) J I