glasair

HORIZONTAL STABILIZER & ELEVATOR ASSEMBLIES

TABLE OF CONTENTS

A. HORIZONTAL STABILIZER AND ELEVATOR LAYOUT . B-3

C. RIB FITTING . B-6

D. RIB BONDING . B-7

E. RIB LAMINATIONS B-9

F. LEADING EDGE SEAM LAMINATION B-10

G. STABILIZER AFT BULKHEAD CONSTRUCTION B-12

H. BULKHEAD LAMINATIONS . B-13

J. HINGE CONSTRUCTION AND LAYOUT . B-1S

K. STABILIZER HINGE INS~ALLATION . B-17

L. BONDING THE ELEVATOR TRAILING EDGE SEAM B-19

N. ELEVATOR BULKHEAD LAMINATIONS. B-21

PAGE

B. HORIZONTAL STABILIZER RIB LAYOUT AND CONSTRUCTION. . . . . . . . B-4

M. ELEVATOR BULKHEAD CONSTRUCTION AND INSTALLATION . . . . . . . B-20

P. ELEVATOR RIB CONSTRUCTION AND INSTALLATION B-22

Q. ATTACHMENT OF ELEVATOR CONTROL YOKE . B-24

~ STODDARlJ.HAMILTON

AIRCRAFT. INCORPORATED

MODEL ASSEMBLY NAME REVISION DATE VOLUME PAGE

I B-1GLASAIR TD STABILIZER-ELEVATOR ASSY'S

HORIZONTAL STABILIZER & ELEVATOR ASSEMBLIES

INTRODUCTION

The horizontal stabilizer and elevator are made from two shell halves. Each shell is separated along a premarked line into the stabilizer and elevator halves. Final attachment of the stabilizer to the fuselage is accomplished in the fuselage assembly section. Figure B-1 below shows the major components of the horizontal stabilizer and elevator assemblies. The stabilizer is built upside down on a flat table. This makes a straight trailing edge on the TOP panel producing a straight hinge line.

ELEVATOR UPPER HALF

STABILIZER ELEVATOR TIPS

ELEVATOR BULKHEAD

ELEVATOR LOWER HALF

ELEVATOR RIB

STABILIZER BULKHEAD

FIGURE (B-1)

NOTE: A pre-cover inspection must be performed and recorded in the construction log before closing the stabilizer. See the General Information section of the Instruction Manuals.

~ 5TODDARD-HAMILTON



GLASAIR TD STABILIZER-ELEVATOR ASSY'S I B-2

CONSTRUCTION PROCEDURE

After gathering all the tools, parts, and materials required and before starting construction sit down and study all the followinginstructions and illustrations.

A. HORIZONTAL STABILIZER AND ELEVATOR LAYOUT

STEP A-1

<t SYMty1ETRY

50Y1s -----.r FIGURE (B-2)

Sand the mating edges of both stabilizer and elevator halves smooth. Remove all roughness to the ge1coat. Use medium grit sandpaper and sanding block.

STEP A-2 Check the premarked stabilizer elevator separation line on the inside of each shell half. It should measure 5-3/4" from the trailing edge of each shell half (see flag 1). Remark the line if necessary using a straightedge or chalkline. This line is the separation or pivot point of the horizontal stabilizer and elevator.

STEP A-3 Layout the centerline of each shell half· by measuring 50-7/16 tt from each tip. The centerline should be perpendicu1a~ to the stabilizer elevator separation line.

~ STODDARD-HAMILTON


GLASAIR TD STABILIZER-ELEVATOR ASSY'S MODEL ASSEMBLY NAME REVISION DATE VOLUME

I PAGE

B-3

STEP A-4 Layout the rudder cut-out area. (See Flag #2, Figure B-2)

STEP A-S Separate the elevators from the horizontal stabilizer with a saber saw. Use a sharp fine tooth metal cutting blade to insure againstchipping the ge1coat. After the elevators have been separated, cut out the rudder area per step A-4. Save the material cut from this area for "capping" the roots of the elevators at a later time. Sand the cut edges of the stabilizer and elevator smooth with sandpaper and long sanding block.

Completed 0

B. HORIZONTAL STABILIZER RIB LAYOUT AND CONSTRUCTION

STEP B-1

<t SYMMETRY

I

--3Y2 I \ I

I®\\

\ 'I J

I t

-- ~1Js

=~~----39r8 ----------l

@ I I

I I

I

~31f--20~~ --

FIGURE (B-3)

Layout the stabilizer rib center1ines on the inside of the top shell. (see figure B-3)

STEP B-2 Transfer the full size rib templates (at the end of this section) onto a sheet of 1" thick foam. Draw two ribs from each templatefor both sides. NO~E: The templates are only approximate. See the paragraphs on cutting foam parts, page 7 of the Fabrication Techniques Section.

~ STODDARD-HAMILTON

AIRCRAFT, INCORPORATED

MODEL ASSEMBlY NAME REVISION

GLASAIR TD STABILIZER-ELEVATOR ASSY'S PAGE

B-4

STEP B-3

INB'D

LAFT

1/8" TAPER--JPLAN VIEW

RIB A

UP

L AFT

III I

SIDE VIEW ( RIGHT RIB SHOWN)

FIGURE (B-4)

Cut out the ribs. Allow excess material for final sanding and fitting. NOTE: Rib A has a tapered trailing edge (see FIGURE B-4). This taper is necessary because this rib is not parallel to the centerline of the stabilizer. Taper the rear and sanding block.

end of Rib A with sandpaper

STEP B-4 Mix a wet 50 gram Q-cell mixture. Apply a thin coating of this mixture to both sides of each rib with a squeegee. Keep the Q-cell mixture o~£ the upper and lower surfaces of each rib. Set ribs aside to cure.

Completed 0

~ STODDARD-HAMILTON


MODEL

GLASAIR TD ASSEMBLY NAME

STABILIZER-ELEVATOR ASSY'S REVISION DATE VOLUME

I PAGE

B-5

C. RIB FITTING

TOP PANEL

RIB

STEP C-l

FIGURE (B-5)

Lay the top shell of the horizontal stabilizer face down on a flat working table. Measure in from the trailing edge 1 3/16" ras-shown in figure B-5) and mark this dimension on each rib centerline as previously drawn in step B-1.

STEP C-2

RIB

TOP PANEL

FIGURE (B-6)

On each rib end (fore and aft) mark the center with a felt-tip pen 1/2" from the side of the rib (see figure B-6, flag 3). Align the rib with the 1-3/16" and 1/2" dimensions and trace its outline onto the inside of the shell.

~ STODDARD-HAMILTON


MODEL

GLASAIR TD ASSEMBLY NAME

STABILIZER-ELEVATOR ASSY'S REVISION DATE VOLUME

I PAGE

B-6

STEP C-3

2.0

FIGURE (B-7)

With all the ribs in place lay the bottom panel onto the ribs and top panel being careful not to disturb the ribs. Make sure the leading edges and tips of each panel are properly aligned. Gather eight 10-15 pound weights and place them on top of the bottom panel over the rib centerlines.

NOTE: Use discretion when choosing weights so that they do not scratch or damage the gelcoat surface. The loading should be even and distributed with no high point loads. Stacks of large books work fine.

With the weights in place the leading edges of each panel should come together flush with no gaps. Also the trailing edge of the stabilizer should measure 2" at the center and 1 1/4" at the tips from the outside surfaces as shown in figure (B-7).

NOTE: The 2" and 1 1/4" dimensions are critical dimensions and must be adhered to or the elevator halves and elevator control yoke will end up too thin or narrow making rework necessary. (Refer to step Q-5 on page B-24.)

Completed 0 D. RIB BONDING

STEP 0-1

FIGURE (B-8)

~ STODDARD-HAMILTON



I PAGE

B-7

Mix a thick 110 gram Q-cell mixture. Apply a large bead of Qcell mixture to the upper surface of each rib and press rib into its appropriate location until the Q-cell mixture oozes out from beneath the edges. Use a 1/2" diameter tube or dowel rod to remove and radius the excess Q-cell mixture by drawing the rod the length of the rib (see figure B-9). If after checking the thickness of the trailing edge of the stabilizer per figure B-7 the measurements fall outside of the 2" and 1 1/4" requirements, the foam ribs will need to be either sanded or re-filled. If the thickness of the stabilizer at the trailing edge is greater than the 2" and 1 1/4" dimensions, sand the foam ribs until the trailing edge of the stabilizer meets these dimensions. Remove the weights and upper panel, sand the ribs, and try again until everything fits. If the stabilizer trailing edge is too narrow the fqam ribs will need to be built up with a thick Q-cell mixture in the low spots. Check for low spots or gaps with a flashlight. After the Q-cell cures re-sand the ribs until the 2" and 1 1/4" dimensions are met.

Y;' ROD

FIGURE (B-9)

STEP 0-2 Place another bead of Q-cell mixture on the top of each rib. Be careful not to move ribs when applying mixture.

STEP 0-3 Carefully lay the other panel down on top of the ribs making sure that both panels are properly aligned. For this step another person is helpful. Again, be careful not to move ribs when laying panel down.

STEP 0-4 Tape the leading edge of the panels with 3/4" masking tape just enough to hold the panels in place. Now apply the 8 weights onto the panel over the rib centerlines. Press down on the panel slightly to insure that the Q-cell mixture oozes out around the edges of each rib. Now, add one continuous piece of masking tape the full length of the leading edge.

STEP 0-5 Radius the excess Q-cell mixture as described in step 0-1 and let the horizontal stabilizer cure overnight.

Completed 0

~ STODDARD-HAMILTON


MODEL ASSEMBL Y NAME REVISION

GLASAIR TD STABILIZER-ELEVATOR ASSY'S DATE VOLUME

I PAGE

B-8

E. RIB LAMINATIONS 2 LAY-UPS

STEP E-l NO LAY-UPS

7J;.LENGTHI

REQ'O

2 LAY-UPS 2 LAY-UPS THIS SIDE ONLY FULL LENGTH

FIGURE (B-10)

Only Ribs A and D receive laminations. Rib D requires 2 laminates on the outside surface only and Rib A requires 4 laminates, 2 perside as shown in figure B-10. Using the full-size rib templates cut (4) pieces of fiberglass cloth on the 45 degree bias,per diagram in figure B-ll to the dimensions shown.

RIBQ

\

\

FIGURE (B-ll) ~

STODDARD-HAMILTON AIRCRAFT. INCORI'ORATED



STEP E- 2 To start with mix a 50 gram batch of resin to get a feel for how much resin will be needed for this step. Once this is determined mix in small amounts only enough resin to complete this step. Apply the lay-ups as shown in figure B-lO in a conventional manner. Use the cloth alignment probe and extension brush to assist in the layup. When the first lay-up is tacky apply the second lay-up. When the laminations are stiff enough, trim the excess cloth flush with the trailing edge of the ribs. Use a sharp knife or hacksaw blade.

completed 0

F. LEADING EDGE SEAM LAMINATION

STEP F-l '

1" WIDE SEAM TAPE

4 LAY-UPS 1" SEAM --""IIIiiiC:::::~~

TAPE

TYPICAL CROSS-SECTION

FIGURE (B-12)

The leading edge of the stabilizer is seamed together requiring (4) layers of 1" wide fiberglass seam tape. Each lay-up will be applied as two separate strips with a 2" overlap in the center. Cut (8) pieces of 1" wide fiberglass seam tape 60" long ..

~ STODDARD-HAMILTON


MODEL ASSEMBL Y NAME REVISION


I PAGE

B-lO

STEP F-2

FIGURE (B-13)

Mix a 50 gram batch of resin and then mix batch sizes accordingly as required. NOTE: To apply the seam tape to the inside surface of the leading edge use the tape applicator and brush extension. These tools are required to reach inside ,the stabilizer. It is easier to apply and lay up the tape if the stabilizer is positioned perpendicular to the workbench instead of laying flat. Prop it up with suitable supports. Use a flashlight to visually inspect the quality of each lay-up. First wet the area to be laminated using the brush extension. Then using the tape applicator slide the tape in from the side by hooking the end of the tape onto the nail in the applicator. Once the tape is centered on the seam saturate it with resin using the brush extension. Let each lay-up become tacky before applying the next layer. Laminate each side alternating back and forth from side to side until the four lay-ups are complete leaving a 2" overlap area in the center.

Completed 0

~ STODDARD-HAMILTON


MOOEL ASSEMBLY NAME DATEREVISION VOLUME PAGE

GLASAIR TD STABILIZER-ELEVATOR ASSY'S I B-ll

G. STABILIZER AFT BULKHEAD CONSTRUCTION

STEP G-l

I I , II I I I I I I I

1.30 1.60 1.85

FIGURE (B-14)

Cut the aft bulkhead from a 8' section of 1/4" foam to the dimensions shown in figure B-14. Fit the bulkhead to the stabilizer, sanding as required. NOTE: Allow excess material for sanding to exact fit. The bulkhead spans from the outside edge of each Rib D.

STEP G-2 Mark the centerlines of each rib on the outside surface of the bottom shell. These marks will be used as references when pressfitting the bulkhead into position.

STEP G-3

SMALL RADIUS

FIGURE (B-15)

Mix a batch of body putty and apply a small amo un t to the rear end of each rib. Set the bulkhead into position and press fit the bulkhead firmly against each rib. NOTE: Do not press inbetween ribs. Use the previously drawn rib centerlines (STEP G-2) for reference to avoid dishing inbetween ribs. Let body putty cure before proceeding to next step.

~ STODDARD-HAMILTON



I PAGE

B-12

STEP G-4 Mix a wet 40 gram Q-cell mixture. Apply mixture with small squeegee to bulkhead. Buil d up a small 1/8" radius in each corner as shown in figure B-15. NOTE: Do not press too hard with the squeegee when applying mixture. BUIKhead should remain flat without any dishing inbebNeen ribs.

Completed 0

H. BtIT..KHEAD LAMINATIONS

STEP H-l '-'---50---~

FIGURE (B-16)

From 50" wide cloth cut out (7) strips on the 45 degree bias 62 i l X 4\" (see figure B-16). NOTE: Make sure the 4\" dimension is measured perpendicular to the strip. (see Flag 1).

STEP H-2 place the stabilizer shell marked top facedown on a flat workbench. the gelcoat surface should be toward the workbench. This is to insure a straight hinge line.

~ STODDARD-HAMILTON

AIRCRAfT. INCORPORATED



STEP H-3

!

FIGURE (B-1])

Mix a 50 gram batch of resin to start with. Then mix batch sizes accordingly as required. First wet the area to be laminated. Then apply the first lay-up starting at the outside edge of rib D and working to the center. Do the same for the other side. This will result in a generous overlap of these two lay-ups in the center of the bulkhead. Laminate in the order shown in figure B-17. Before proceeding to the next two lay-ups cut the ends of each lay-up,fold, and saturate against the outside surface of rib D as shown in figure B-18.

CUT CLOTH HERE &. FOLD AGAINST RIB ..Q..

FIGURE (B-18)

~ STODDARD-HAMILTON



r,LASAIR TD STABILIZER-ELEVATOR ASSY'S I B-14

STEP H-4 Once the first layer is tacky proceed laying-up the additional layers in the same manner as in step H-3. This will result in a 3 layer thickness at the ends and a 6 layer overlap thickness in the center. Now lay-up the last piece of cloth over the center of the overlap area. Set assembly aside to cure.

STEP H-S

..

i>:~l

SAND

j1 ..... ,I '.'..

'.

FIGURE (B-l9)

Sand the trailing edges of the stabilizer straight and smooth with a long sanding block and medium grit sandpaper.

Completed 0 J. HINGE CONSTRUCTION AND LAYOUT

STEP J-l From the s uno Lde d MS200Ql-P4 hinge stock cut (6) hinges 5" long. Trim, round corners, and break all sharp edges as shown in Figure B-20. NOTE: Holes will be drilled later.

.

< •

,.it

•+

I I

+

+ ,, +

+

5

I

+

+ --

,, +

r::+h- I-_ ...fl-_----l.--+_- _+-_-+ __-+__.+::"_-_-_-'+' _ r ~ J -, I I J

4 +

j J-2 ~1 HINGE LAYOUT

FIGURE (B-20)

~ STODDARD-HAMILTON


MODEL ASSEMBLY NAME REVISION


I PAGE

B-IS

STEP J-2 Remove the MS20253-P2 hinge pins and cut them to 4-3/4" lengths. Remove all burrs. Reinsert p~ns into hinge halves. Center the pin in the middle of the hinge and crimp both ends, using a hammer and center punch as shown in Figure B-21.

FIGURE (B-21)

STEP J-3 ~ I

FIGURE (B-22)

Layout the hinge locations on shown in figure B-22 above.

the TOP PANEL of the stabilizer as

Completed 0

~ STODDARD-HAMILTON




I PAGE

B-16

K. STABILIZER HINGE INSTALLATION

STEP K-l

NO.30 HOLEr--1~ CS'K 1000

~ + + + + 7~6 ~6INSET

MS20001-P4 FIGURE (B-23)

At each hinge location on the stabilizer cut a 1/16" X 5" inset. Make sure the inset is parallel to the trailing edge. This will insure proper alignment of hinges.

o~ ,

\

FIGURE (B-24)

Also bevel the inset to allow the radius portion of the hinge to fit properly in place. (See Figure B-24, Flag #1)

~ STODDARD-HAMILTON



I PAGE

B-17

.

STEP K-2 With each hinge properly aligned and fitted to the r,tabilizer the next step is to drill and countersink the mounting holes. "C"-clamp the hinges in place and layout the hole pattern as indicated in Figure B-23. Next using a #30 drill bit. drill through the shell and hinge at the same time. After each hole is drilled insert a cleco clamp to assure alignment of all holes. After all holes are drilled remove the hinges. clamps. and clecos and countersink the holes using the machine stop countersinking tool.

STEP K-3 Flush rivet the hinges to the stabilizer using the supplied AN426AD4- rivets. (See Figu~e B-25 below) NOTE: Clamp the hinges in place using cleco clamps. Start 'with 4 clecos per hinge removing one cleco at a time for each rivet until finished. Add a laminate to the upper trailing edge of the stabilizer so the outermost hinge lies flat (see Flag #1) if needed.

STEP K-4 Take all (4) elevator shells and sand the edges straight and smooth that were cut with the saber saw.

STEP K-5 Lay all the elevator shells facedown on a workbench. Draw a line 7/8" aft of the leading edge of the elevator on the inside of all four panels. (See Figure B-26. Step L-l)

STEP K~-~6~ ------------rl - I -<

(

~ N4 2 6 AD ~- 6

~2-GAP

•• • •

\AN426AD4-5

..\ ..

KALIGN HERE FIGURE (B-25)

Take the elevator shells that were cut from the panel marked TOP and align them with the stabilizer panel marked TOP as shown in Figure B-25. Layout the hinge locations from the stabilzer onto the elevator.

~ STODDARD-HAMILTON



I PAGE

B-18

STEP K-7 As in step K-l cut a 1/16" X 5" inset in the elevator shell at each hinge location. Also bevel the inset to fit the radius portion of the hinge. Layout the hinge hole locations on the outside face of the elevator half to the same dimensions as in figure B-23.

STEP K-8 Align the elevator with the stabilizer as in step K-6. "C"-clamp the elevator to the outboard hinge on the stabilizer. Hold the elevator at a gap of 3/32" from the stabilizer and drill a 1130 hole through the panel and hinge at the outermost hinge hole location. After drilling this initial hole insert a cleco clamp. Turn the entire assembly over facedown and layout the innermost hinge hole location on the hinge itself. (See figure B-20 for dimensions) Again holding the elevator at a gap of 3/32" from the stabilizer drill through the hinge and elevator at the innermost hole location. Insert a cleco clamp. Turn assembly over again and proceed to drill the remainder of the holes. NOTE: Due to the inaccessability of the innermost hinge by a "C"clamp it is necessary to hold the elevator by hand when drilling the two initial ali~ment holes. The center hinge also cannot be "C"-clamped to the eevator when drilling so make sure to provide proper backing when drilling so the the holes do not become enlarged. Do not countersink holes at this time.

Completed 0

L. BONDING THE ELEVATOR TRAILING EDGE SEAM

STEP L-l

MILL FIBER & Q-CELL MIXTURE

FIGURE (B-26)

Cut a sheet of wax paper the length of an elevator panel and place it on a flat workbench. Lay one elevator panel facedown on top of the wax paper.

~ STODDARD-HAMILTON




STEP L-2 Mix a 25 gram combinacion Q-cell, mill fiber mixture. Apply a bead of this mixture 1/8" high by 1/4" wide the full length of the trailing edge.

STEP L-3 La¥ the mating panel down on top of the first panel. Carefully al~gn the edges and C-clamp securely in place with just enough pressu7e to uniformly join the trailing edges their full length(See f~gure B-26), but not enough to dent or distort the panels. NOTE: A wood block pad the full length of the elevator should be used to distribute the load and also protect the ge1coat finish.

Completed 0

M. ELEVATOR BULKHEAD CONSTRUCTION AND INSTALLATION

STEP M-l

(MAKE STEP AS SMALL AS POSSIBLE)

FIGURE (B-27)

Bevel the bottom trailing edge of the stabilizer. (See flag #1) Use the 3/4" rotary file in a hand drill for best results and then fine sand with a sanding block.

STEP M-2 In order to cut the elevator bulkhead the proper height the completedelevator assembly must be simulated. To do this aluminum shims are necessary. Make several aluminum shims to simulate the bulkhead laminations. The shims should be thick enough to cause the stabilizer upper surface to be flush with the elevator upper surface. Cleco clamp the elevator to the stabilizer with the shims in place. (See figure B-27, flag #2)

NOTE: The elevator yoke must fit inbetween the two elevator leading edges. Do not make the elevator bulkhead height too short or the elevator yoke will not fit.

~ STODDARD-HAMILTON



GLASAIR TD STABILIZER-ELEVATOR ASSY'S B-20

STEP H-3 To allow the elevator full downward travel the lower surfaces of the stabilizer and elevator cannot be flush. The elevator lower surface must be slightly higher than the stabilizer lower surface. Determine the optimum bulkhead height by experimenting with the elevator to see which height will allow full downward operation of the elevator. (See flag #3, figure B-27) The elevator may need to be spread apart and held with makeshift spacers to get the proper measurements. The bulkhead will be placed 7/8" aft of the leading edge of the elevator so make the bulkhead height measurements at the previously drawn 7/8" lines. Two measurements will be required because the bulkheads taper from center to end. (See figure B-28)Full downward travel of the elevator should be 22° .

L DIM.~ROOT DIM.

FIGURE (B-28)

STEP M-4 Cut the bulkhead to the previously determined dimensions out of 1/4" thick foam. • NOTE: Make sure to leave excess material for final sanding and fi t-up.Final fit the bulkhead to the elevator.

STEP M-5 Lay the hinge side of the elevator down on a flat workbench. Place small amounts of body putty about every 3" where the bulkhead will be positioned. Slide the bulkhead into place and clamp securely until putty cures.

STEP 1-1-6 Mix a wet 20 gram Q-cell mixture for each elevator as needed. Squeegee mixture onto the bulkhead and radius the corners the same as in step G-4. (See flag #4, figure B-27)

Completed 0

N. ELEVATOR BULKHEAD LAMINATIONS

STEP N-l Cut strips of fiberglass cloth on the 45 degree bias to the following dimensions. This will be enough for both elevators.

Qty (4) 3-1/2" x 48-11/16" (20) 5/8" x 5" (2) 3-1/2" x 12" (2) 3-1/2" x 4-7/16"

~ STODDARD-HAMILTON


MODEL ASSEMBLY NAME DATEREVISION PAGEVOLUME

I B-2lGLASAIR TD STABILIZER-ELEVATOR ASSY'S

STEP N-2

Fill the elevator hinge attach holes with modeling clay to prevent resin from seeping onto them while laminating.

STEP N-3

7 LAYER LAMINATE

4

5/a'X 5" 3 LAYER LAMINATE 5" 5""8 X

FIGURE (B-29)

Mix a 50 gram batch of resin to start with. Then mix batch sizes accordingly as required. Wet tne area to be laminated wich resin. Lay up 2 layers of the 3-1/2" x 48-11/16" strips first, then 1 layer of the 3-1/2" x 12" strip, and then 1 layer of the 3-1/2" x 4-7/16" strip per elevator as snown in Figure B-29. When the laminates have cured enougn, trim the excess cloth flusn with a sharp knife or equivalent. Lay up tne 5/8" x 5" pieces of cloth at the hinge locations on tne underside of tne leading edge of the elevators as shown in Figure B-29. Repeat the aBove procedure for the other elevator half. Set Botn aside to fully cure.

Completed 0 P. ELEVATOR RIB CONSTRUCTION AND INSTALLATION

STEP P-l

Using the full size template at the end of this section, transfer the elevator rib template onto a sheet of 1/4" thick foam and cut out. Allow excess material for final sanding and fit-up. Taperthe leading edge of tne rib 0.10" as indicated By dotted line on the template.

~ STODDARD-HAMILTON




I PAGE

. B-22

STEP P-2

.90

I I

:~::t-I I ......... -: - .........I I ......... .::::-

I I II II I

I I I I I I

ELEVATOR RIB c::::::D

......... --""'" -......... ......... ""'" -"""'-<. >

--......... -......... ] I I

FIGURE (B-30)

Place elevator rio into elevator assembly and secure with a small amount of body putty as shown in figure B-30. Let cure.

STEP P-3 Mix a wet 20 gram Q-cell mixture. Apply mixture to outside surface of rio (see flag #1, figure B-30) with a small squeegee and build up a small 1/8" radius in each corner. NOTE: Use a small brush when applying Q-cell mixture to the trailing edge surface of the rib. Set aside to cure.

STEP P-4 Using the full size elevator rib cloth templates at the end of this section cut on the 45 degree b Las (4) long full length pieces and (2) short reinforcement pieces of fiberglass cloth. These quantities are enough for both elevator ribs.

STEP P-5 Mix 35 grams of resin to start with. Then mix batch sizes accordingly as required. Wet the rib with resin. Lay-up the two long pieces first, then the short reinforcement piece last. Let each layer become tacky before applying the next layer. When laminations are stiff enough trim the excess cloth with a sharp knife and set assembly aside to cure.

Comp Le t e d 0

~ STODDARD-HAMILTON




I PAGE

B-23

Q. ATTACHMENT OF ELEVATOR CONTROL YOKE

STEP Q-l Re-drill the elevator hinge attach holes that were plugged when laminating the elevator bulkhead. Use a #30 drill bit.

NOTE: Countersink the holes for the AN507-6-R7 screws as shown in Figure B-33.

STEP Q-2

l r·15

: : ;; ;; ;; ;; : : .~

~'::iiiWiiil!!) \ 45·

..

FIGURE (B-31)

Chamfer the elevator control yoke 4 places, as shown in Figure B-31 above, enough to allow the elevator control yoke to fit flushlyagainst the elevator bulkhead. (Approximately a .15" x 45° degree chamfer)

STEP ~-3 Wax t e elevator control yoke on surfaces to be mated with elevator halves. This will allow easy separation of yoke from elevator when disassembling.

STEP Q-4 Mount both elevator halves to the stabilizer with cleco clamps. Clamp the elevator halves flush together, using 2 straight boards and C-clamps. (See Flag #1, Figure B-32.)

~ STODDARD-HAMILTON




I PAGE

B-24

STEP Q-5

FIGURE (8-32)

Mix a 40 gram Q-cell mill fiber mixture. Cock the elevator at 90 degrees to the stabilizer to allow access for bonding. Apply Qcell mixture to elevator where control yoke contacts. Press waxed control yoke into place letting excess Q-cell mixture ooze out. (See flag #2) Scrape excess mixture away with putty knife and set aside to cure.

NOTE: Depending on the accuracy of the horizontal stabilizer and elevator halves the elevator control yoke may need to be filed so that it fits in between the leading edges of the elevator halves. Do not reduce the height of the elevator control yoke any more than 1/4". If the elevator yoke needs to be reduced any more than 1/4" in height the stabilizer and elevator halves will require rework. Contact us if there is a problem.

~ STODDARD-HAMILTON

AIRCRAfT. INC<JRFlQRATED

GLASAIR TD STABILIZER-ELEVATOR ASSY'S MODEL ASSEMBL Y NAME REVISION DATE VOLUME

I PAGE

B-25

STEP Q-6

<t I

AN507-6-R7 BOLT AN364-632 A NUT

AN509-8-R11 BOL AN364-832A NUT (TYP. 5 PLACES)

PLAN VIEW HORIZONTAL NOT SHOWN

FIGURE (B-33)

Layout the hole pattern for the elevator yoke onto the top and bottom surfaces of the elevator halves as shown in Figure (B-33). Use a #20 drill bit to drill through both the elevator halves and aluminum control yoke. Countersink the holes, using a machine stop countersinking tool. Mount the elevator control yoke to the elevator halves, using the supplied AN509-8-RII screws and AN364-832A nuts. Countersink the holes for mounting the elevator halves to the stabilizer. Mount the elevator halves to the stabilizer, using the supplied AN507-6-R7 screws and AN364-632A nuts.

WARNING: Make sure that no internal spaces of the stabilizer or elevators are sealed airtight. Drill vent holes, if necessary, to insure that the structure is not damaged as the result of pr~ssure changes due to changes in altitude.

NOTE: The attachment of the stabilizer and elevator tips has been deleted from this section. The empennage counterweight system has been modified. Do not attach the stabilizer and elevator tips at this time. (Refer to Appendix E, page H-24 in the Appendices Section. )

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~ STODDARD-HAMILTON




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