CHAPTER 1 - INTRODUCTION

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CHAPTER 1 - INTRODUCTION Powered By Docstoc
					Just Aircraft, LLC

CHAPTER 5 – PITCH CONTROLS

Section Number                   Section Title                                                                                             Page

                                  Contents .................................................................................................... 5-1
5.1 ..............................Tailplane (Horizontal stabilizer) Installation ............................................ 5-2
5.2 ..............................Trim Tab Installation ................................................................................ 5-7
5.3 ..............................Elevator Installation .................................................................................. 5-8
5.4 ..............................Elevator Control Installation ..................................................................... 5-9




           Revised 6-28-10




 Chapter 5, Rev1                                                  Pitch Controls                                                                Page 5-1
                                                                      Just Aircraft, LLC

        PITCH CONTROLS
5.1     TAILPLANE (HORIZONTAL STABILIZER) INSTALLATION

The horizontal stabilizer is in two pieces. The two halves are symmetrical, but once fitted to a
particular side they should remain there because after drilling and fitting with securing bolts they
become “handed”. F-1000.0 becomes the left hand side; F-1010.0 becomes the right hand side.

The F-1020 front attach bracket determines the angle of tailplane incidence, see Figure 5.1. Once the
stabilizers etc. are fitted, they must be adjusted to give zero degrees incidence. These angles are relative
to a level headrack; see Step 2.


           F-1020                                                     Picture shows the front
                                                                      attach bracket secured in
                                                                      place after setting of correct
      Protruding                                                      incidence
      bushing

      Horizontal
      stabilizer
                                          Figure 5.1


The horizontal stabilizers are held in place with bushing tubes (one front and one rear), which go
through the fuselage sockets. The legs of each stabilizer unit will slide onto the protruding part of the
bushing. The stabilizer legs are then secured to the sleeve by bolts in the front attachment.

STEP 1
Ream the following to clear powder coating over-spray and weld penetrations:
    On each stabilizer half:
          o the 2 bushings for flying wire attachment
          o the two elevator hinge points
    Front attach bracket (use bushing tube to ensure correct fit).
    Rear Fuselage socket (use bushings to ensure correct fit).

STEP 2
Immobilize the fuselage frame using scrap timber and clamps. Ensure that it sits level in both side-to-
side and forward-backward directions by using a spirit level across the cockpit head-rack tubes.




(REVISED 06-28-10)


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Just Aircraft, LLC

STEP 3
The forward attach bracket F-1020 is placed on the fin insert post. When the horizontal stablizer has
been fitted and positioned you will drill a ¼” hole for the AN4-11A bolt which holds the attach bracket
to the insert post. See Figure 5.1 above.

STEP 4
Insert F-1040 rear bushing plug-in sleeve tube; insert F-1020 front bushing tube in sleeve tube. See
Figure 5.1.4.




                                                       Forward attach bracket with bushing
                                                       tube through sleeve and inserted into
                                                       stabilizer legs (there should be no gap
                                                       when finally fitted, gap shown to help
      F-1020.1 front        F-1040 rear
                                                       clarity
      bushing               bushing
                  Figure 5.1.4                                        Figure 5.1.5

STEP 5
Plug stabilizer halves onto bushing tubes (front and rear). Stops are built into the stabilizer legs to
ensure that the correct amount of bushing tube is inserted. See Figure 5.1.5 Trim bushing tubes so they
bottom completely at joint line.

STEP 6
Align the rear edge of the stabilizers - the elevator must not bind, to ensure that the elevator hinge
points on the stabilizer line up correctly; use a straight edge to achieve this. When finally fitted the
stabilizer halves are secured to the front bushings; drill 3/16” holes into stabilizer and through the
bushing tube approximately ½” outboard of join line. Use bolts AN3-11A. This bolt also will hold
transport jury strut attach point at final assembly.



(REVISED 06-28-10)


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                                                                     Just Aircraft, LLC


STEP 7
The symmetry of both halves has to be set so that the stabilizers are at 90 degrees to the fin/fuselage
and are held firmly in this position during the next steps of fitting flying wires. This is achieved by
measuring from a point at the top of the fin to identical marks on the horizontal stabilizer’s spar tube –
these marks should be equal from the stabilizer’s center (use masking tape to aid clear marking).
Adjust horizontal stabilizer until both dimensions are identical and clamp securely in place.

Step 8
The four upper cable braces are fitted next. Ream any powder coat residue from the 12 flying wire
attachment tabs (F-1110) for the (3/16”) securing bolts. Drill out the other ear of each tab to 7/32”
(5.5mm) and ensure that a Nicopress thimble will pass through the hole without binding.

Step 9
Secure a tab with each of the stabilizer strut bolts (AN3-14A and AN3-14A), one at a time without
disturbing the symmetry setting of the horizontal stabilizer. Add 3 adjustment washers between
horizontal stabilizer and tab see Figure 5.1.12.




                                              Figure 5.1.12




(Revised 06-28-10)


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Just Aircraft, LLC

STEP 10
Secure a tab either side of the 2 bushes in the fin with the AN3-14A (front) and AN3-14A (rear) bolts
provided using 3 washers each side as spacers (i.e. between the bush and tab) and a single washer under
the nut; this is to provide for later adjustment for cable stretch in service. See Figure 5.1.13




                              Figure 5.1.13 Fin with flying wire attachments

Make up the cable braces (use F-1140 cable) in the same way that the rudder cables were fabricated
using a Nicopress sleeve (F-1150), a thimble (F-1160) and protective heat shrink sleeving at the each
end of the cable. Whilst fabricating the cables try to keep them as taunt as possible - this will ensure
that you do not use up the adjustment washers on the initial fit. Build the cables using 3 washers, on
final assembly use only 2. This gives good tautness. See Figure 5.1.13

Hint: make, Nicopress and finish off one end of each cable first. Then set up the cable with all its
components in place and with the correct tautness, using a fine felt pen make marks on both pieces of
cable that go through the Nicopress sleeve so that you can remove the assembly and then realign “off
the job” - this will give a more accurately positioned sleeve than trying to maintain tension while
crimping the sleeve.




Step 11
The lower flying wires are made up of a single piece of cable that goes thru a nico sleeve, around a
thimble and back thru the nico sleeve. The cable must be long enough to go from front and back of
flying wire tabs on the bottom of the horizontal stablizer. Install heat shrink tube over nico sleeve
attach to fuselage with shackle and # 3 bolt. The loose ends will go thru nico sleeve and thimble on the
front and rear tabs and are pulled tight, marked then removed for crimping. You should do one at a
time to make sure you get proper tension (preferably front first). With washers under tabs final
tightening can be achieved maintaining horizontal alignment.


(Revised 06-28-10)

Chapter 5, Rev1                             Pitch Controls                                     Page 5-5
                                                       Just Aircraft, LLC

Thimbal, Nico Sleeve and Shrink Tube (Typ)




                                                         Lower Fuse. Tab #3 Bolt




Revised 6-28-10

Page 5-6                              Pitch Controls                  Chapter 5, Rev1
Just Aircraft, LLC

5.2
TRIM TAB INSTALLATION
Trim tab control is covered in Chapter 6.16

STEP 1

Locate the elevator trim (piano-type) hinge MS20257-1 that will fit between the trim tab F-1180 and
the elevator F-1200.0 (left half). Position the elevator upside down on a work surface, then position the
tab upside down (i.e. with its lever arm pointing upwards). The gap between the two will be
approximately 1/8”, i.e. the thickness of the hinge’s center section.
See figure 5.2.1




                                              Figure 5.2.1




STEP 2
The hinge will need trimming on one side to go around the lever arm on the tab – this will be a small
square nick (about 1/8” wide).

STEP 3
For safety purposes, to stop the hinge pin from coming out of the hinge, the pin should be trimmed to
be slightly shorter than the overall hinge length, and a small hole drilled through each end of the hinge
(beyond the pin ends) to take pin-retaining lockwire. See Figure 5.2.3.

Revised 6-28-10


Chapter 5, Rev1                               Pitch Controls                                    Page 5-7
                                                                     Just Aircraft, LLC




                                                                                     Figure 5.2.3
REVISED 9/28/10
STEP 4
Mark the hinge for the rivets that will locate it on the elevator and tab. There will be 7 or 8 equally
spaced rivets along each long edge of the hinge; these will be approximately 1½” apart and should start
at ½”- in from each end. Pilot drill the holes.

STEP 5
With the hinge in position between the elevator and trim tab, pilot drill through the hinge into the 2
components (elevator and trim tab). Now drill out all the holes for the CCP42 1/8 x 1/8 Stainless
rivets.

It is recommended that you don’t actually rivet the components until the final assembly phase, after
covering/painting etc. is finished.

5.3    ELEVATOR INSTALLATION
STEP 1
Locate both halves of the elevator F-1200 (left side with trim tab cut-out) and F-1200.1 (right side).
Ream through hinges and control horn holes to clear powder coating over-spray and weld penetrations.

STEP 2
The elevator half F-1200 (left side) has 6 tabs welded into it for elevator trim purposes. Attach part#
F2740.0 to the aft most four tabs on the elevator using the CCP-44 rivets. Now line up part F2760.0 on
this plate by laying the trim tab into position and lining up F2760.0 with the trim tab. F2760.0 should
be straight with the tab on the trim tab and in the aft most position on the plate F2740.0. See picture
below.




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Revised 6-28-10
Step 3
Ream out the elevator control horn to enable the fitting of bushing F-1470.4.

STEP 4
Attach each elevator half to the horizontal stablizer with the F-0770.0 pins provided. At this stage it is
a temporary fit, so save the cotter pins for final assembly.

STEP 5
The two halves of the elevator are secured together using the AN3-4A bolt. See Figure 5.3.4




Revised 9-4-08




     AN3-4A bolt holding
     2 halves together                                                               Hole reamed for F-
                                                                                     1470.4 bushing




                                             Figure 5.3.4

5.4   ELEVATOR CONTROL INSTALLATION
The two F-1380 control sticks are connected together inside the F-1260 mixer.

STEP 1
Take the F-1280 connecting rod and to each end screw a lock nut (AN316-4R) and fork end (AN486-
4P).

STEP 2
Install the control stick pivots into the mixer F-1260 using the AN4-17 bolts.

STEP 3
The ends of the connecting rod (fork ends) are bolted to the control stick pivots (F-1261) using AN3-5
bolts; they should be positioned such that both sticks are parallel, adjust length of connecting rod by
screwing fork ends (it may help temporarily to fit the control stick to the pivot). See Figure 5.4.3.


Chapter 5, Rev1                              Pitch Controls                                      Page 5-9
                                                                     Just Aircraft, LLC

Revised 6-28-10




                                            Figure 5.4.3



STEP 4
The nylon control mixer bushings F-1310 (4 pieces - 2 pairs) locate over the control mixer and are
secured to the airframe mounting tabs (which should be reamed) using the AN3-25A bolts. AN970-3
Penny washer should be used on each bolt between the UHMW blocks to act as a crush spacer. A
second washer under the bottom on the UHMW blocks acts as a surface bearing. (It may be necessary
to machine a notch in the bottom blocks to allow for bolt length.) See figures 5.4.4a and b




5.4.4a and b.
                                 Figure 5.4.4a (mixer, from front)
  #3 Penny                                                                     Ensure that the
  Washer                                                                       push pull attach
                                                                               lugs are on the
                                                                               left



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         Pair of UHMW
         bushings




                                            Figure 5.4.4b
The bushings should give a snug fit. The top bushing should be drilled with a 1/8” oil hole in the
center.

STEP 5
Nylon stops are fitted to inhibit sideways movement of the control mixer assembly. Locate the mixer
assembly centrally and fix the F-1310.1 UHMW strips to the control mixer on the outer side of the
bushings (between them and the control mixer towers) and secure with the CCP44 1/8 x ¼ Stainless
rivets. See Figure 5.4.5.




Drill Lubrication
                                                                               Mixer bushing
Hole Center of
                                                                               Add Hole
Mixer Bushing

                                                                              Mixer stop

                                                                              Mixer tower
                                            Figure 5.4.5

Note: The control mixer and fuselage frame act as control stops - full forward elevator (down) is
obtained when the mixer assembly is against the fuselage tube in front of the mixer; full aft elevator
(up) is obtained when the mixer assembly is against the fuselage tube behind the mixer. Aileron left
and right control is “stopped” by the stick pivot coming against the pivot tower side.


REVISED 01-04-11

Chapter 5, Rev1                            Pitch Controls                                   Page 5-11
                                                                   Just Aircraft, LLC


REVISED 6-28-10
STEP 6
Fit the control sticks F-1380 onto the control stick pivot assembly F-1261; push them down as far as
the weld. Locate, mark and drill a side-to-side hole for the fitment of AN3-11A bolt 1” up from the
bottom of stick. See Figure 5.4.6.




            AN3-11A




                                             Figure 5.4.6
STEP 7
Install F-1330 rod end bearing and AN316-4R lock nut on one end of the F-1350 long elevator push
pull tube; the other end can be installed after the push/pull tube is installed in the nylon bushings.

STEP 8
Insert the F-1370.0 push/pull control rod nylon bushings into the 4 fuselage positions and lock in place
with the F-1370.1 retaining rings, see Figure 5.4.8.




                                                                                  Figure 5.4.8


STEP 9
Install the (rear) push pull bellcrank F-1400 using an AN6-40 bolt with an AN310-6 Castlelated Nut
and an AN960-616 Washers as needed. Ream the bushings and the bellcrank using a 3/8” reamer, be
sure to use a generous amount of grease on the bolt. Do not over tighten the nut, the bellcrank should
move freely.



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See Picture

(Revised 06-28-10)




STEP 10
At the front, install the push/pull tube through the front two F-1370.0 bushings and then install the
second rod end and lock nut.

STEP 11
Attach the long push/pull tube rod end to the operating arms on the bottom of the control stick mixer
assembly (F-1260) with the AN4-11A bolt; space with washers as necessary. Secure with a Nyloc Nut
(not the castel nut in the picture). See Figure 5.4.11.


Install push rod tube
Temporarily (must be
Removed for final floor
Board installation).



                     Figure 5.4.11

STEP 12
Attach the F-1350 long elevator push pull tube to the rear bellcrank using the AN4-11A bolt. The long
tube attaches to the long arm (bottom) of the bellcrank and is padded out with washers to ensure correct



Chapter 5, Rev1                             Pitch Controls                                    Page 5-13
                                                                    Just Aircraft, LLC

clearance. Sequence from top to bottom: bolt goes through the bell crank, 2 washers, rod end, 2
washers, bell crank, washer and nut. See Figure 5.4.9a.

REVISED 6-28-10
STEP 13
Fit a AN-316-4R nut and F-1330 rod end bearing to the forward end of the short push pull tube F-1440.
Insert the push pull tube through the 2 rear nylon bushings then fit a AN-316-4R nut and F-1450 fork
end on the rear end.



Secure forward end of push pull tube to the bellcrank with AN-4-11A bolt (as per long tube
instructions).




STEP 14
Before securing the clevis fork end F-1450 to the elevator horn fit the brass bushing (F-1470.4) into the
elevator horn (previously reamed in readiness) and then attach the fork end securely to the elevator
horn with AN4-7 bolt. See Figure 5.4.14.




              Figure 5.4.14




STEP 15
With the pitch control run fully assembled, check for full and free movement of the stick and control
run. The control run must be free enough for elevator to drop to the full down position when the stick
is released. The roll control should also be checked for full and free movement, but this can only really
be done during final assembly with the wings on etc. It is also advisable to check that the range of

Page 5-14                                   Pitch Controls                              Chapter 5, Rev1
Just Aircraft, LLC

elevator movement conforms to 28° UP and 28° DOWN + 2°; adjust the lengths of the push/pull tubes
to achieve this.

Revised 6-28-10




Chapter 5, Rev1                          Pitch Controls                                 Page 5-15

				
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