Step 1. Landing Gear
Bulkhead Reinforcements |
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7/3/05 New shop Set up the new workshop
in our new house in Florida. Went from a 2-car to a 3-car
(1-plane) garage. Much nicer! |
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7/3/05 Reinforcing layups Here are the
reinforcing layups on the front LG bulkhead. |
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7/6/06 Reinforcing layups ...and on the
rear LG bulkhead. The reinforcements for the middle are done also,
just not shown here. |
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Step 2: Preparing the
Strut for Installation |
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7/9/05 LG Strut To get the 8-degree
incline, I cut a board at 8-degrees for reference. |
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7/9/05 LG Strut I put a mark on the top
of the strut at where it measured 95", lined up the 8-deg board to that
mark, and drew a line. |
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7/9/05 LG Strut The resulting 8-degree
line drawn on the strut. |
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7/9/05 LG Strut I secured the strut to
the work bench with a long 2x4, to keep it steady while I cut it. |
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7/9/05 LG Strut At first I tried to use
the jig saw, but it got so hot that I couldn't use it for more than a
few seconds. Once I had the cut deep enough I switched to using
the hacksaw. The cut was much faster an easier with the hacksaw,
but I was worried because the blades are so flimsy, that they wouldn't
keep a straight cut. |
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7/9/05 LG Strut But as you can see, the
cut came out nice and straight. |
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7/9/05 LG strut layups The strut raised
on nails on the workbench, ready for glassing. |
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7/9/05 LG strut layups I measured out the
UND at the correct angle, drew cut lines, and taped it off with
painter's tape. This ensured that the UND fibers kept straight
while waiting for their turn. |
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7/9/05 LG strut layups The first 4 plies
of UND are drying. It's the end of a long day. |
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7/10/05 LG brake line This is 3/8" OD
vinyl tubing. The painter's tape is keeping it straight and in
position while the 5ME dries. |
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7/10/05 LG brake line The 2-ply BID tape
is in place over the brake line, against the aluminum tape. Many
builders reported using something different from the alum tape, but I
found it easy to work with and strong enough for this purpose. To
each his own I guess. |
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Step 3: Attach Tabs &
Installation |
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7/14/05 Attach tabs Leaned the strut up
against the table, made the appropriate marks on the plywood board and
floor, and shimmed the strut level. The 2x4 on the floor in front
of the strut ensures the LE is the correct distance in front of the
board. |
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7/14/05 Attach tabs Ensuring A is level. |
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7/16/05 Attach tabs The jig box fit in
place and level. |
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7/16/05 Attach tabs The box is done, and
the strut is on the table (with appropriate lines drawn for the FSs on
the table). Perfectly level with no adjustment! Though I did
have to shim the back of the box a bit, to get the LE lined up with FS
108.25. |
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7/16/05 Attach tabs 25 plies of UNI and
20 plies of BID, drying. I had no trouble with the clamps causing
the plies to slide around, as described in the FAQ. |
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7/17/05 Attach tabs I made a small round
jig to help ensure a good, round tab. |
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7/17/05 Attach tabs The outside tabs have
been finished. |
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7/17/05 Attach tabs In preparation for
doing the insides of the tabs, I put down some packing tape. This
will make it easier to cut the glass away from the strut, trim with the
tab. (Lesson learned from the outside tabs.) |
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7/17/05 Attach tabs Inside tab layups are
done, clamped, and drying. |
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7/26/05 strut install This is the trial
fit of the strut. I still don't have the 1/4" aluminum for MG-1,
so the full install won't be for a little while. I drew the FS
lines on the floor to check the position of the LE, and found that it
was just a bit forward. Will adjust some more later, before
installing for real. |
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7/26/05 strut install It is, however,
perfectly level, which is very cool. |
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8/09/05 attach tabs Cut holes in tabs
with the 3/4" counterbore. Had to sand the holes a bit with a file
to get the rods to fit. |
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Step 4: Landing Gear
Cover |
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7/27/05 LG cover Here you can see the
duct tape and shelf made for the LG cover. |
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7/27/05 LG cover The 3/8" PVC foam cut
and in place for the cover. This part was fun! |
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Step 5: Installing
Axles, Brakes and Brakelines |
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Step 6: Constructing
the Landing Brake |
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7/31/05 Cut LB loose Not the cleanest
cut. You can see some places where the 5ME just didn't want to let
go. |
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8/12/05 Sanding LB LB-23 is installed.
This shot is after sanding 1/8" deep into the foam and radiusing the
corners. |
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8/12/05 LB I started to cut out the hole
for the LB, but decided to wait until I've received the LB actuator from
Wayne Lanza. So this part is on hold. |
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9/11/05 Landing brake Glassing the inside
of the LB. |
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9/11/05 Landing Brake Plastic covering
the LB hole, so that when the LB is put back in place it doesn't cure to
the fuselage bottom. |
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9/11/05 Landing Brake Floxed the hinge in
place (which would detach later), and weighted down the partially-cured
LB. |
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9/13/05 Landing Brake Some boards are
called to service to hold the LB in place while I drill and tap holes
through the hinges to bolt it in place. |
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9/13/05 Landing Brake Hinge bolted in
place. |
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9/4/05 LB-18 brackets These turned out
nice. |
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5-16 Axle attach At this point the strut
has been trimmed to make room for the caliper, and the 2-plies BID have
been attached. I used a laser level to the mark on the wall
(visible in the background), rather than the tube sighting method
described in the plans. |
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5-16 Axle attach Another view of the axle
drying in place with the marks on the wall. |
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5-17 The tires have been installed on the
wheels, and are waiting for the axles to be ready. |
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5-17 Wheel attach The plane is on its
wheels! The brake line has been run on the inboard side up to the
conduit... |
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5-17 Brake lines ...and inside through
the fore LG bulkhead.
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5-17-07 Wheel install A farther view of
the plane on its wheels.
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5-17 Gear box closure Trial fitting the
foam for the top of the gear box. |
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5-17-07 LG box cover Getting ready to
glass... |
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5-18-07 LG box Drying in place. |
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