Ideas for those still building

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Ideas for those still building

Postby gkremers » Sun Aug 17, 2014 2:36 pm

During my build I asked tons of questions and looked at this site often for ideas, tips and tricks others posted. I'm going to post a few of the them here, some are my ideas and others were shamelessly stolen from others.

Many of us decided to use a Ray Allen servo for the elevator trim. Steve D posted a pic a couple of years ago that simplified the install of a fiberglass cover. The cover itself is not that hard, I used blue foam to get the correct shape and then covered with 2 layers of 9oz glass. I decided on the T2-7A servo, it has plenty of throw and is controlled with a coolie hat on the grip.

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9oz glass over the shaped foam


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Cover before filling and sanding for paint


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Brackets to simplify mounting the cover (Stolen fro Steve D)


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Final install
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Re: Ideas for those still building

Postby User GDS » Sun Aug 17, 2014 2:45 pm

Until recently I wasn't interested in the electric trim, I like the simplicity of the cable system. My cable is starting to have some resistance and when I'm light in the tail, I don't get enough nose-up-trim. Thanks for the pictures, I'm putting it on my list for the next annual.
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Ideas for those still building

Postby gkremers » Sun Aug 17, 2014 2:46 pm

I wanted a little more room for the access cover back by the elevator control horns. My openings droop down which gives you additional room to get to the bushings and bolts. The backing plate that the cover screws into is made from 4 layers of 9oz glass. To get the correct contour for the fiberglass I covered the area with 1 mil plastic, 4 layers of glass were used. Nutplates were then riveted to the backing plates. I've seen some planes that have removable plates that cover much of the fuselage area under the horizontal stabilizers, this would be another way to go and gives the addition benefit of getting to the tailwheel spring bolt.

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4 layers of glass and nut plates


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Backing plates covered (Stewarts System)


IMG_1416.jpg
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Ideas for those still building

Postby gkremers » Sun Aug 17, 2014 2:58 pm

I decided to use an invisible hinge on the oil door. One nice feature of this hinge is it is spring loaded to the open position. Once the Cam Lock is opened the door stays open and will flop around in the breeze. I always open mine after landing, it helps the heat escape, hopefully helping to cool the electronic ignition.

IMG_0910.jpg


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Bonding the doubler to the underside of the cowl.


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Ideas for those still building

Postby gkremers » Sun Aug 17, 2014 3:08 pm

The close out pieces between the flaps and turtle deck was something I knew I wanted. Rick posted a pic of his final product, that's what I tried to duplicate. I started with some cardboard templates to get the correct shape. I decided to fabricate small ribs to close out the ends.

IMG_0891.jpg
Templates


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Ideas for those still building

Postby gkremers » Sun Aug 17, 2014 3:18 pm

The firewall to boot cowl closeout was something I really wanted to change. The factory instructions have you use a piece of baffle seal. It works, it's simple but I wanted something more durable that would seal better and give the boot cowl more strength in that area. Troy posted some great pis of his Super STOL build, low and behold he did exactly what I wanted. I used his idea, added some nut plates so the boot cowl is now very strong in that area and is easily removed if needed.

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Fabricating the aluminum angle with nut plates. The relief cuts allow you bend the angle to match the shape of the boot cowl.


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The corners are too sharp to bend the angle. I used a shrinker to fabricate the corners, they also have nut plates.
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Ideas for those still building

Postby gkremers » Sun Aug 17, 2014 3:22 pm

Rick posed a pic of his under seat storage, no need to recreate the wheel, used his idea.

IMG_1134.jpg
I added sides and bent the aft end up 1.5" so things don't fall into never never land.


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Pained black and added fabric to the bottom.
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Re: Ideas for those still building

Postby Just Aircraft NZ Ltd » Mon Aug 18, 2014 5:37 am

Beautiful work. Those flap seals should really enhance the wing.
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Re: Ideas for those still building

Postby Johnny C! » Mon Aug 18, 2014 12:41 pm

Very nice!

I want to add an oil door & the flap
to fuse seals, as well.

Thanks!

John
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Re: Ideas for those still building

Postby jjacky » Thu Aug 21, 2014 3:54 pm

Thanks for posting this...Nice work and Good Ideas.
Plan not to be the first at the scene of the accident!
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Re: Ideas for those still building

Postby jjacky » Thu Aug 21, 2014 7:58 pm

Hi Again...I'm preparing to mount a Ray Allen servo and reread the installation info. In there it says "Ray Allen Servos can be mounted in any position, but they must be protected from water exposure." Have you had any moisture problems? I'm trying to think of how one would do this. From Ray Allen again "For most aircraft designs, the trim servo will be installed inside the control surface to control a trim tab" Damn...for some reason I got the impression that they were essentially water proof and could be mounted in the weather.
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Re: Ideas for those still building

Postby danerazz » Thu Aug 21, 2014 9:35 pm

You should be able to just mount a cover as above. As long as you can keep direct water exposure from spray and rain off it should be good (I.e. seal the front of the cover).
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Re: Ideas for those still building

Postby gkremers » Sat Aug 23, 2014 10:07 am

You can't see it in the picture but the cover has a small seal on the inside that compresses into the fabric.

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Re: Ideas for those still building

Postby alan » Mon Aug 25, 2014 3:43 pm

I had to replace my ignition modules a couple of years ago. That same year I saw all of the EuroFoxes at Sun&Fun with circular, screen covered, vents in the cowlings. I talked to a EuroFox rep and he told me it was to prevent fuel boiling after shut down. I have never had vapor lock but I thought, even before I saw these vents, that heat might be the cause of the module failures. So I made my own using light-weight aluminum screen, not window screen, from Lowes and fiberglass cloth and epoxy from Auto Zone. They are placed above the carbs, slightly off because the carbs aren't exactly even and I wanted the vents to be, well, you know.

Check these pics out.

Alan
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20130501_125331.jpg
All materials cut and ready. I doubled, crosswise, the black aluminum screen.
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Inside shot of finished product.
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Showing size relative to a copper penny.
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All done.
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Re: Ideas for those still building

Postby gkremers » Mon Aug 25, 2014 3:49 pm

Alan,
Anything you can do to let the heat escape after shutdown is a good thing for the ignition modules.

Nice job
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