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updated: 09/05/2022
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20/06/2007 – In this chapter the main moulded S-glass Landing Gear strut, purchased from Featherlite and the Landing brake are installed. Attachment tabs are added to the strut, so that the gear can be bolted onto the fuselage. The wheels, disc brakes, brake lines and brake fluid reservoir are also installed. My landing brake will be electrically operated and I will need to custom make the mounting bracket for the motor. This is a lengthy chapter, so I have added links to the various sections below:- Step 1 – Landing Gear Bulkhead Reinforcements Step 2 – Preparing the Strut for Installation Step 3 – Attachment Tabs and Installation Step 5 – Installing Axles, Brakes and Brake lines Step 6 – Constructing the Landing Brake
Step 1 – Landing Gear Bulkhead Reinforcements The forward face of the FWD bulkhead is reinforced on both sides with 5 plies of BID at 45° fibre orientation as shown in Fig 1 of the plans (2 different sizes). I set-up my table again on the trestles and placed the fuselage back onto the build table and lowered the legs to the lowest position to save my back whilst working one these 3 difficult areas. I then started by cutting the corner off the end of the doublers, rounded all corners with micro and sanded all surfaces. I also marked with a pencil where the 2 lay-ups would be going. I did not make a pattern as suggested in the plans, but instead laid up the 3 layers of BID onto grease proof paper, at the table and then placed the wetted out glass into place, followed by the remaining 2 layers over the hard points. This seemed to work OK for me and I didn't have too much trouble getting all the air out of the lay-up. It took me more than 2 hours per side to complete the Fwd bulkhead lay-ups, so I tackled one side at a time. The next day I found that an air buddle had formed along the side of one of the doublers about 1" long by 1/2" wide as can be seen in the 2nd photo. I will have to repair this by drilling a hole into the buddle and filling with epoxy.
I then turned the fuselage onto its side, so that I could get better access to the area between the Bulkheads and again adjusted the table legs to a height that would not kill my back. As above all surfaces were sanded and prepared for glassing. This time I did follow the plans recommendations and made a paper template of the inside area to be glassed. This seemed to be a difficult area to cover and I included a dart to allow the glass to fold properly without lifting. The 3 pieces of BID were cut exactly to the same size as the template and again were wetted out on grease proof paper. I cut the dart as per template before fitting into place. I was very happy with the final finish and completed both sides, including the 2 BID lay-up over the hard points in about an hour per side.
To complete the reinforcement lay-ups between the aft landing gear and firewall, I turned the fuselage upside down and again adjusted the height of my table. I rounded the outside corners of the foam, sanded all glassed areas, vacuumed, microed the foam and radius all the inside corners with micro. I made a paper template and the 3 pieces of BID were cut exactly to the same size as the template and again were wetted out on grease proof and laid into place as one piece. Overall I was quite happy with the final finish, it was just very frustrating trying to work in such a small space. |
