Tri-R Technologies  TR-4

BUILDER'S MANUAL

This Builder's Manual is NOT the official manual as published by TRI-R Technologies.  

SPAR PREPARATION

LEVELING AND FIXTURING
SPREADER STICKS
TEMPORARY FITTING OF THE FUSELAGE TOP

FIREWALL
FIREWALL FRONT FACE
ADDED REINFORCING IN FIREWALL AREA

STATION 139.5 BULK HEAD
STATION 180.5 BULKHEAD

MAIN SPAR AND OUTBOARD SPAR PRE ASSEMBLY
REAR SPAR
MAIN SPAR LOCATION AND INSTALLATION
POSITIONING
SPAR MOUNTING LAMINATIONS

MAIN GEAR BOX REINFORCEMENT
SEAT FRONT BULKHEAD & CONTROL MOUNT
FUSELAGE BELTLINE CONDUITS
FRONT SEAT BACK ASSEMBLY
REAR SEAT BACK INSTALLATION
CONTROL CONSOLE - FRONT SEAT AREA
ELEVATOR IDLER BELL CRANK
SEAT BOTTOM ASSEMBLY
FRONT SEAT
REAR SEATS

FRONT FLOOR ASSEMBLY
STICK LINKAGE ASSEMBLY
FLAP HANDLE ASSEMBLY BRACKET
AILERON IDLER INSTALLATION
FLAP ACTUATION TORQUE TUBE INSTALLATION
RUDDER IDLER LEVER INSTALLATION

HORIZONTAL STABILIZER
INSTALL RUDDER POST

ELEVATOR AND PUSH/PULL ROD INSTALLATION
RUDDER CABLE ROUTING AND INSTALLATION
MAIN GEAR INSTALLATION
BRAKE LINE INSTALLATION

FIN RIGHT HALF INSTALLATION
INSTALL LEFT FIN HALF
HANGING RUDDER
INSTALLATION OF FUSELAGE TOP
BAGGAGE AREA BACK PANEL

DOOR PREPARATION
WINDOW INSTALLATION
DOOR LATCH ASSEMBLY
MOUNT DOORS
LATCH PLATE INSTALLATION
AIR STRUT INSTALLATION
REAR WINDOWS

INSTRUMENT PANEL
WINDSHIELD

FIN RIGHT HALF INSTALLATION

The fuselage upper section should be temporarily installed for fitting the fin halves to the fuselage lower section.

• Carefully locate the center line in the aft edge of the fuselage top section, and mark it for reference during the procedure below. The fin half joggles will go below the top section aft edge, and on top of the bulkhead in this area.

• Select the right side fin half molded part from the kit, and dry fit the part to the appropriate position on the fuselage assembly, using the previously drilled holes and clecos or small sheet metal screws (slipping the edge below the aft edge of the fuselage top).

• Note any areas which may require added trimming, or filling, and mark and trim as required (do not trim the trailing edge flange, where the rudder will be installed at this time, this will be trimmed after laminating to the rudder post)

• The bulkhead may have to be trimmed or built up with dry MICRO to assure a smooth line through the fuselage top to fin joint. This bulkhead can be built up with dry MICRO by taping off the bonding inner surface of the fin half and pulling the fin half section up against the fuselage top inner surface with sheet metal screws or clecos. Tape over the open area on one side of the gap and fill from the other side with dry MICRO. Allow to harden, and the separate the surfaces and grind away any surplus, and roughen bonding areas.

• Clean and prepare all areas which will be involved in the bonding operations (the joint to the fuselage, and the area which will be bonded to the rudder post) Particularly check the relationship with the rudder post such that neither part will displace the other, and check the fit up for bonding.

• Also check the fit of the other fin half at this time, also using the pre drilled holes for location and mounting. Remove the other fin half if required to get a good fit with the top of the STA 139.5 bulkhead and trim or adjust as with the other fin half, as required to assure proper installation later. After assuring that there will be a good fit in subsequent bonding, remove this part and set it aside .

• When you are satisfied with all fit up procedures and are ready to bond the fin halves into place, prepare and "butter" on the adhesive ( wet FLOX can be used for this bonding operation) on both surfaces, at all bond areas, including the edge of the standing rudder post.

• Secure the parts in place with the screws and/or clecos and any other clamping or taping that might be required. Remove the screws or clecos when the adhesive is in the ''rubber" state.

• Cut out the front rib/spar, and the large fin rib from the Pre marked panel, and fit them to the fin half profile in the location as shown in the figure XXX.

• Prepare the inner surface of the fin half, and the surfaces of the cut out parts, for bonding. Tack the rib/spar and rib in place with 5 minute epoxy. Recheck with other fin half, and trim these ribs if needed to avoid pushing the fin out of shape, and to provide for a good bonding fit.

• Bond the front rib/spar and the large rib to the inner surface of the fin with two inch wide two ply pre wetted BID. The rib is installed parallel to a horizontal line and rests on top of the front rib/spar at the front end (see figure XXX).

• Bond the rib in place, also using two inch wide, 2 ply BID tape. Trim the right side vertical fin trailing edge at this time, using the scribe line on the molded surface. This line should extend about 3/4 inch aft of the fuselage length.

• Temporarily mount the rudder to the edge of the fin molding (clecos or small screws through the hinges).

• During this temporary installation of the rudder assembly to the rudder post (spar), the location of the rudder bell crank shall be verified. This rudder bell crank appears lopsided at first glance, but the system pivot plane is along one edge of the rudder. Ensure that the height of this bell crank will not result in any interference between the rudder cables and the elevator horn.

• Be sure that adequate adhesive is applied (surplus will be squeezed out and removed later). Mount the part and install clecos or screws to close the joint adequately. If any areas buckle apart adjust the clecos or screws on each side, and add additional fastenings if required to close the entire joint line.

• Clamp the fin half shell and the rudder post together to assure good fit up between those components, and install a 2 in wide, 2 ply BID tape between the forward surface of the rudder post, and the inner surface of the fin half .

• Clean off any adhesive which squeezes out to minimize sanding at a later time.

• Join the inner surface of the vertical fin to the upper surface of the horizontal stabilizer with 4 ply BID with a roughly 3 inch overlap.

The fin vertical spar structure is primarily provided by the multi layer wet BID bonded to the back surface of the tail post, and up the inside surfaces of the fin sides.

• Three layers run the entire vertical length of the tail post. Make sure that the side plies in this "U" section are laid in smooth and flat to avoid unnecessary bulk in this area where the rudder hinges will be installed.

• Four more plies shall be added in the hinge areas (about 1 inch past the length marks previously noted), covering the total flange within this zone, and overlapping about a half inch on to the tail post area.

• Green trim the surplus material extending past the fin skin.

• Check condition of the adhesive as it cures, and remove the temporary fastenings while the adhesive is still rubbery. Make sure that the adhesive has the required strength to maintain the bond, but not so hard that the fasteners cannot be removed (heating the temporary fasteners can aid in their removal).

• Mark the location and length of the rudder hinges on the outside of the fin half. These marks will be used later to locate local reinforcement for the rudder hinges. Remove the temporarily installed rudder and proceed with the fin assembly process.

IMPORTANT- IMPORTANT-IMPORTANT. The VHF comm. antenna should probably be mounted inside the vertical fin at this time. This antenna is not included in the kit and can either be a commercial unit, or one of the numerous built-in Units that are marketed for home builders. Arrangements are being made to offer a kit for this as a low cost option, so it would be a good idea to contact Tri- R Technologies before this operation is scheduled.

INSTALL LEFT FIN HALF

• Dry fit the other (left side) fin half in the same manner as for the right half, with special attention to the fit-Up with the ribs and tail post as before, and follow the same preparation and bonding procedure, except the ribs and internal structure will require special preparation for bonding at this time.

• Remove, or crush back the honeycomb core for about a 1/4 inch depth along all the panel edges which will be bonded. These recessed areas will be filled with a thick FLOX mixture during the bonding operation.

• Temporarily position the fin half to transfer some of this FLOX to the mating areas . Remove the fin half, and using the transferred mixture as a guide, coat these areas with additional FLOX, as well as adding adhesive to the obvious bond zones.

• Reassemble and bond the fin half in place (wipe away any excess adhesive that may be squeezed out of the joints) The top of the fin is left open at this time. Paper tape is suggested on the leading edge to help hold all components in position during this gluing operation.

• Apply four plies of BID to join both fin halves to the upper surface of the horizontal stabilizer. The best procedure to follow is to lay an initial two ply strip 6 inches wide (3 inch overlap on each side), followed by a 5 inch wide and a 4 inch wide. This will provide a tapered surface patch for easier smoothing and painting As in all previous inside angle joints, provide a MICRO fillet radius in the corners. Make sure the surfaces are roughened and cleaned prior to applying the BID.

HANGING RUDDER

• Install the rudder in the same location as the previous temporary installation The right side flange of the rudder post channel section shall be drilled for mounting the hinges. Drill holes to match the hinges, and use countersunk head screws with the counter sunk Tinnerman washers, and elastic stop nuts on the inside.

• Verify the required travel, and trim any areas of interference. Check the actuation rod length for proper rudder position with the rudder pedals centered. Verify that this rod and the rudder can be cycled through their full travel without interference or undue binding on any structure.

INSTALLATION OF FUSELAGE TOP

The top fuselage section should be final installed after both fin halves have been bonded in place.

• Carefully dry fit the top molded section, verifying the trim line of the top half is installed aligned to WL -1.25 (-1 ¼"), which is the bottom of the joggle in the bottom fuselage molding (Remember that WL 0 should be the top trimmed edge of the fuselage bottom half, resulting in a 1.25 inch overlap on the bond line).

• Prepare the bonding surfaces (of both parts) by roughening with coarse sand paper, and cleaning away all traces of parting compounds or oily residues with MEK or acetone.

• Drill alignment holes for clecos or other temporary fastenings such that the bond line will be continuously clamped without buckles or gaps. CAUTION - DO NOT DRILL TROUGH THE Graphite (BLACK) STRIP ALONG THE BELTLINE OF THE LOWER FUSELAGE HALF SINCE THIS IS A MAJOR STRUCTURAL ELEMENT.

• Mark the ends of the bond area length on the lower fuselage molded half, for reference in applying the adhesive.

• Separate the halves and mix the Hysol adhesive, or epoxy FLOX, according to the appropriate material instructions, "Butter the adhesive on the outside of the lower fuselage, and also on the inside of the upper fuselage section, in the bond areas (directly above the joggle line to the previously marked length).

• Replace the top molded shell, using care to keep from scraping away the adhesive in any areas. It is recommended that a helper be enlisted for this operation since it is realistically at least a two person job. If the adhesive is scraped away from any of the bond areas pry that section of the joint apart and work adhesive into the area.

• Replace the Cleco' or screws to clamp the joint together. Observe that adhesive is squeezed out in all areas and wipe away the excess before it cures.

• Remove the clecos or temporary screws when the adhesive has cured to a rubbery stage, (heating the screws or clecos with a soldering gun can be an aid in removing them if the adhesive has hardened too much).

• Use spreader bars to maintain fuselage contour, and double check all work.

• The horizontal stiffener on the seat back of the rear seat, (which was set aside early in the seat installation) may now be installed and bonded to the seat back, and the lower fuselage shell with 2 inch wide 2 ply pre wetted BID. Fill the joint between the ends of this stiffener and the upper fuselage shell with a dry MICRO fillet, and bond the seat back stiffener to the upper shell with 4 ply BID. provide at least a 2 inch wide overlap on the seat back stiffener, and 4 inch overlap to the fuselage upper half.

• The upper sector of the STA 139.5 bulkhead should now be bonded to the fuselage upper half with 2 inch wide 2 ply BID bias tape, both front and back (this bulkhead was similarly bonded to the lower fuselage half at an earlier stage, and this completes the tie in). As in other similar bond operations a dry micro fillet is worked into the joint before taping.

• The upper half of the firewall should also be bonded to the fuselage upper half at this time. Use 2 inch wide, 2 ply pre wetted BID on the forward surface, and a 3 inch wide 2 ply BID for the inner joint to assure an over one inch overlap on both surfaces. As before, use a dry micro fillet on the inside corners to assure joint integrity.

BAGGAGE AREA BACK PANEL

• The baggage area back panel is totally non structural, and shall be removable for maintenance access to the rear of the fuselage . It is to be fabricated from locally obtained materials and must be light weight, but sturdy enough to prevent items stowed in this area from migrating back in the fuselage.

Baggage area tunnel

The area established behind the seat back up to the baggage bulkhead will become the baggage area, and it is mandatory to avoid any items carried in this area interfering with the control components which pass through this zone. The primary components of concern in this area is the elevator push-pull tube assembly, and the associated idler on the seat back, and the rudder cables which should be exiting from the seat back at the edges of the console assembly. Jamming any one of these items with a carelessly tossed item of clothing or luggage could be a major flight safety issue.

• Fabricate an inverted "U" shaped "tunnel for this area which is just a bit wider than the console, to clear the cables, and just a bit higher than the push rod idler at the forward end ( height can be reduced as you go aft if desired).

• Unless you have sufficient panel stock remaining, select a suitable section of locally procured material such as light plywood or door skin. Layout the pattern as shown in figure XXX, to protect the appropriate control linkages.

• Cut a pair of grooves along the "fold" lines on the inner surface of the panel and fold it into a "U" shape. Bond the inside corners with wet micro and tape the inside and outside of the corners with a single 2 inch wide strip of BID at each location (see figure XXX).

• Make four "L" brackets out of 3 ply bid laid up as an angle strip (using an aluminum angle or a strip of wood covered with plastic tape as a mold will simplify this procedure).

• Bond these to the floor such that they will sit inside the tunnel. Install the "tunnel" over the control components, fasten it to these "L"s with self tapping screws so it can be readily removed for any required maintenance on these components.