Tri-R Technologies  TR-4

BUILDER'S MANUAL

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


HORIZONTAL STAB AND ELEVATOR

IDENTIFY PARTS - (figure 3-1)

CUT APART STABILIZER AND ELEVATOR SECTIONS

PREPARE FOR ASSEMBLY

A large square will be handy during the next steps.

 

HORIZONTAL STABILIZER JIG

Using the templates provided in the drawings (TR4-H2) fabricate the jig components from 1/2 inch plywood or particle board.

Figure -3, Horizontal stab jig showing skin mounting location.

NOTE - YOU WILL BE BUILDING THE STABILIZER UPSIDE DOWN IN THIS JIG.

Figure -4: top skin mounted to jig. Spar installed. Ribs ready to install.

PREPARE AND FIT RIBS - (figure 3-4)

 

INSTALL SPAR - (see figure 3-4)

INSTALL RIBS - (figures 3-5 and 3-6)

Figure -5: Spar and Ribs installed.

Figure -6: Radius and prelam as shown.

 

FITTING AND INSTALLATION OF BOTTOM SKIN

Final fit the bottom skin of the horizontal stabilizer to the ribs and spar by carefully sanding the ribs to size using the bottom skin as a guide. Take your time and try not to over sand the ribs. The closer the fit the better. Do the next step before finishing the sanding of the ribs and spar to help in the fit up.

Figure -7, Bottom skin bonded and weighted into place.

PREPARE HINGE ATTACH AREAS

The elevator hinges are mounted on the upper skin, (still in the assembly jig), since this maintains a straight line. The lower skin aft edge is angled (peaked at the center of the stabilizer {BL-0}) and the resulting geometric error would cause binding if the hinges are installed on the wrong (skin) edge.

Figure -8, Hinge pre lam reinforcement. Note screws holding wing skin to spar.

CLOSE OUT TIPS

You will notice that the tip cavities are open and the two surfaces are not joined at the tip.

Figure -9, Horizontal stab end showing relief for flox fillet.

 

ELEVATOR CONSTRUCTION

Construction of the elevator is performed somewhat like the stabilizer except that it is best to prepare the selected metal parts, prepreg and phenolic spar pieces, and prepreg ribs prior to starting. Verify that the peel ply and other debris have been removed front all molded parts used in this assembly.

CUT OUT AND PREPARE RIBS AND SPAR SECTIONS

NOTE - THE ELEVATOR ASSEMBLY WILL ALSO BE FABRICATED UPSIDE DOWN

CUT AWAY THE FOAM IN TRIM TAB HINGE JOINT AREA

Figure -10, Trim tab cut away.

 

SPAR LOCATION

Sand the area within two inches of these lines with 80 grit sandpaper and remark for easy identification.

Figure -11, Spar showing phenolic block.

Figure -12

 

LAMINTATING SPAR AFT FACE

All the following procedures should be done in one session.

Figure -12, Pre lam on spar aft face, covering phenolic block.

Figure -13,BL- 4.5 rib showing bend location and alignment.

Figure -14, Trim tab spars installed, ribs cut to fit.

Figure -15, Prelam ribs into place as shown.

Figure -16, Foam bulkhead.

Figure -17, Ribs and spars installed.

 

FIT AND INSTALL BOTTOM SKIN

The bottom skin may now be added. Take plenty of time to make sure that the bottom fits properly on top of the spar, ribs, and trim tab spars. Remember the foam must be cutout for the trim tab. No doubt some areas will have to be relieved with a sanding block to permit a good flush fit of the skin at all the joining edges.

 

CUT TRIM TAB SURFACE LOOSE

Figure -18, Trim tab separated from elevator.

 

HINGING TRIM TAB

Figure -19, Trim tab horn. Holes at bottom are for bonding.

Figure -20, Side view of trim tab horn installation.

Figure -21, Horn installed into trim tab.

MOUNT ELEVATOR CONTROL HORN

Figure -22, Elevator horn installed.

 

HINGING THE ELEVATOR

Figure -23, Drill jig for hinges. (also used on wings and rudder)

Figure -24, Straight edge check of hinge alignment.

Figure -25, Mass balance close out

Figure -26, Shaped end of mass balance.

MASS BALLANCING

You are now ready to mass balance the elevators.

Figure -27, Mass balancing elevator.

When the aircraft tail section is complete you will see that the elevator needs to be split in order to install or remove it from the aircraft.


Construction of the horizontal stabilizer and elevator assemblies are completed.