Chapter 10 & 11 – More stuff

I started off today by knocking out the small 1-ply BID layup that sits just inside the swoosh tip on each end of the canard.  The Roncz canard plans states to create a flox corner around the perimeter of the foam and then layup the glass.

Personally, I would have preferred to have this “mini root rib” set back a little bit somewhat like the front inboard rib of the wing, with a little bit of an edge with the vertical wall of this layup sunk back from the edge, say a 1/2″ or so.  The problem is that this adds a little more time to the layup, and since I’m not sure if I would be adding to some kind of drag here or something else negative, I simply pressed forward with the plans version of this layup.

I cut a little trough around the hinge pin tube since there wasn’t a lot of meat or mass holding them into place on either side.   Also, once I put the flox in the corners, there was about 1.5 square inches of foam left so I simply finished out the tiny bit of flox I had left by using it to surface prep the foam vs. spending the time to mix up micro.  I KNOW!  The weight I added by such reckless building should be noted!  (Read: sarcasm!)

Inboard edge layup of right swoosh tipInboard edge layup of left swoosh tip

Next I focused on the elevator weights.  But before I actually installed any weights I weighed them to better match them up for total weight on each side.  All told there was a difference of 13 grams from one side to the other.  The blue tags on each weight is the actual weight in grams of that lead piece.

Elevator weights … weighed

I mocked up the right elevator to get all the parts synched up, and then started cutting the tough 6 lb. yellow foam.

Attaching outboard elevator weight

I put tape over the jigs to keep them clean and also enable removal of the weight assembly once it’s floxed to the LE of the elevator.

Prepping jig for outboard weight

I then prepped the elevator by giving it an extra good sanding in the area that will get the 2-ply strip of UNI holding on the outboard elevator weight.

OUTBD elevator glass prepped for weight

Once all the prep was complete, I floxed the elevator weight in place (I surrendered my 5-minute glue here in Virginia when I moved to Germany and never seem to get around to picking up another bottle).

Outboard elevator weight added

While the elevator weight flox was curing, I traced the remaining Vortilons onto the 4-BID sheet I had just laid up.  I then used a jig saw to cut them out (last time I did it by hand with a coping saw).  When I traced them I used a Sharpie to make thick lines, so they’re cut just a hair oversized.  I’ll dial in the exact shape when I go to install them.

VortilonsVortilons cut

I then went back to work on the hinge pins.  The right pin needed to be cut shorter since I had already made the notch for set screw and didn’t like the way that every time I moved the elevator in a distinct up or down fashion the flat tip flagged out past the canard tip glass into the airstream.  I went back and looked at the plans again, and what I had looked pretty darn close to the diagram.  However, to be fair the plans do say to keep the tip out of the airstream.  So I simply cut it shorter & redrilled the 1/16″ hole more inboard.

Regardless, here are the two functional hinge pins.  I still have to clean them up to beautify them, but besides their need for a surface makeover they work as designed.

Hinge pins rough finished

Also, here’s a shot of inboard swoosh tip layup after I knife trimmed it.   The other side looks pretty much the same.

Inboard layup razor trimmed

As I was working on other stuff, I noted that this was the first time I had seen the canard in this state: elevators removed and the hinge tabs showing.  Something different so I snapped a pic.

Shot of hinge tabs on canard

The plan for tomorrow is to simply finish all the number of little jobs that will get Chapters 10 & 11 into the history books.  I’ll finish adding the elevator weights and cut the slots into the canard for the outboard elevator weights, glass those slots, etc.


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