       Working on Chpt 10 - Canard Construction updated: 19/08/2008
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I decided when I was still working on the fuselage back in Chapter 7, not to follow the plans method for the Landing gear cover, but to use Wayne Hick's method for making and attaching the cover instead. It seems far easier and more logical than the plans method. At this stage of the build I ordered my 2nd 30kg kit of MGS 285 Epoxy from IronBark Composites in Melbourne, I still have about 5l left before I run out. I started by cutting 3 pieces of white 2lb density Poly Foam - Wicks part No. F100-035 and force fitted the 3 pieces into the Fuselage bulkhead slot. I marked the position of the foam pieces, removed and microed them together. When the mirco was cured, I forced the foam block back into the bulkhead slot for sanding.
With the shaping of the foam completed I applied 2" wide packing tape along the seams of the cover and the fuselage, 1" over the cover and 1" over the fuselage. Using the same method as detailed back in Chapter 7, page 2, the inside of the NACA scoop was microed and then covered with 2 plies of BID. After cure the sides were trimmed level with the top of the foam and a flox corner was made along each side before applying another 2 layers of BID from the NACA scoop to the leg openings.
07/01/2008 - After the Christmas break I got stuck back into finishing off the Landing Gear Cover. I removed the Cover from the Fuselage, trimmed the sides level with the foam and sanded the foam down to an overall thickness of 3/8". The ends were also profiled to match the landing gear legs. When I was happy with the fit I then glued mixing sticks to the cover, using 5 minute epoxy, to keep the cover level with the fuselage. Using Bondo I then fixed 2 support sticks across the outside of the cover, to prevent warping or distortion when glassing the inside of the cover.
The inside of the cover was glassed with 2 BID plies. After cure I removed the 2 support sticks, trimmed the edges and fitted it back into the fuselage. The fit was perfect with no warping or distortion. The inside edges of the cover were taped with 2" wide box tape before placing the cover back into the fuselage. The mixing sticks glued onto the cover earlier, were then Duck taped onto the fuselage, to hold the cover in place when the fuselage was turned over to make the inside lip. I decided to make the 2 inside lips on the landing gear bulkheads from 4-ply BID strips, instead of the the 6 plies mentioned on Wayne's website. I laid up the 2 BID tapes, 2 plies at a time and found that this worked well for me and had not real issues with the tapes following the 90° bends along the face of the LG Bulkheads. I completed both sides in about 2 hours. After cure I removed the cover and trimmed the lips back to about 3/4" wide and was satisfied with their general stiffness and strength.
I marked out the 16 locations for the Nut Plates and screws for the cover, drilled and countersunk all the holes. I used the same screws called for in the plans, MS24694-S50 and purchased matching Nut Plates to suit - MS21069-L3. I also had to purchase a 1-1/2" 360 DEGREE Rivet Squeezer and Yoke with a 6 piece Rivet set to complete the job. This was obtained from Western Airmotive at Jandakot for AUD$324.50. Due to limited space next to the Nut plates, I selected and used the 2 1/2" Flush Style rivet sets - AN470, with the Squeezer to complete the riveting. The clearance notches for the landing gear access were then cut into the lips. The placement of the 2 middle Nut Plates on the FWD bulkhead lip could have been placed better, thereby making more room for the cut out. I would recommend cutting the notches first before drilling and fitting the Nut Plates. To finish off I taped the edges of the Cover with electrical tape, refitted and filled any gaps between the cover and fusealage with micro. After cure everything was sanded smooth and I was very happy with the final finished product. Now onto Step 5, time to fit the axles, wheels and Brakes. This Chapter just seems to go on forever!!!! Back to Step 3 ½ HOME ½ Step 5 |
