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david.corbett5(at)btinter
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 Posted: Sun Jul 15, 2007 10:58 am Post subject: Mod 73 - some practical experience |
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Having received the Mod 73 instructions on Friday afternoon, I have spent the weekend working on 3 sets of tailplanes with the following results; Adrian Lloyd, my inspector, has been around all weekend, and has inspected at the relevant stages, and the owners have helped:
1 The aircraft are UK no’s 10, 76, and 265; 76 and 265 are on the airfield here at Shobdon, the tailplanes for 10 came by car.
2 Opening up all 6, ready for lay-up, was completed in 3 hours. We were surprised by the differences inside – apparently early classic models had TP6 positioned with the centre of the tube on the centreline of the ply bulkhead, so the pip pin holes are not half way along TP6.
3 All 6 tailplanes had strong flox bonds attaching them to the ply bulkhead, and none showed any sign of dis-bonding.
4 After opening up in the workshop, we moved down to the airfield and positioned the tailpanes for 76 and 265 onto the TP4’s of those aircraft as instructed.
5 I did not consider that grease alone would be sufficient release agent, and therefore on top of the grease I positioned a triangle of very thin polythene sheet – sheet that I had been using throughout my build to wet out lay-ups on, and then transfer the lay-up onto wherever it was required. In the context of Mod 73, this sheet is so thin that it does not increase the thickness of the grease – in fact, the opposite – and therefore the flox “lip” is not compromised.
6 Because of the shorter than expected length of TP4 showing through the dug-out hole on no’s 10 and 76, because of the factor referred to in 2 above, there was quite a gap between the bottom of the foam and the TP4 itself; this needs either a very stiff flox mix, (“outside” the runny flox mix on the TP4 itself) or an added fillet of foam, or both, because of the fairly severe stippling required to get the BID layers into place without any creases or air bubbles.
7 I worked on all 4 tailplanes at the same time yesterday; in retrospect, I would do 2 at a time in future.
8 Around the dug-out hole, we have to stipple down the 2 BID layers onto the sanded off skin; it was very hard work getting a satisfactory lay-up, and I support the thoughts of those who have commented that a flox joint would be better.
9 Today we returned the tailplanes for 76 and 265 to the workshop for inspection and then (tomorrow?) covering. We then found that 10’s tailplanes would not fit onto either 76 or 265’s TP4.
10 I have a short length of plastic pipe – almost the correct size – around which I had previously wrapped masking tape to give a good fit into my TP5 and TP6. We therefore wrapped one layer of the very thin plastic sheet around what would be the TP6’s band of masking tape and laid up one tailplane; this was successful, and after 4 hours I turned the plastic pipe, which immediately freed itself from the flox lay-up. I have now laid up the second tailplane for 10.
11 On all 6 tailplanes, the two layers of BID stippled down onto the sanded down 1” width of tailplane skin around the hole are already proud of the painted surface outside them; there are another two layers to be added when the holes are covered after final inspection, so there is going to be more sanding off of paint required (another 1” at least all round), and then lots of filler to blend the raised area into the existing tailplane surface. How lucky that this mod is on the under side!
12 So this is definitely not a “one day to cosmetic finish” job! Provided that I can get the last two tailplanes inspected tomorrow, I should get all 6 covered by the end of the day – some of the foam plugs are already prepared. Then the sanding and finishing has to be done…
I am lucky, because I had the aircraft, the materials, the workshop, and my inspector all on site. We have discovered that the job can be done away from the aircraft, but it is essential to be sure that whatever “insert” you use is a good fit, and is properly fitted with a good release agent.
I hope this helps, and does not frighten anyone off!
David
G-BZAM - UK 265
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richard(at)scarrhillalpac
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| Posted: Sun Jul 15, 2007 11:19 am Post subject: Mod 73 - some practical experience |
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David,
Did you find that the TP6 was loner in to the recess than others? below is a copy of my post from Saturday. This makes my recess finished at 60mm instead of 50mm.
" Starting the mod 73, as my tail planes are still in the workshop and not filled or painted; In I went with the knife.
I have found that the TP6 bush measures at 50mm from the face of the inboard side of the outboard rib. This puts it 10mm inboard more than the, instructions on the Mod 73 paper work, in turn will make the span wise diameter 60mm instead of the described 50mm.
Before I continue, I ask is anyone finding the same measurements?
I have checked the first instillation of the TP6 from the manual and I fine it is as it should be. "
Visit - www.EuropaOwners.org
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