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~~~ ~~1lding ~he f~iel.ge ~k~wn ab~1fiC~eaS~ t~~ ~engtn ot the ct~~tqi~$ we3.1 as the ~t~ek to $tio~ I'q&~.J 4Jt'torque iype. The lef\gth ~1' t;'i'tfmake up t~e elev.t9J?' h,v, 1ff(J ~. es~~p:J,i8he,after the reve~ser p.,m hayt b~~n ~~st~i~~;,

LoQ~ -\ f~g, .not~ to. ¥eFy s~9rt tub4 ~n~~i~l-d ~"down f~om the toP ~ongor~n ~.t~een s~a~ 24 .~P ~O, rh~sshort tube prevents the ~ta. 30 t~~e fro~ be~4in~ ~~geploads ~~useQ by the rear c.~~ne le~$.

In '::i,g, 3. not~ thetaiJ.spring fJ1gn~ bQlt cro~~memb.r.atst~t lQ2. The etO.sm,m~er is sho~ in FigJ below .nd ~s alot e~~ier to make. It 18 ~~5Q more ~cq~rate and '4~ier toposi~ion and weld.

:tn F:ig~4 'b~~~w we see a photo showing how th, ~Q" S~i, mem-geri ~~~ 'po ~,~gerQns are m~t~ed ~5 de~rees t~ prq4Y~e abette. JO~Qt wh~re th.se me~ber~ c~~e toget~.r. Tn~ pb9t~alsQ iiQQ.."S a Ing;i.ne moup~ SPGO'J. welq.~ in the c;cprp~1', moreab"ut thi$ .r. al~ter date, ~e IWit:l'. jqipt; is easier t(f",~1

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DON'T BOX YOURSELF IN AT THE TAILPOST

At the top righthand corner of Sheet 11 of the plansis an important note concerning clearance of the ele-vator horns between the two top longerons at the tail-post. This is a very tight area but with a little cau-tion taken during welding of the longerons to the tailpost there is adequate room.

Looking at the top view of the bottom truss(Fuselage)on page 2 of the plans t ~.e see the centerlines of thelower longerons intersecting the centerline of, the tail-post. This is absolutely OK so build this are.a accordingto the plans. However, we see the same lines for the toplongerons intersecting the centerline of the tailpostand this is where you can go astray. When cutting thetop longerons to meet the tailpost, do it as in Fig.5 below.

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INTER-MEDIATE PHASE

NEEPLE BEARINQ. MQUliTED TORQUE 1!lBE

The torque tube assembly is one of the frustrating items

over whi~h you can lose hair and sleep but it doesn't haveto be that way. Many a Skybolt and Starduster builder hasspent hours and days trying to free up the assembly after Ewas welded in the airframe. The metal to metal contact ofthe split tubular collars and all the mis-alignment due

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tur~ pe.rts that is, not our torque tube parts. Exces3ivewelding leads to distortion from heat and we want our fixtureas accurate as possible. Use a sh2rp steel scribe to markthe alignment lines or i~dex line on the fixture where wewant to position the various parts of the fixt~re.

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By now it is obv1oU8 tbat w. build the torque tube a~.'y\Ap.~d. dowl\ on the tixture.

In F1g.7 please note that ~h. bottom or the stick bootp.tt.!"n is st.railht instead of concave 2S shown in theplans. This gives us greater depth and consequently moreatick tr.v~l which 18 important s1nce w~ need 25 degr..stravel of the elevators UP and down. To build the assembly.8 ahown in the planSc, leaves us with little ro08 fer .ticktr.vel.

In making the front and rear s~ick rcd end brackets, drillaaly the 140 pilot holes in one end of the piece. Fig. 9,10,11. 12. Form the bracket around a piece of 51S~ coldrolled plate using the center line of the drawing to lineup the piece on the cold rolled plate. Bend one side 90delrees, drill a #40 hole through the cold rolled platethen bend the other side into a "U" shape and then drillthe 140 hole through this leg of the bend. This gives youan accurate hole that is perpendicular to the face of thepart. Use the #40 pilot holes to insert a cleco to hold thepatch plates in place when it is time ~o tack weld them. WeflDish the holes to .250 after all welding has been completedby drilling ~rl th a letter "C" drill and then reaming.

ID Fig. lJ and 14, the stick sockets are flattened cold us-1ng a plastic mallet or a leater mallet. Do not drill anyholes in these parts until all ~le.ldi~g has been complated .

F18. 16 shows the torque tube and the way it is cut to receivethe stick boot. Before cutting the torque tube, check to see1f the needle bearings fit the tube freely. Since most 4130tubing is .001 to .0025 oversize, it may be neccessary tohave the O.D. of the 15/8" tube machined or ground down ata machine shop so the bearing fits very The needlebear1ngs and the thrust rings ( Fig~ .the torque tube beforeto the torque tube takes place.

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'iC. 22 shows the bearing collar and the collar mountingbracket. Weld all parts together as shown including the in-side parts consisting of the retainer rings ( Fig. 19 ). Thebolt bushings ( Fig. 21} and the collar mounting bracke~Fig. 19 and 22. Be sure that there is an accurate 518 spat:einalde of the collar for the needl-e bearing. After all piecesare welded together, saw them in half along the saw line asindicated in Fig.22. Accuracy here is very important. Aftersawing be sure ~o re~ove all burrs and weld scale from theinterior portions of the pieces. Depend'ine; on the th1cknessat your saw, it may be necces~ary to ~Se slightly more shimbetween the collar halves than the AN 96~-4 washers as shown.The bearing must not bind on the torqiJ.e tube when the ~~llarhalves are bolted tocether and properly tightened and cotter

keyed.

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~D!AICED f.W!

11.

BALANCING THE DY~AMIC BALANCE PLATES ON THE ELEVATORS

)

Under no circumstances do we want ~ pe~fectly balancedelevator with respect to st~tic balance. To do so canresult in flutter problems the same as an un-balancedsurface. The trick is to differ the vibration resonancefrequency of the elevator with respect to the horiz.surfaces so that they will not couple at the same frequencyand amplitude. Therefore we dis-connect the. elevator pushpull rod at the elevator horn and add enough lead in theelevator dynamic balance tip plates so that the elevatoris just slightly down heavy with the tail group in thelevel flying position. The fabric and dope wil~ meke itjust a little more d~wn heavy when they are applied. Drill1/8" holes thr~ugh the tip plates and insert 118" ~eldingrod through the holes then weld the ends of the rods toeach tip plate. Thi3 gives us a method of securing the leadin tha tip plates ~'hen it hardens after pouring it in thetip plates.

AILERON BALANCE

The r~ason that we balance the ailerons is the same asfor the elevators except that ~le try to prevent vibrationfrequency coupling between the wing structure and theaileron. By all means use the forward mounted slave strutsit at all possible since it will require quite a largeamount of lead inside the leading-edge of the ailero~s ifyou use the original plans type of slave strut rnounting.Wecan get away with less weight by using the newer forwardmounted slave strut since it in itself adds the weightwhere we want it. Just a slight un-balance i~ what we wantwith the aileron actuating links dis-connected from theaileron bellcranks. If additional weight i~ required, weprefer to use 3/8" lead wire flattened to 1/8 and screwedand epoxied to the aft face of the leading edge nose stripon the aileron. This type of material is available froma plumbing supply company or hardware store.

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