Tri-R Technologies  TR-4

BUILDER'S MANUAL

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

SPAR PREPARATION

LEVELING AND FIXTURING
SPREADER STICKS
TEMPORARY FITTING OF THE FUSELAGE TOP

FIREWALL
FIREWALL FRONT FACE
ADDED REINFORCING IN FIREWALL AREA

STATION 139.5 BULK HEAD
STATION 180.5 BULKHEAD

MAIN SPAR AND OUTBOARD SPAR PRE ASSEMBLY
REAR SPAR
MAIN SPAR LOCATION AND INSTALLATION
POSITIONING
SPAR MOUNTING LAMINATIONS

MAIN GEAR BOX REINFORCEMENT
SEAT FRONT BULKHEAD & CONTROL MOUNT
FUSELAGE BELTLINE CONDUITS
FRONT SEAT BACK ASSEMBLY
REAR SEAT BACK INSTALLATION
CONTROL CONSOLE - FRONT SEAT AREA
ELEVATOR IDLER BELL CRANK
SEAT BOTTOM ASSEMBLY
FRONT SEAT
REAR SEATS

FRONT FLOOR ASSEMBLY
STICK LINKAGE ASSEMBLY
FLAP HANDLE ASSEMBLY BRACKET
AILERON IDLER INSTALLATION
FLAP ACTUATION TORQUE TUBE INSTALLATION
RUDDER IDLER LEVER INSTALLATION

HORIZONTAL STABILIZER
INSTALL RUDDER POST

ELEVATOR AND PUSH/PULL ROD INSTALLATION
RUDDER CABLE ROUTING AND INSTALLATION
MAIN GEAR INSTALLATION
BRAKE LINE INSTALLATION

FIN RIGHT HALF INSTALLATION
INSTALL LEFT FIN HALF
HANGING RUDDER
INSTALLATION OF FUSELAGE TOP
BAGGAGE AREA BACK PANEL

DOOR PREPARATION
WINDOW INSTALLATION
DOOR LATCH ASSEMBLY
MOUNT DOORS
LATCH PLATE INSTALLATION
AIR STRUT INSTALLATION
REAR WINDOWS

INSTRUMENT PANEL
WINDSHIELD

STATION 139.5 BULK HEAD

The mid tail cone bulkhead is located at station 139.5. This bulkhead is located at the joint between the fuselage top section and the right and left hand fin halves. This bulk head is cut from a section of the two ply prepreg panel that has the outline of this part drawn on the panel at the factory.

• Cut this part out carefully since the station 180.5 bulkhead is outlined in the center, and will be cut out from this part. Use a fine tooth saber saw blade or similar tool for this operation. The outline provided is on the generous side so some trimming or block sanding may be required to fit it to the two fuselage halves.

• Cut out the center section containing the 180.5 bulkhead and set it aside for the next step. Carefully install and remove the fuselage top half for fitting these components.

• The 139.5 station location is to the front face of this bulkhead panel. Remember that the station 0-0 reference is at the ""joggle"" where you lined up the firewall, reference these locations from that point. Test fit the bulkhead into the proper position, trimming as required for a good fitted joint, and prepare both the bulkhead surface and the inner fuselage surface for bonding. Mark the upper fuselage edge position (Water line 0.0) on the bulkhead.

• Fit the bulkhead and align it carefully. Secure in place to the bottom fuselage half with some dabs of five minute epoxy.

• When it is secure enough to work with, bond it to the lower section with two layers of two inch BID tape on both front and back faces. In this location, as other places where there is an inside angle joint, fill the corner with a small radius MICRO/FLOX fillet and wet out the bonding areas with brushed on epoxy. Provide a uniform one inch overlap on each part.

• Insert the 1" by 1" plywood insert at belt the line as shown in the drawing with a 2 by 6 inch, 4 ply prelam BID front and aft of these plywood inserts. These are "hard points" for the shoulder harness for the rear seat passengers.
  

Image 126-127: Station 139.5

STATION 180.5 BULKHEAD

The aft tail-cone bulk head is located at station 180.5. This bulk head is located at the leading edge of the horizontal stabilizer. The bulkhead is cut from the pre-marked two ply prepreg panel (inside the opening of station 139.5 bulkhead).

• This part should be cut out carefully with a fine tooth saw and located with the front face at station 180.5 . It may need to be trimmed for proper fit and should then be tacked into place with five minute epoxy. This bulkhead will have to be removed temporarily during the installation of the horizontal stabilizer, so use a minimum amount of the five minute epoxy in "tacking" it into place.

This bulkhead will also require a hard point for mounting the rudder idler bell crank as follows:

• Cut a 3 inch square of the 1/4 plywood, and cut away an equal size skin (one skin only) on the aft face of this bulkhead as shown in figure XXX.

• Inset the plywood with MICRO slurry, and cover with 4 plies of BID large enough for a full overlap around the patch and extending outwards to the edge of the bulkhead as shown in the sketch (this hard point supports the rudder idler which can have high loads applied at times by the pilot's feet).

• Mock up the idler assembly with the two KIS-3 brackets and locate the mounting holes on the ply insert.

• Lightly "tack" this bulkhead in to place at the stated location - it will be removed and permanently installed during the horizontal stabilizer installation.