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

FRONT FLOOR ASSEMBLY

• Temporarily install some cushions in the seat area, securely support the fuselage assembly and sit in place to verify the location where you will be installing the rudder pedal assembly on the front floor section.

About plus or minus 3 inches of adjustment can still be made in rigging after the rudder block positions are set. The floor panel itself is to be installed with the outer ears touching the back of the firewall.

• Check to be sure that there is 1.5 inch clearance between the upper surface of the floor panel and the bolt hole position for the engine mount. If this value is not attained reduce the forward outer width of the floor panel slightly to lower the panel.

In general the rudder pedal system should be located as close to the fire wall as the linkage will permit. However, if the intended primary pilot has relatively short legs, it may be beneficial to move this pedal assembly back closer to the seat, and adjust the location of the hard points for the rudder pedal pivot blocks accordingly.

The front floor assembly is fabricated from three pieces of the two ply prepreg panel material supplied. The basic floor panel, are cut out and fitted to the fuselage inner contour as shown figure XXX.

• Before the assembly of these pieces, "hard points" for the rudder pedal assembly are added to the basic floor panel, located as shown in the Figure XXX enclosed and with any adjustments in location dictated by the "sit test".

The configuration shown for the rudder pedal mounting inserts are individual plywood blocks inserted into the floor for a total of four hard points for the four mounting blocks. An alternate configuration is an enlarged rectangle which will encompass all four of the center holes (both center rudder pedal mounting blocks) at some small penalty in weight .

• Cut out the three (or four) pieces of the 1/4 inch plywood and locate them on the bottom surface of the floor panel in the positions called out in the figure XXX (remember that you are installing the hard points on the back side, so turn the floor over).

• Use the cut pieces as a cutting guide, and cut through the bottom skin of the panel. Figure XXX shows the recommended standard location, revise if required to position the pedals to your requirements (as previously defined in your sit test).
• Remove the skin and the core material, and clean the exposed inner surface of the top skin in preparation for bonding.

• Bond the inserts into there cavities, and fill any gaps between the insert and the core with a relatively dry FLOX/MICRO paste. Cover these inserts with two ply BID, with minimum 1 inch over lap over the existing bottom skin around the insert.

• Fabricate the four rudder pedal assembly mounting blocks per the figure XXX. Two of these blocks have a 7/8 inch lower segment, and two have a 1 inch high lower segment (ref. Figure XXX). The shorter (7/8 inch) rudder blocks will be used in the locations where the blocks are to be installed on the top of the 1/8th inch thick aluminum angle used for the brake cylinder mounting bracket. The supplied material for all four blocks is the 1/2 inch thick phenolic contained in the kit (other suitable bearing material such as nylon can be substituted). The two center blocks may require some reduction in the 1/2 inch thickness to provide clearance for the flanges on the pedal tubing, to allow the rudder pedals to rotate freely. This is most easily accomplished with a belt sander.

• The bolts mounting the two blocks on the left (pilot side), will also mount the brackets for the brake master cylinders. Fabricate these brackets from 1/8 in. thick aluminum angle supplied with the kit. The smaller bracket will be installed on the left side for the left toe brake, and the larger (longer) angle will be used for the right toe brake. Use figure XXX to fabricate the brackets, using the respective rudder mounting blocks as drill jigs to assure proper fit through the bolt holes.

• Position the blocks on the floor panel (with the hard points installed), using either the rudder assemblies, and use the blocks as drill jigs for the eight attach bolts (#10 - 32 hex head screws about 2 1/4 inches long - AN3-22A).

• Use the attach bolts to hold the nut plates in position, and drill for the 3/32 in. rivets which will be used to attach the nut plates (K 1000 - 3). Rivet the nut plates in position as shown in the preceding sketch.

• Temporarily install the bearing blocks for the rudder pedal assembly, with the brake cylinder mounting angles on the pilot side, and the pedal assembly for fit and functional testing.

A "U" shaped cutout at least one inch square, must be provided on both the front and rear close out panels of the floorboard assembly. These cutouts allow for the passage of the fuel, brake, and other lines or wires between the spar area and the fire wall area.

• Attach the end panels to the floorboard assembly with two inch wide two ply BID at the corners, and fit the assembly to the fuselage inner surface.

• As mentioned earlier, the location of the rudder pedals shown in the drawing is the nominal value used in the prototype. If the anticipated pilots are taller, or shorter, the location of the rudder pedals can be adjusted to provide the desired distance between seats and the nominal rudder pedal location. The floor panel however, is to be installed with the front, side "ears" up against the fire wall as shown in figure XXX. When located in this position, bond the floor assembly into place with two inch wide two ply BID tape. Roughen the surface of the fiberglass on the firewall and the plywood gusset to prepare these surfaces for bonding. Bond the "ears" to the firewall with a two ply pattern with double overlap on the firewall at the engine mount location. This will add four plies to the lower engine mount pads.

STICK LINKAGE ASSEMBLY

• The stick linkage assembly process is started by temporarily installing the stick assembly mounting brackets (KS -29) to the control cross over (KS-30) at the two pivot brackets welded to the bottom of KS-30).

• Position the control cross over assembly up against the rear face of the front seat forward bulkhead, with the pivot line at WL -11.75 (11 3/4") and the stick assembly centered in the fuselage (caution - the elevator push rod clevis is not centered on the control cross over assembly).

• Using the mounting brackets as templates, mark and drill, the two 3/16 in. dia. bolt holes through the bulkhead hard points.

• Bolt the two stick pivot brackets to the aft face of this bulkhead, using the previously drilled holes, using four hex head #10- 32 bolts about 3/4 inch long (AN 3-SA), and associated nuts and washers supplied in the kit.

FLAP HANDLE ASSEMBLY BRACKET

This would also be a good time to install the bracket for the flap actuation linkage and the lever sector plate assembly (KS- 26). Use the flap sector stampings (two flat plates with the flap position notches) to mock up the vertical location for this bracket by assembling the flap handle assembly.

• The recommended position is to mount this bracket on a 1/4 inch plywood spacer and center the upper hole in the mounting bracket on the upper edge of the bulkhead (this hole is not used in mounting). With the control crossover assembly installed to it's mounting brackets and the flap handle assembly held in place, cycle this assembly to determine clearance with the flap sector bracket and the sectors.

• Use the lower hole as a jig and drill the lower bolt hole in the front seat front bulkhead for mounting.

• Mount the bracket with the one hex head #10-32 bolt about 1 in. long, AN3-7A or similar, and required nut and washer .

• Select the flap sector sides, and the flap handle assembly and temporarily assemble to the just mounted bracket.

• Locate and drill the bottom mounting hole through the side of the console 4 1/4 inches aft of the bulkhead aft surface. Before doing so, hold the assembly in place and fit the console cover over the assembly and make sure there is not any interference with the flap handle or sector sides.

• Locate the top hole on the side panel using the sector side panel hole with the assembly held in place.

• Using the supplied nuts, bolts, washers, and spacers (the spacers are cut from the 5" steel tube supplied). Install the flap actuation assembly of the handle and the two sector panels. The push rods for these areas will be installed at a later step.

AILERON IDLER INSTALLATION

• The aileron idler, two pieces, left and right are to be fabricated from a section of the 1 by 1 inch .125 wall aluminum channel furnished in the kit using figure XXX. Fabrication should be easily accomplished using simple hand tools such as hacksaw, files, and drill .

• Locate the pivot point for this link by positioning a KS-3 bracket face against the aft surface of the seat front bulkhead, base against the inner fuselage wall with the hole 2 5/8 inches below the top of the seat front bulkhead (see sketch). Mark the hole location in the seat front bulkhead.

• Insert a 2 in. square hard point in this position (if this was not accomplished at an earlier time.

• Space the KS-3 bracket with the idler link and two washers and mark the mounting holes in the fuselage wall.

• Insert a hard point on the inner wall to make a flat spot for the bracket (the insert piece to be about 1/16 inch less tall than the span of the bracket but 2 inches wide. Close with 2 ply BID with at least 1/2 inch overlap all around.

• Drill holes and mount KS-3 bracket with counter sunk #10-32 bolts.

• Using the idler and bracket, locate the position of the hole to be drilled into the 31 bulkhead hard point. Drill a ¼" hole.

• Install the idler with a 1/4 inch bolt (AN4-16 or similar) and castleated nut and washers .

• Assemble the stick to idler push rod with two rod end assemblies and a section of ¼" inch threaded rod and the required nuts. Rig the length of this rod to set the indicated idler holes in a vertical plane when the stick is neutralized. (see figure XXX).

Repeat this procedure on the other side of the fuselage.

FLAP ACTUATION TORQUE TUBE INSTALLATION

The flap actuation torque tube is a one piece assembly and it mounts on the aft face of the wing rear carry through spar.

• Mount one of the three torque tube mounting brackets (CS-23) at each end of the spar, located 3/8 inch below the top edge, and one inch in from the end. Mount these with only the top bolt at this time such that they can align with the assembly. The bolts are #10-32 flat head counter sunk bolts (MS-24 694-S56 ), counter sink the front face of the spar such that the bolt head does not protrude above the surface (the wing rear spar surface will be bolted up tight to this surface) .

• Using the bracket as a guide, mark and cut at least a 1.25 inch dia. hole (this hole will be elongated due to the fuse’ angle), with a hole saw or Dremel in the fuselage side, to allow the tube to protrude through the fuselage surface and operate freely without binding. Repeat this step on the opposite side.

• Prepare the torque tube assembly by installing the actuation arm (CS-32) on each end of the torque tube. These must be installed as precisely parallel as possible to avoid dangerous eccentric flight loads when the flaps are deployed. The recommended way to accomplish this is to work on a flat level surface and install first one actuation arm at one end, drilling through both the arm and the tube with a 3/16th in. dia. 2 places as close together as 2 #10-32 hex head bolts can be spaced. Install each bolt as soon as the hole is drilled.

• Align the other arm using the flat surface as a guide, and drill and install the bolts in the same manner. Mark the actuation tube and the arms such that they will not be switched when reassembled. Remove the right side arm to prepare for the following steps.

• Slip the torque tube through the mounting bracket and fuselage hole on the left side. Slip the remaining mounting bracket and the flap actuation input lever arm (in this order), onto the inboard end of the torque tube, and pass the end of the tube through the other fuselage wall, and the hanger bracket on the far side.

• Position the actuation arm on the torque tube assembly, such that it is in line with the flap actuation lever assembly in the center console (not centered in the console but aligned to the left side to permit room for the elevator push pull rod assembly on the right side).

• Locate the loose (center) flap hanger bracket adjacent to the actuation arm, and drill the top mounting hole for the middle mounting bracket (this bracket location should be near the airplane centerline if the assembly is proper). This center mounting bracket may be mounted with hex head #10-32 bolts since the flush surface is not required, and access will be better for a wrench than a screwdriver.

• Center the actuation tube in the aircraft, and assure that sufficient free end is available at each end for mounting the flap driver arms (the torque tube should be even with the ends of the spar).

• Level the flap actuation arms that are at the ends of the torque tube and secure in this positon. Set the center input actuation arm vertical, and drill through the flap actuator arm, and the tube for two #10-32 bolts. Space the bolts just enough to provide wrench access.

• Install the bolts pointing aft when the actuation arm is vertical, to permit free rotation during flap actuation.

• With the torque tube assembled, pivot it several times to clear up any interference and binding, and locate and drill for the second mounting bolt in each bearing bracket. The outer bolts are also the flat head #10-32 countersunk bolts, installed as before, and the second mounting bolt for the center bracket is another hex head #10-32..

• Select the flap actuator push rod assembly ( part CS- 24 ) from the included parts, and trim the open tube end such that the nominal length of the assembly will hold the torque tube actuation arm vertical in the flap retracted (forward) lever position.

• Complete this assembly by installing the AN 490HT8P adapter (rivet in place) and MW-3M8/F34-14 rod end, and install in place. Cycle the assembly through the flap positions to assure free movement and no interference with structure or other control components.

RUDDER IDLER LEVER INSTALLATION

This aircraft uses a rudder idler arm mounted on the station 180.5 bulkhead, connected to the rudder cables, and transferring actuation force to the rudder push/pull actuator "rod". This cleans up the aircraft aerodynamically by eliminating the external cables to the usual rudder actuator bar.

• This idler arm is fabricated from a section of the 1 inch aluminum "C" channel section furnished in the kit. Reference the figure X-10 for dimensions and configuration of this idler. Two options are provided for the making of this idler, one without outer bushings and one with. It is suggested that bushings be used wherever there is a chance of the bolt turning in the bolt hole.

Figure -10, Rudder Idler Arm.

• This idler rotates on the supplied hat shaped oilite bushings provided. It is best to ream these holes to 3/8" for the best fit of the oilight bushings. If the bushings are not a tight fit in the hole, a drop of epoxy or one of the "Locktite" compounds will secure them in place.

• Assemble the idler to the two support angles (KIS -3 ) with a #10 bolt with a washer between all rubbing surfaces as shown, and secured with a castleated nut to provide freedom of movement with a minimum of clearance, as shown in figure x-x

• Position the assembly on the 180.5 bulkhead at the leading edge of the horizontal stabilizer (as shown in figure XXX). Drill and mount with #10 bolts and lock nuts. Drill these holes square to each other so binding will not occur.

• Locate and cut holes in the bulkhead to allow full movement of the idler arm and allow installation of the rudder push pull tube. Verify operation and fill the edge of the holes with dry MICRO.

• The correct geometry will be assured if the rudder cables are crossed forward of this idler, and the push rod installed on the left side in a straight line to the rudder actuation arm.

• There is sufficient room in this idler link to install both the rod end and the cable thimble. See figure xx. Use sufficient washers to avoid interference between the two, and a large number of washers on the other end to keep the cable thimble roughly centered.