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

HORIZONTAL STABILIZER

The horizontal stabilizer surface of the four place KIS is located above the fuselage horizontal joint line. This means that side pieces will be used to mount the stabilizer above this level. These pieces are a portion of the vertical fin moldings for the respective sides, and the cut lines are scored on the mold, and should be visible on the fin half parts. These score lines should be located and darkened with soft pencil or lacquer type fine line pen (do not use oil or wax based markers in any area where bonding or painting is to occur ).

• Temporarily mount the fin halves to the fuselage to transfer the exact location for these cut out pieces. Carefully align the trailing edge of the two fin halves with the aft edges of the fuselage top molding, and drill holes for Clecos or small sheet metal screws for securing and aligning these parts (the screws actually work better than clecos for this job, and are a lot cheaper). Locate these attachment devices closely just in front of and behind each of the cut lines.

• Remove the fin halves, and cut out these marked pieces carefully to size using a saber saw or similar tool. Clean and prepare the joining surfaces for bonding, and attach these pieces with HI-SOL adhesive. Fixture in place using the previously drilled holes, with clecos or small screws to prevent shifting during curing. The airfoil shaped portion of these scribe lines is the opening for the horizontal stabilizer, not used in the assembly and may be discarded. (see figure XXX for clarification)

This cut is slightly oversized to permit leveling the stabilizer from side to side, and establishing the design incidence value.

• Prepare both the horizontal stabilizer, and the fuselage surfaces adjacent to the cut out, for bonding (clean and roughen those surfaces which will be bonded in with BID tape as described in the procedures section).

• Use small pieces of wood to shim the stabilizer into the desired location which includes setting the hinge line at STA. 203. Centering, and leveling from side to side, and setting O degrees of incidence relative to the fuselage waterline level. Also set the hinge line carefully square with the fuselage centerline by measuring forward to the firewall from each tip.

The chord line of the symmetrical horizontal airfoil section should nominally be set at the WL 3.5 inch station (the bottom surface just touching the top edge of the bottom fuselage section at the thickest point). This dimension is not as critical as the requirement to set the assembly level and square with the fuselage section.

• When these measurements are satisfied, fill the major portions of the gap between the stabilizer and the oversized cut out with a relatively dry "MICRO" mix. Allow this MICRO to cure, and then trim away excess (including any ends of wood shims sticking out).

• Prepare the stabilizer surfaces and the inner and outer adjacent fuselage surfaces for bonding. Clean and abrade all areas which will be covered and remove any loose material (wipe down several times with acetone or MEK to insure a wax free surface).

• Build a radius of about 1/4 to 1/2 inch of relatively dry MICRO between the fuselage sides and the lower surface of the stabilizer. This bonding will be done both inside and out, so the STA. 180.5 bulkhead should be removed or adjusted for these steps (which is why it was only temporarily tacked in place with 5 minute epoxy).

• Apply 4 layers of BID pre-lam on both inside and out of the fuselage and the stabilizer with a minimum of 3 inches of overlap. Stagger the width of the overlap on the outside surfaces (those areas which will be visible and subject to aerodynamic drag on the finished aircraft) to minimize the amount of smoothing in these areas for the final finishing of the airplane.

• Replace the STA. 180.5 bulkhead, cleaning away any residue from the other operations. Position this bulkhead carefully, and bond in place with A 4 PLY PRELAM on the front face covering the insert hard point and overlapping the fuselage by a minimum of 2 inches around it's edge (this is to support the rudder idler loads). On the rest of the bulkhead perimeter apply a 2 inch wide 2 ply pre-wetted BID, on both sides (work through the hole in the bulkhead and from the rear of the fuselage, to place the back side BID layers.

INSTALL RUDDER POST

• Re-install the rudder post at the station 206.75 (fwd face) and bond it to the lower fuselage molding with 3 ply BID on the front side only (rear side bonding will be accomplished as the vertical fin halves are bonded in place). Proper alignment of this component is critical to the trim and flight characteristics of the completed aircraft, so perform this leveling with care.