FLS HORIZONTAL STABILIZER
Chapter 5
GENERAL NOTES
1. Do not use instructions on page 1 of Chapter 5.
2. Use all notes in Chapter 5 Horizontal Stabilizer construction drawings ONLY if they do not conflict with these instructions.
3. The following instructions are given in a specific sequence. Any deviation may result in increased building time and possible construction error.
4. Horizontal Stabilizer Center Spar should already be assembled before closing of Horizontal Stabilizers.
NOTE: 12 nutplates for H. S. attachment are to be installed after drilling H.S.s to H.S. Center Spar.
5. Drill H. S. attachment holes to Center Spar only after Center Spar has been installed in fuselage.
NOTE: Center Spar installation is detailed in FLS Fuselage Assembly Instructions.
6. HS-19, 20, 21, and 24 are fitted and installed after H.S.s have been drilled to Center Spar.
NOTE: This is detailed in FLS Fuselage Assembly Instructions.
7. HS-2 Rear Spar was supplied with the upper flange .125 too narrow. Should be .75 wide and not .625.
8. Bottom trailing edge of skin may need to be final trimmed for Trim Tab clearance.
9. Close outer trailing edges of H.S.s ONLY after Trim Tab has been drilled into place.
10. Drill hole in HS-35 Support Angles for safety wiring to AN5H-7A Bolt after permanent installation.
11. Check bend angles on parts during construction and again just before final assemble. Bend angle call outs in construction drawings are nominal and angles should be adjusted to ensure proper nesting of parts against each other.
12. Use a #40 size drill for drilling all pilot holes.
13. Use a fine point plastic tipped marker only for marking on aluminum.
NOTE: DO NOT use a scribe or lead pencil.
14. When cutting aluminum, make sure all sharp edges are removed and cleaned of all burrs and roughness.
15. When drilling holes, make sure all burrs and roughness are removed from the edge of the holes before dimpling, bolting or riveting in place.
16. Before Prosealing, degrease, metal etch and alodine all parts for better bonding of Proseal and corrosion protection.
HORIZONTAL STABILIZER CENTER SPAR
1. Center Spar is supplied as a partially assembled component in the FLS kits or from the BD-Micro Technologies, Inc. Jig Alignment and Drilling Service.
2. Installation of HS-29 through HS-34 and 12 H.S. attachment nutplates is detailed in FLS Fuselage Assembly Instructions.
3. Make a revised drill template as shown in Detail E, page 7.
NOTE: DO NOT use the pattern as shown in Detail E. It is dimensionally wrong. Use top view of the assembled Center Spar on page 6 as a pattern.
NOTE: Revised template will be used to drill H.S.s to Center Spar as detailed in FLS Fuselage Assembly Instructions.
4. Determine thickness of HS-16 and HS-40 Shims as follows.
PROCEDURE:
1. Refer to View C-C, page 10 for pictorial overview.
2. Measure height of Center Spar (use vernier calipers if available) at the specific points where HS-16 and HS-40 Shims contact H.S. Main Spar inner surface.
3. Measure height of Main Spar at the specific points where HS-16 and HS-40 Shims contact inner surface. Subtract .128 (thickness of the four layers of the Main Spar and Sub Spar) from this measurement for Main Spar inner surface dimension.
4. HS-40 Shim thickness is one half the difference of the Center Spar height and Main Spar inner surface dimension.
5. HS-16 Shim thickness is the above dimension minus the thickness of the HS-40 Shim.
5. Make Shims as shown in Detail H, page 10 in appropriate thickness.
6. Use contact cement to temporarily bond Shims to Center Spar.
NOTE: Do not use tape to secure Shims. It will be too thick and will cause installation and removal difficulties in next procedure.
NOTE: Shims will be permanently rivet to Center Spar after H.S.s have been drilled in place as detailed in FLS Fuselage Assembly Instructions.
7. Disregard items 5 and 6 of Notes: on page 10, View B-B.
TRIM TAB
1. The following directions are for a split Trim Tab.
NOTE: This will simplify attachment and removal of H.S.s.
2. Detail P, page 15, will be used as a general overview for Trim Tab construction, except as specifically noted.
3. Disregard the 3.92 dimension given in Section B-B. Use Trim Tab Skin as supplied.
4. HS2 Rear Spar upper flange should be .75 and not the .625 dimension as supplied.
NOTE: Upper H.S. Skin will overhang Rear Spar. DO NOT trim to Rear Spar.
5. Cleco both Horizontal Stabilizer halves together.
6. Slip Center Spar into both H.S. halves and place on a flat work table.
7. Position both H.S.s on Center Spar as shown in Detail G, page 9.
NOTE: Scale from drawing to obtain approximate spacing from centerline.
8. Butt the Rear Spars together as shown in Detail P, upper view, page 15.
9. Align both H.S.s to each other by leveling across the Rear Spar tops and ensuring that the trailing edge (where the trim tab attaches) is straight.
NOTE: Use blocks of wood for positioning and secure to work table with duct tape.
RECOMMENDATION: Obtain a 58.00 (or shorter) long, straight and rigid, length of angle extrusion of either steel or aluminum. Align H.S. trailing edges to edge of extrusion and clamp. H.S.s will now be level horizontally across the Rear Spar and the trailing edges perfectly straight.
10. Drill the two #40 pilot holes on left side of HS-17 Channel into left Rear Spar. Enlarge to a #19 hole size.
11. Disassemble H.S.s and install two nutplates as shown in View A-A of Section A-A, page 15 to left Rear Spar.
NOTE: AN515-8R5 Screw should be a -8R6.
NOTE: If stripping out of the Phillips head is experienced with the AN515-8R6 Screw, it may be substituted with a higher tensile strength MS27039-08-06 Structural Screw.
12. Reassemble H.S.s as previously noted and secure to work table.
13. Fit HS6 Trim Tab Skin to H.S. trailing edge by trimming one end as needed.
NOTE: There should be a .06 gap at each end.
NOTE: To obtain proper Trim Tab clearance, it may be necessary to square up the .25 radius corners in the H.S. Skins with a file.
14. Mark BL 0.00 on top and bottom of Trim Tab Skin for cutting later on.
15. Adjust length of HS-5 Trim Tab Spar to match Trim Tab Skin length.
16. Position and drill six HS-14 Ribs to Trim Tab Spar as noted.
NOTE: Leave a .06 gap between the two Ribs at BL 0.00. Gap is necessary when Trim Tab Skin and Spar is cut.
17. Layout rivet pattern and predrill Trim Tab Skin to #40 hole size.
NOTE: Use three rivets equally spaced between Ribs instead of one as shown.
NOTE: Add a second rivet to top and bottom of Ribs. Drill second top rivet 1.75 back from Spar and second bottom rivet 1.625 back from Spar. Staggering rivets will prevent them from interfering with each other when being installed.
NOTE: DO NOT drill #40 pilot holes on bottom of two BL 0.00 Ribs.
18. To prevent the Trim Tab Skin from having pillows between the rivets, follow drill sequence as follows:
PROCEDURE:
1. Fit top of Trim Tab Skin to Trim Tab Spar as shown in Section B-B. Drill and cleco to Spar upper flange only.
HINT: To ensure that Ribs are properly aligned for drilling, draw a straight line down the rib rivet line with a fine point plastic tipped marking pen. When line becomes visible in the Trim Tab Skin pilot hole, Rib is properly positioned for drilling.
2. Drill and cleco 2nd rivet pilot hole in top surface of Trim Tab Skin.
3. Making sure the Trim Tab Skin is firmly against the Ribs, drill the second pilot holes on the bottom side and cleco.
4. Finish drilling bottom pilot holes along the Trim Tab Spar.
19. Locate and drill to Trim Tab Spar the four HS-23 Hinges as shown in Section A-A.
NOTE: Position outboard Hinges as shown in Detail P to be equally spaced between the three rivet holes. Mark position on Trim Tab Skin.
NOTE: Single HS-22 Hinge has been replaced by two HS-23 Hinges. Position Hinges left and right of BL 0.00 about 1.312 and adjust for equal spacing to pick up three rivet holes. Mark position on Trim Tab skin.
NOTE: Hinges must be positioned exactly as shown vertically to allow proper clearance as Trim Tab moves through its arc.
NOTE: Make sure to allow for thickness of H.S. Skin and Rear Spar to ensure top surface of H.S. and Trim Tab are even.
NOTE: H.S. Skin will overhang Rear Spar slightly because of short flange as noted earlier. DO NOT trim to Rear Spar flange.
NOTE: Drill Hinges to Trim Tab Spar only at this time.
20. Remove CT-9 and 10 Angles from FLS Electric Trim Series package.
21. Position Angles on bottom of Trim Tab skin at BL 0.00 as shown in Chapter 7, page 40 and Section C-C, page 41. Drill six #40 pilot holes.
NOTE: Use a scrap piece of .090 material as a shim to help position Angles.
22. While Trim Tab is clecoed together, cut Trim Tab in half at BL 0.00 marks with an X-Acto Razor Saw.
NOTE: An X-Acto Razor Saw is the ONLY tool recommended for this operation. A Dremel tool, or any other method, will not give a quality cut as will the razor saw. A X-Acto Razor Saw is inexpensive and can be bought at most hobby shops.
23. Enlarge #40 pilot holes in Hinges, Rib ends, and corresponding pilot holes in Trim Tab Spar to #29 hole size.
24. Disassemble Trim Tab.
25. Dimple Trim Tab Skin and Ribs with appropriate shallow and deep 120 degree dimple dies and enlarge to a #29 hole size.
NOTE: DO NOT dimple six rivet holes where CT-9 and 10 Angles are attached.
26. Deburr edges and rivet holes of all parts.
27. Metal etch and alodine all Trim Tab parts.
28. Apply Proseal as needed and attach Ribs and Hinges to Trim Tab Spar with 1604-0410 Dome rivets.
29. Apply Proseal to Trim Tab Spar and Ribs as needed and attach Trim Tab Skin with 1604-0412 Flush rivets.
30. Apply Proseal to CT-9 and 10 Angles and attach to Trim Tab with 1601-0410 Dome rivets.
31. Clean up excess Proseal with MEK.
32. While H.S. halves are still in position on the Center Spar, drill the Trim Tab Hinges to H.S. trailing edge as follows.
PROCEDURE:
1. Put a small piece of double backed Scotch Tape on each Hinge.
2. Using duct tape on the top surface only, position and tape Trim Tabs to H.S.s.
3. Carefully remove H.S. halves from Center Spar.
4. Clamp inboard Hinge to H.S. trailing edge and drill the first inboard pilot hole ONLY and then cleco.
5. Gently raising the Trim Tab, push the outboard Hinge upward so it contacts the H.S. trailing edge.
6. Mark the last hole ONLY in the outboard Hinge.
7. Remove Trim Tab from H.S. and carefully drill the outboard Hinge mark with a #40 drill size.
CAUTION: Center punch mark to ensure drill does not wander from mark when starting to drill.
8. Cleco Trim Tab back on H.S. trailing edge and finish drilling remaining holes to a #40 drill size.
HORIZONTAL STABILIZER ASSEMBLY
1. Use page 2 as pictorial overview of Horizontal Stabilizer assembly.
2. HS-25 and 26 Braces are deleted.
3. HS-22 Hinge is deleted.
4. Increase HS23 Hinge quantity to four (4).
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5. Lightening holes are optional.
NOTE: Flanged lightening holes may cause some distortion to HS-3 Spar flanges making it difficult to rivet.
6. Instructions are for right side. Left side assembly is the same except for HS-17 Channel attachment.
7. Disregard Detail L, page 13 concerning edges of H.S. Skins. FLIGHTLINE Series H.S. Skins are supplied with edges net trimmed.
NOTE: Outboard trailing edge is trimmed and riveted together after Trim Tab is drilled in place.
NOTE: Inboard end may require some trimming for fuselage clearance after H.S.s have been installed.
8. Drill #40 pilot holes in HS-1 and HS-3 Spars to #30 hole size. Countersink using a 120 degree x #30 bit.
NOTE: Countersink deep enough to allow dimpled skin to fit snugly in hole but not so deep as to enlarge #30 rivet hole.
9. Drill out four temporary flush rivets holding HS-1 Sub Spar in position.
10. Dimple all 7 Ribs and HS2 Rear Spar with a 120 degree deep dimple die for skin attachment.
11. Dimple H.S. Skin using a 120 degree shallow dimple die. Enlarge to #29 hole size.
12. Enlarge three #40 pilot holes in each Hinge to a #30 hole size. Countersink using a 120 degree x #30 bit.
13. Position HS-17 Channel on Rear Spar as shown in View A-A of Section A-A, page 15 and drill four #40 pilot holes.
14. Enlarge four Channel pilot holes to #29 hole size.
15. Deburr edges and rivet holes in skin, ribs, and spars.
16. Metal etch and alodine all parts.
NOTE: If zinc chromate primer is used, areas that will have Proseal must be masked off before primer is sprayed on.
17. Apply Proseal to Sub Spar and reposition inside Main Spar. Rivet together using four 1604-0412 Flush rivets.
18. Refer to page 2 and apply Proseal as needed to ribs and spars for riveting together.
19. Rivet ends of ribs to spars with 1601-0410 Dome rivets.
20. Apply Proseal as needed to ribs and spars for attachment of H.S. Skin.
NOTE: Use sufficient #30 clecos to ensure that rib flanges are pulled firmly against skin before riveting. If not, rivet may squeeze out between rib and skin which will require drilling out and reriveting.
NOTE: DO NOT rivet Rear Spar where Hinges attach. Leave clecos in place until Proseal cures.
21. Rivet H.S. Skin to ribs and spars with 1604-0412 Flush rivets.
22. Attach HS-17 using Proseal and four 1601-0410 Dome rivets.
23. Clean up excess Proseal with MEK.
HORIZONTAL STABILIZER TIP
1. Mount H.S. halves on Center Spar as described earlier in instructions.
2. Cleco Trim Tab Hinges to H.S. trailing edge.
3. Place a straight edge on Trim Tab trailing edge and mark H.S. Skin outboard trailing edge with a plastic tip fine point marker.
4. Remove Trim Tab and store in a safe place.
5. Trim outboard trailing edge to this mark.
NOTE: When trimming, be sure to compensate for thickness: of marking pen.
6. Deburr trailing edge.
7. Bend the trailing edge skin very slightly .50 from edge as shown in Detail O, page 14.
NOTE: Do not rivet edges together at this time.
8. Trial fit fiberglass H.S. Tip.
NOTE: Some trimming of H.S. Tip flange may be required for proper fit.
9. Predrill #40 pilot holes in H.S. Skin.
NOTE: Use a .25 to .312 edge distance and begin rivet line 1.00 from leading edge. Equally space rivets 1.00 to 1.25 apart.
10. Attach H.S. Tip securely to H.S. and drill into place.
11. Fabricate two .50 wide strips from .125 material the length of H.S. outboard trailing edge.
12. Insert strips between trailing edge of skin and drill as shown in Detail L, page 13.
NOTE: Use five MS20470AD-3-_ rivets of appropriate length instead of three.
NOTE: Disregard .25 dimension.
13. Some shaping of H.S. Tip trailing edge and flange may be required for a smooth transition to H.S. trailing edge.
14. Apply Proseal as needed and rivet H.S. trailing edge and shim together.
15. Dimple pilot holes in H.S. Skin with a 120 degree shallow dimple die and enlarge to a #29 hole size.
16. Make four rivet backing strips from .016 (or .020) material .625 wide and clamp to inside of H.S. Tip flange.
17. Drill backing strips through H.S. Tip pilot holes.
18. Enlarge backing strip pilot holes to a #29 hole size.
19. Enlarge H.S. Tip pilot holes to a #30 hole size and countersink with a 120 degree x #30 bit.
20. Apply Proseal as needed to backing strip and install using #30 cleco to hold until Proseal cures.
21. After backing strip Proseal has cured sufficiently, apply Proseal as needed to H.S. Tip flange and install in H.S. using 1604-0412 Flush rivets.
22. Clean excess Proseal with MEK.
HORIZONTAL STABILIZER INSTALLATION
Set aside Center Spar, H.S.s, and Trim Tabs for later installation as detailed in FLS Fuselage Assembly Instructions.