Tri-R Technologies  TR-4

BUILDER'S MANUAL

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


FUSELAGE


Quick Links to Wing Assembly Sub-Sections:

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



FIREWALL

Figure-4: Firewall Position

The plywood may be temporarily spaced with large pins or small nails through these holes and may be temporarily secured with small nails or pins through small holes drilled to the center of the plywood.

 
Figure 128-130: Filewall Positioning
Measuring from the tail to square the firewall to the fuselage.  Extending
the measurement point increases the accuracy of the measurement.
A level attached to the inside of the firewall helped in the level process and
to remove a bow from the plywood.
Horizontal line is at the waterline 0.0
and the vertical line is center line.  The shims helped clamp sides against
firewall during bonding.



FIREWALL FRONT FACE

The full width stiffener should be tied into the edges of the upper gussets (cut to length if necessary).

Figure -5, Fire wall gussets and stiffener.

Figure -6, Gusset pre lams.

Figure-7: Gusset pre lams.

Figure-7:  Gusset Pre-Lams.

Figure-8: Between lower gusset pre lam.

The areas between the upper braces will be the most demanding because of the a angle between the gussets. Try to optimize the pattern to provide full coverage of the firewall in the bolt area with the three layers of each overlap ( 24 layers total in these mounting bolt areas).

The lower engine mount areas have only one plywood angle per hole. The area between these gussets with a total of 8 plies of pre-lam. This is the large pattern - 18 inches long. (this is the nose gear mounting area). The fire wall area next to the gusset will have the corner overlapped for a total of 16 plies.

The other side (bolt hole side) will also get an 8 layer set of plies, doubling the overlap at the mounting bolt points for a total of 16 plies at this time, (4 added plies will be installed during floor installation).

Before each new lay-up wet out the surface that the pre-lam BID will cover with a thin coat of brushed on epoxy. This applies to all areas where the pre-wetted BID is to be applied. This helps to assure a good bond in these areas.

Completing the upper surface of the upper gussets ( which will be laminated into the upper fuselage half ) will require special treatment and will be delayed until the fuselage top is being permanently installed. ( Except as noted below )

Any previously cured BID layers which will be bonded to in later steps must be roughened and cleaned prior to applying added layers. This applies to any portion of the assembly process, and should be kept in mind when scheduling lay-up work . What you leave unfinished in one work session will have to be re prepared before continuing at the next work session.

 


ADDED REINFORCING IN FIREWALL AREA

This is the reinforcement for the upper nose gear attach point. The heavy loads on this gear mounting area are the reason for the generous number of layers. Green trim the surplus glass cloth overhanging the edge of the plywood parts or grind these edges to shape after curing.

IMPORTANT - Any remaining unbonded perimeter of the firewall and the lower fuselage section, should be taped with a two layer three inch wide BID tape. Reference figure XXX showing engine mount reinforcements.