FireFlys' Cozy Mark IV, #1500

Dedicated to those that lost their lives on 9/11

 

Chapter 9 

Main Landing Gear and Landing Brake

 

Chapter 9 Research Summary (PDF Document) - Please contact me if you have tips/FAQ's that should be added

 

Step 1 - Landing Gear Bulkhead Reinforcements  

Step 2 - Preparing the Strut for Installation

Step 3 - Attach Tabs & Installation 

Step 4 - Landing Gear Cover

Step 5 - Installing Axles, Brakes, and Brakelines

Step 6 - Constucting the Landing Brake

 

TIPS / WHAT I DID...

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Step 1 - Landing Gear Bulkhead Reinforcements  

9.1.1 Reinforcement Layup on foward face of foward bulkhead, 5 plies BID (Fig 1). (1st paragraph Step 1)

9.1.2 Reinforcement Layup between bulkheads, 5 plies BID (Fig 2). (2nd paragraph Step 1)

9.1.3 After cure, open holes. (1st and 2nd paragraph Step 1)

9.1.4 2 ply BID over NACA scoop (Fig. 3). (3rd paragraph Step 1) - Prepped area by shaping corners and microing around all corners to insure glass would conform, then glassed per plans (sandwich between wax paper and cut notches at intersection of corners). Completed during Chapter 7    Step Done  

9.1.5 3 ply BID over Rear LG Bulkhead, Side, and Firewall (Fig. 4). (4th paragraph Step 1) - Per plans - Make a good template, then sandwich plies between wax paper and cut.  Place into position starting from center of side and working out towards Firewall and LG Bulkhead. Completed during Chapter 7   Step Done 

9.1.6 3 ply BID from LG hardpoint to Firewall hardpoint (Fig. 5). (5th paragraph Step 1) - Per plans, similar to 9.1.5. Completed during Chapter 7   Step Done

Step 2 - Preparing the Strut for Installation  

9.2.1 Remove the "Flash" from strut. (1st paragraph Step 2) -

9.2.2 Measure 95" equally divided along the centerline of strut. (1st paragraph Step 2) -

9.2.3 Create jig and/or draw cut line 8 degrees up to trailing edge. (1st paragraph Step 2) -

9.2.4 Trim strut ends at 8 degrees up to trailing edge. (1st paragraph Step 2) -

9.2.5 Remove trailing edge bulge where attach tabs will go. (2nd paragraph Step 2)

9.2.6 Suspend strut off work surface for layups, trailing edge up. (3rd paragraph Step 2)

9.2.7 4 ply alternating UND layup (@35 degrees) over strut (Figs. 6-8). (3rd and 4th paragraph Step 2)

9.2.8 Flox tubing (brake line conduit) onto trailing edge. (5th paragraph Step 2)

9.2.9 Build trailing edge support, cover with peel ply, then micro fill and 2 ply BID opposite. (5th paragraph Step 2)

9.2.10 After cure, remove support and micro fill and 2 ply BID other side (Figs. 9-10). (5th paragraph Step 2)

9.2.11 Remove strut from suspension, and smooth leading edge transition. (5th paragraph Step 2) - Moved this step. Plans have you do this after step 9.2.7, then resuspending trailing edge up - did not make sense to me.

9.2.12 Suspend strut off work surface for layups, leading edge up. (6th paragraph Step 2)

9.2.13 4 ply alternating UND layup (@35 degrees) over strut (Fig. 11) (6th paragraph Step 2)

9.2.12 Remove strut from mount, trim excess glass, and smooth transition. (6th paragraph Step 2)

 

Step 3 - Attach Tabs & Installation 

9.3.1 Nail plywood vertical to bench & position strut against it. (1st paragraph Step 3)

9.3.2 Mark center and attach points on strut and plywood. (1st paragraph Step 3)

9.3.3 Cut and shape piece "A" of template box. (2nd paragraph Step 3)

9.3.4 Cut and shape pieces "B-E" of template box.. (2nd paragraph Step 3)

9.3.5 Transfer centerline and attach points from plywood to box. (2nd paragraph Step 3)

9.3.6 Draw fuselage reference lines onto work table. (3rd paragraph Step 3)

9.3.7 Position Strut/Box upside down on work table and check reference lines. (3rd paragraph Step 3)

9.3.8 Mark attach tab patterns on box and cover with tape . (4th paragraph Step 3)

9.3.9 Make 45 ply UND layup over tabs, and clamp until cure. (5th paragraph Step 3)

9.3.10 Make jig to drill out 1/4" holes at attach points. (6th paragraph Step 3)

9.3.11 Using jig, drill out the 4 attach point holes. (6th paragraph Step 3)

9.3.12 Remove box from strut, then shape radius around tabs. (7th paragraph Step 3)

9.3.13 Prepare inside of tabs for layup, and fill attach holes with wax. (8th paragraph Step 3)

9.3.14 Make 45 ply UND layup over inside of tabs, and clamp until cure. (9th paragraph Step 3)

9.3.15 Shape radius around tabs, open all 4 holes, and check fit to bulkheads. (9th and 10th paragraph Step 3) - 

9.3.16 Make 4 MG-1 and 4 MG-2. (10th paragraph Step 3)

9.3.17 Position MG-1's and MG-2's in place, and secure with bondo. (10th paragraph Step 3) -

9.3.18 Drill holes through MG's, note/record orientation of all. (10th paragraph Step 3) -

9.3.19 Flox and screw MG's into place. (10th paragraph Step 3) -

9.3.20 Open holes in MG's to 5/8". (10th paragraph Step 3) -

9.3.21 Flox MKMG-4 bushings into 5/8" holes. (11th paragraph Step 3) -

9.3.22 Open holes in attach tabs to 3/4". (12th paragraph Step 3) -

9.3.23 Install 2 MKMGA's into tabs. (12th paragraph Step 3) -

9.3.24 Dimple MKMGA's, fit/shape foam beneath bushings, and cover with 2 ply BID. (13th paragraph Step 3) -

9.3.25 Flox washers onto tabs, and cover with 2 ply BID (Figs. 6-8). (9th and 10th paragraph Step 3) - 

 

Step 4 - Landing Gear Cover - Replacing Plans method with Wayne Hicks Method

 

Step 5 - Installing Axles, Brakes, and Brakelines

9.5.1 Fit torque plate to axle (Cleveland Brakes). (2nd paragraph Step 5)

9.5.2 Make back-up plates for inside of strut. (3rd paragraph Step 5)

9.5.3 Mark the axle positions on the strut. (4th paragraph Step 5)

9.5.4 Using targets, sand struts to create proper toe-in on strut. (5th paragraph Step 5)

9.5.5 Make Gear Leg jig blocks. (6th paragraph Step 5)

9.5.6 Mark and rough cut clearance for calipers. (6th paragraph Step 5)

9.5.7 Flox axles into place. (6th paragraph Step 5)

9.5.8 Extend holes through axle and back-up plate, and attach with bolts. (6th paragraph Step 5)

9.5.9 Install wheels, tires, calipers and brake lines. (7th paragraph Step 5)

9.5.10 Cut out and glass bottoms of LG enclosure pieces. (8th paragraph Step 5)

9.5.11 Flox LG enclosure pieces in position, 2 ply BID over top. (8th paragraph Step 5)

9.5.12 Wrap strut with Fiberfax and Aluminum tape near brake discs. (Side Note over Fig. 46 Step 5) - 

   

Step 6 - Constucting the Landing Brake

9.6.1 Cut landing brake out of fuselage bottom  . (1st paragraph Step 6)

9.6.2 Fabricate landing brake inserts, LB-19 and LB-23  . (2nd paragraph Step 6)

9.6.3 Rout out foam in fuselage bottom for LB-23. (3rd paragraph Step 6)

9.6.4 Install aluminum hardpoints onto LB-23. (4th paragraph Step 6)

9.6.5a 5min epoxy hinge to LB-19. (5th paragraph Step 6)

9.6.5b Cut and attach shims to LB-23. (5th paragraph Step 6)

9.6.5c Attach hinge to shims. (5th paragraph Step 6)

9.6.6 Trial fit assembly, then attach to landing brake. (6th paragraph Step 6)

9.6.7 Attach LB to 2 boards, then flox unit into place. (7th paragraph Step 6)

9.6.8 Pop brake and hinge free from LB-23 (at shims), then remove 1/8" foam from fuselage bottom. (8th paragraph Step 6)

9.6.9 Cut hole for LB actuating arm, then prep for glassing. (9th paragraph Step 6)

9.6.10 Glass exposed foam on fuselage with 3 plies BID. (9th paragraph Step 6)

9.6.11 Trial fit, then glass interior side of LB with 3 plies BID. (10th paragraph Step 6)

9.6.12 After partial cure, replace brake assembly against LB-23. (10th paragraph Step 6)

9.6.13 Insert bolts through hinge into LB-23 and LB. (11th paragraph Step 6)

9.6.14 Make LB-18 Brackets and attach to LB (12th paragraph Step 6)

     

Chapter 8    Chapter Index    Chapter 10(Not Started)

N911HF - No 911 Heroes Forgotten