The Murphy Builders Site

Working on "final" install of the flaperons. The space between flaperons
and their hinges varies from 1-3 std. washer widths, depending on how the
three bolts per wing are snugged up. It seems there are three places to
describe/spec this: 1) each side of the center hinge (two places but
presumably they should be more or less the same), 2) each end hinge, and 3)
the resulting space between the flaperon horns where the push tube bearing
end connects.

Obviously, chafe or binding with the hinges needs to be eliminated. Beyond
that, what's the optimal setup, if there's "extra" room for adjustment?
Should washers be used to fill any small gaps?

Ron

Hi Ron !

This is another place to use the large nylon 'pog' washers -
out next to the supports. They can be snug, without wear....
just like on the ends of the elevators & rudder. You don't
want any end play, or everything wears quickly.

OK, I've got the "POG" washers installed around the flaperon hinges.
However, now I have 13/16" between the flaperon horns where the push-pull
tube from the wing connects. After accounting for the bearing end, that
leaves room for 5 (!) AN960-4 washers. I'm reluctant to reduce that space
and make things around the bearing end any tighter, because the horns are
already a slight bit stressed, already adding friction pressure on the
center hinge point.

The POG washers only account for a small part of all that extra space --
maybe none given the flaperon horns are already pulled in toward the
bearing end a bit.

Using that many washers to fill the space doesn't work well -- even when
snugged up, the bolt is a bit wobbly. The manual doesn't show any spacer at
all. Is that much space normal? (Looks like it would be.) Should I make a
spacer from aluminum rod (like the W-62's used at the wing root horns)
or...?

Ron
254R

Hi Ron !

There is a lot of space there. Remember to use a couple
of penny washers next to the ball end, then one or two
regular washers outboard on each side, as needed to get
the rod coming straight back .... the large washers are
a safety factor - in case the ball should fail, they will keep
the rod in approximate position long enough to get you down.
They should be on every rod ball end connection.

It's not unusual to see a lot of washers there. You may
have to remove one of the POG's if there's any load - the
flapperons should move freely, falling under their own
weight when not connected. You can put it back in
after a few years of wear .... ;-)

OK, I've got the "POG" washers installed around the flaperon hinges.
However, now I have 13/16" between the flaperon horns where the push-pull
tube from the wing connects. After accounting for the bearing end, that
leaves room for 5 (!) AN960-4 washers. I'm reluctant to reduce that space
and make things around the bearing end any tighter, because the horns are
already a slight bit stressed, already adding friction pressure on the
center hinge point.

The POG washers only account for a small part of all that extra space --
maybe none given the flaperon horns are already pulled in toward the
bearing end a bit.

Using that many washers to fill the space doesn't work well -- even when
snugged up, the bolt is a bit wobbly. The manual doesn't show any spacer
at
all. Is that much space normal? (Looks like it would be.) Should I make a
spacer from aluminum rod (like the W-62's used at the wing root horns)
or...?

Ron
254R




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Ron.. I don't know what it is with you ISP but I can never get a message
thru to you directly. How many you need @ $5/dozen.. send me your address
directly.

Wayne

----- Original Message -----
From: <rshannon@dcsol.com>
To: <rebel-builders@dcsol.com>
Sent: Wednesday, December 12, 2007 11:50 AM
Subject: Re: [rebel-builders] Rebel - flaperon hinge lateral play

OK, I've got the "POG" washers installed around the flaperon hinges.
However, now I have 13/16" between the flaperon horns where the push-pull
tube from the wing connects. After accounting for the bearing end, that
leaves room for 5 (!) AN960-4 washers. I'm reluctant to reduce that space
and make things around the bearing end any tighter, because the horns are
already a slight bit stressed, already adding friction pressure on the
center hinge point.

The POG washers only account for a small part of all that extra space --
maybe none given the flaperon horns are already pulled in toward the
bearing end a bit.

Using that many washers to fill the space doesn't work well -- even when
snugged up, the bolt is a bit wobbly. The manual doesn't show any spacer
at
all. Is that much space normal? (Looks like it would be.) Should I make a
spacer from aluminum rod (like the W-62's used at the wing root horns)
or...?

Ron
254R




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OK, I have now bravely (rashly?) finished putting all the #@$% cotter pins
in all the flaperon bolts. Hours.

But I do think before we put this thread to bed, somebody should explain,
for the record, what POG means, as in "POG washer".

Wayne? Bob?




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Isn't that fun !! 45 degree needle nose are the trick, now that you're
done!
LOL

Never play with Pogs as a kid? Bob named them... I just supply'm !

OK, I've got the "POG" washers installed around the flaperon hinges.
However, now I have 13/16" between the flaperon horns where the push-pull
tube from the wing connects. After accounting for the bearing end, that
leaves room for 5 (!) AN960-4 washers. I'm reluctant to reduce that space
and make things around the bearing end any tighter, because the horns are
already a slight bit stressed, already adding friction pressure on the
center hinge point.

The POG washers only account for a small part of all that extra space --
maybe none given the flaperon horns are already pulled in toward the
bearing end a bit.

Using that many washers to fill the space doesn't work well -- even when
snugged up, the bolt is a bit wobbly. The manual doesn't show any spacer at
all. Is that much space normal? (Looks like it would be.) Should I make a
spacer from aluminum rod (like the W-62's used at the wing root horns) or...?

Ron
254R

That 13/16" space between the aileron horns also represents an
opportunity to match the trailing edge of the two flaperons if needed. I
machined an aluminum spacer for each side of the bolt. One spacer with
an eccentric that could be positioned to match the trailng edge of the
two flaperons. Matching the trailing edge makes it easier to cover the
gap between the flaperons with a fairing if you wish to do that..
Ken


rshannon@dcsol.com wrote:

OK, I've got the "POG" washers installed around the flaperon hinges.
However, now I have 13/16" between the flaperon horns where the push-pull
tube from the wing connects. After accounting for the bearing end, that
leaves room for 5 (!) AN960-4 washers. I'm reluctant to reduce that space
and make things around the bearing end any tighter, because the horns are
already a slight bit stressed, already adding friction pressure on the
center hinge point.

The POG washers only account for a small part of all that extra space --
maybe none given the flaperon horns are already pulled in toward the
bearing end a bit.

Using that many washers to fill the space doesn't work well -- even when
snugged up, the bolt is a bit wobbly. The manual doesn't show any spacer at
all. Is that much space normal? (Looks like it would be.) Should I make a
spacer from aluminum rod (like the W-62's used at the wing root horns) or...?

Ron
254R

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That 13/16" space between the aileron horns also represents an
opportunity to match the trailing edge of the two flaperons if needed. I
machined an aluminum spacer for each side of the bolt. One spacer with
an eccentric that could be positioned to match the trailng edge of the
two flaperons. Matching the trailing edge makes it easier to cover the
gap between the flaperons with a fairing if you wish to do that..
Ken

Good morning Ken, I'm glad you mentioned the "gap cover" it's something I
was going to do but hadn't put it on my current list of upgrades.
I'm currently working on the ground handling handle at the tail and
organizing skis. With all this snow so early this year I think we might
actually get a great deal of use from skis. Does Guelph clear the runway
down to the pavement or is there a place to land with skis?

And yes one of the other things on my list is the encoder for the
transponder.
Cheers
Jim
333R

Interesting idea, Ken. My flaperon sections are perhaps 1/8" off, though
symmetrically so on each side, which leads me to believe Jim L. made
them as matched pairs after all and, blowing the 50/50 odds, I just
missed the right match. I thought I'd wait until after the 40 hr. fly
off*, when I disassemble them once more for painting, put them back in
the right combination and do the gap seals then -- but your idea is
intriguing.

I'm at the point where "what's essential" just to get the plane in
the air takes on more meaning. After spending oodles of time on mods,
I'm trying to segregate remaining tasks into three categories: a) things
required for operation or airworthiness, b) things that have to be done
before items in a), and c) things I can do whenever. If it's not in a)
or b) it may not get done until after this thing flies.