GLASAIR II & III ELECTRIC FLAP INSTALLATION 632-0195-009

The electric flap system was designed to be retro-fitted into existing Glasair II (TD, Fr, and RG) and Glasarr III models, including those that have not installed their flap system. This installation will not work for Glasair I models.

The system utilizes an electrically driven, ball drive actuator which free wheels at the travel limits, eliminating the need for limit switches. The flap motor is actuated by a three position momentary contact, center off switch used to position the flaps anywhere between the travel limits indicated below.

PREPARATION:

Before you can install the electric flap system, the aircraft must be partially dismantled as follows:

1. Remove pilot and copilot seat pans.

2. Remove belly panel.

3. Remove manual pitch trim wheel box.

4. Remove the existing manual flap handle hardware.

5. Remove the flap control sleeve assembly.

6. Remove the co-pilot aileron control torque tube assembly.

7. Remove the gear warning switch (RG's).

For wings still in progress the following applies:

1. The 6" x 2-1/2" piece of 40 lb. foam normally installed in rib "A" may be disregarded.

2. The teflon bushings for the flap torque tubes and flap control sleeve must be installed.

3. The wing must be closed.

4. Flap down travel required:

Standard Flaps:

NOTE:

G lasair III - 50°

Glasair II's - 53 °

Slotted Flaps: Glasair III - 37°

Glasarr II's - 40°

I. For wings with standard flaps installed, you may have to trim the lower trailing edge of the wing to allow the flaps to achieve the required down travel, as specified above. Be careful not to damage the flap hinges on the wing when trimming.

2. You will need a 12V power source (battery) to actuate the flap motor during the installation phase.

3. Total weight gain after installation is 4.1 lbs.

� STODDARD-HAMILTON

AIRCRAFT. INCORFORATED

MODEL ASSEMBLY NAME REVISION DATE VOLUME PAGE

Glasair II & III Elec. Flap Inst. B 2/10/94 1

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RIB "A"

FIGURE (1)

INSTALLATION:

Using the supplied 1/2" 20 lb. foam, cut (1) 1-1/2" diameter circle with a 1/4" center hole and (2) l" diameter circles with a 3/16" center hole. A hole saw works well for cutting the circular pieces.

Remove the foam and inner laminate on the upper wing skin for the 4-1/2" and 2-1/8" 40 lb. foam insert supplied, starting flush from rib "A" in the area shown in fig. (1). Remove only the inner laminate and foam required to install the 40 lb. foam into the upper wing skin. The outer wing skin laminates must be left intact

Bond in the 4-1/2" x 2-1/8" 40 lb. foam using a cabosiVmillfiber/resin mixture. The foam should butt up against the main spar cap and be 90 degrees to rib "A" (ideally parallel to the flap torque tubes) as shown in fig. (1 ). Let dry.

Lay up a 5-1/2" x 8" 4 layer laminate on the 45 degree bias in the location shown on fig. (1). The laminates should extend onto the upper wing skins and the upper spar cap approximately 2-1/2". Trim the laminates even with the outboard side of the 40 lb. insert

_,,,-STODDARD-HAMILTON

AIRCRAFT. INCORPORATED

MODEL ASSEMBL V NAME REVISION DATE VOLUME PAGE

Glasair II & III Elec. Flap Inst. B 2/10/94 2

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FLAP LINKAGE AND IDLER ARM ASSEMBLY

PROCEDURE:

Drill out the (2) pilot holes in each of the supplied brackets to 1/4" for the flap motor bracket and 3/16" for the idler arm bracket. The flap motor bracket and the idler arm bracket supplied are identical until drilled by the builder.

Using Loctite, press the NAS75-3-005 bushings supplied into the flap control linkages. Assemble the flap actuator linkage to the flap control sleeve using AN393-11 clevis pins, AN960D10L washers and AN381-2-6 cotter pins, as shown in fig. (2). Assemble the other end of the flap control linkage to the flap motor and the idler arms, using a NAS75-4-124 bushing and the related hardware called out in fig (2).

Assemble the flap motor bracket and the idler arm bracket, as shown in fig. (2). Use a spare AN4 bolt instead of the AN4-32A bolt to mount the flap motor bracket with the head of the bolt facing outboard to the co-pilot side. Do not install the bolt with a nut, the bolt is only used to hold the assembly together long enough to jig.

FLAP MOTOR AND IDLER ARM BRACKET RIGGING:

The flap motor assembly just constructed is used to locate the bracket position and flap motor clearance from rib "A".

PROCEDURE:

Tape an AN970-4 washer to the side of the flap motor that will face Rib "A". The washer will be used to provide an 1/16" gap between the flap motor and rib "A".

Slide the flap control sleeve and assembly onto the co-pilot torque tube. Install the torque tube through the teflon bushing in rib "A" and onto the pilot flap torque tube. Butt the flap motor against rib "A" and clamp the flap motor bracket up against the 40 lb. insen, using the dimensions called out in fig. (3). Center the flap motor in the flap control sleeve by sliding the flap control sleeve in the teflon bushing.

Extend the flap motor electrically to its full length. Adjust the idler arm bracket until the parameters are met in fig. (3). Hot glue both brackets in place. Retract and extend the flap motor several times; check for binding or misalignment. Set the co-pilot seat pan in place and check for any interference problems.

� STODDARD-HAMILTON

AIRCRAFT. lNCORFORATED

MODEL ASSEMBLY NAME REVISION DA.TE VOLUME PAGE

Glasair II & III Elec. Flap Inst. B 2/10/94 5

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FLAP ACTUATOR ARH

AFT FLAP CONTROL SLEEVE

FIGURE(4)

NOTE: The clearance between the seat pan and the flap actuator linkages are close and may conflict due to rib "A" installation accuracy and upper wing panel placement. If any interference exists during the operation of the flap system the seat pan will have to be modified slightly. The seat pan after modification should allow for a 1/8" gap.

Disassembly the idler arms from the idler arm bracket and the flap motor from the flap motor bracket. Do not disturb the brackets hot glued in place. Using the brackets as drill guides, drill (2) 3/16" holes through the lower wing skin and (2) 1/4" holes through the upper wing skin. Finally, drill (1) 1/4" hole through rib "A" using the flap motor bracket as a drill guide.

Remove the primer from the lower wing skin around the 3/16" holes to allow for a 3" x 5" laminate patch to be applied over the holes.

Using the 3/16" holes as a drill guide, cut (2) 1" holes out of the lower wing skin leaving the inner skin intact. Pot the (2) 1" circular 20 lb. inserts cut earlier into these holes with cabosil. Let dry. Lay up a 3" x 5" 4 layer laminate over the inserts. Re-drill the 3/16" holes using the bracket as adrill guide.

Install the 1-1/2" 20 lb. insert into rib "A" using the same process as the inserts except use a 1-1/2" hole saw drilled from the pilots side and finish with (4) 3-1/2" circular laminates. Let dry.

CAUTION: When installing the 20 lb. insert in the "A" rib on Fixed Tricycle style aircraft, avoid cutting into the unidirectional laminate bow. This would severely weaken the rib. On the FT style aircraft modify the shape of the 20 lb. insert as required to clear the unidirectional bow. If necessary, use a Dremel tool with a small router bit to custom cut the opening in the "A" rib for the insert.

� STODDARD-HAMILTON

AIRCRAFT, INCOUPORATEO

MODEL ASSEMBLY NAME REVISION DATE VOLUME PAGE

Glasair II & III Elec. Flap Inst. B 2/10/94 6

Drill the flap actuator and flap torque tubes, as prescribed in your Glasair instruction manual (DO NOT DRILL THE FLAP CONTROL SLEEVE ACCORDING TO THE INSTRUCTION MANUAL).

Assemble the flap assembly into the wing and position the control sleeve arm vertically. Use an angle finder to position the flap actuator arm relative to the flap control sleeve, as shown in fig. (4). Drill the control sleeve as shown in fig. ( 4 ).

CAUTION: Ff aircraft installing slotted flaps will find in necessary to relocate, or add additional, AN509-416R20 countersunk head screws through the Outboard Rib Attach Bracket to clear the flap actuator arm and linkage.

Reassemble the flap assembly for the final time, per fig. (2). Grease the bushings and linkage arms during the assembly. Use the spare bolt once again for the flap motor bracket. Mount the brackets to the fiberglass structure using the hardware called out in fig. (3).

Make 2, 1" square spacers out of the supplied 1/2" x l" x 2" phenolic block to fit between the flap motor bracket and the side wall of rib "A". Attach the flap motor bracket to rib "A" using the supplied AN4-32 bolt. The AN970-4 washer and the head of the bolt are placed on the pilot side of rib "A".

Extend and retract the flap motor to its full limits, check for misalignment or binding. Connect the flap control rods to the control surfaces, as per your instruction manual. Retract the flap actuator and position the flap control surfaces to the up limits specified in your instruction manual. Adjust the flap control rod lengths to fit the flap actuator arms and pin, as required.

Actuate the flap system down slowly, and check for freedom of actuation. Check the flap control rod for proper clearance between the rear spar shearweb and the rod itself; relieve the rear spar shearweb, if necessary. Check the clevis rod end for binding on the teflon bushing in rib "B" at full retraction. The flap control surfaces should not touch the lower wing trailing edge.

FLAP POSITION INDICATOR MARKING:

The flap position can be determined in flight by using the wing's upper trailing edge as a reference line with indicator lines placed on the flap surface at given points.

� STODDARD-HAMILTON

AIRCRAFT. INCORPORATED

MODEL ASS EMBLY NAME REVISION DATE VOLUME PAGE

Glasair II & III Elec. Flap Inst. B 2/10/94 7

PROCEDURE:

Place the flaps in the up position. Tape an angle finder to the upper flap control surface, parallel to the airflow over the wing. Using a pencil, mark the flap surface along the wing's trailing edge approximately 3" long, 2' outboard of the fuselage. For standard (piano-hinged) flaps, move the flap down 15° and place another mark; repeat for 30° and for full flaps. For slotted flaps, make marks at 10°, 20°, 30°, and 40° flap extension. These marks serve as your flap indicator. Paint over the 3" long pencil marks or use 1/16" wide automotive pin-striping material to make the indicator more visible.

NOTE:

Several of our builders have innovative flap position indicators they have developed such as a sliding rule type mechanism mounted behind a plexiglass window, showing the exact degrees of flap deflection. For custom ideas such as these, please refer to out Glasair News Letters.

DC

DDUBLE POLE

DDUl3LE THRO\,'

S'w'ITCH n..AP

ACTUATOR

MOTOR

WIRING SCHEMATIC

FIGURE (5)

ELECTRICAL INSTALLATION:

DIDDE

DIODE SYMBOL

DIODE DIRECTIDN BAR

The flap system is controlled by a 3 position switch wired to the flap motor using 16 A WO wire with a 15 amp circuit breaker (used to protect the circuit). Use the standard practices outlined in AC43.13-1A & 2A for the wiring installation.

� STODDARD-HAMILTON

AIRCRAFT. INCORPORATED

MODEL ASSEMBLY NAME REVISION DATE VOLUME PAGE

Glasair II & III Elec. Flap Inst. B 2/10/94 8

PROCEDURE:

Install the switch in a location close to the pilot, for instance the center console or the instrument panel. The switch actuation should correspond to the direction of the flap movement, for example, forward switch - up flaps, aft switch - down flaps or up switch - up flaps, down switch - down flaps.

Wire the flap system as shown in fig. (5). Use the knife splices supplied to connect the motor wires to the 16 A WG wire from the switch. Be sure to heat shrink the terminals on the switch and the knife splice connection.

NOTE:

Solder the diodes on the switch, as shown in fig. (5), to protect the avionics and related accessories from voltage spikes caused by the flap motor.

If the flap works backwards, when actuated, just swap the motor wires using the knife splices as the junction point. Label the flap switch (UP, DOWN, and MAXIMUM FLAP EXTENSION SPEED [see limits)).

Do not forget to re-install the "Landing Gear UP" warning microswitch (RG's).

LIMITS:

The maximum OilP extension speed: Standard flaps - 120 mph Slotted flaps - 140 mph

NOTE: Remark the white arc on the airspeed indicator as necessary.

Travel limits: Standard flaps:

Slotted flaps:

WEIGHT AND BALANCE:

Glasair III - up 3°, down 50°

Glasair II - up 0°, down 53°

Glasair III - up 3°, down 37° Glasair II - up O°, down 40°

Unit removed: manual flap handle, 2.75 lb. @ station 99.39 Unit installed: electric flap system, 6.85 lb. @ station 94.18

Complete revised weight and balance calculations and enter them in the weight and balance records, showing the weight and station (arm from the aircraft datum) of the actuator and related components. Calculate a new empty weight CG and the forward and aft limit conditions. Date and sign the revised weight and balance record. In the aircraft logbook, enter a description of the work performed, including a mention that a new weight and balance record was completed.

MODEL ASSEMBLY NAME

Glasair II & III Elec. Flap Inst.

COMPLETED [ ]

STODDARD-HAMILTON AIRCRAFT. INCOOPORATED

REVISION DATE VOLUME PAGE

2/10/94