04/10/23 Author: Harry L. Whitehead 1
AVAF 209 -AVAF 209 -IV. Assembly and RiggingIV. Assembly and Rigging
AVAF 209 -AVAF 209 -IV. Assembly and RiggingIV. Assembly and Rigging
A. Rigging Specifications
B. Airplane Assembly
C. Flight Control Systems
D. Control Surface Balancing
E. Biplanes
04/10/23 Author: Harry L. Whitehead 2
Rigging SpecificationsRigging Specifications
Should check “Rigging” during all required inspections and anytime any control or major assembly (I.e. wing) is removed and reinstalled
“Rigging” = check systems and control surface travel and adjust as necessary
Test fly aircraft after reinstallation and adjust as necessary
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
04/10/23 Author: Harry L. Whitehead 3
Rigging SpecificationsRigging Specifications
Type Certificate Data Sheets (or Aircraft Specifications) are best source
Is most accurate for details
Includes:–Leveling means–Control surface travel–Weight and balance information
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
04/10/23 Author: Harry L. Whitehead 4
Rigging SpecificationsRigging Specifications
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
04/10/23 Author: Harry L. Whitehead 5
Rigging SpecificationsRigging Specifications
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
04/10/23 Author: Harry L. Whitehead 6
Rigging SpecificationsRigging Specifications
Manufacturer’s ManualsGive installation and procedures
Don’t believe the details, go to the TCDS
MM usually cover more than one model or Ser. No. range = details may not be accurate for your specific aircraft
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
04/10/23 Author: Harry L. Whitehead 7
Airplane AssemblyAirplane Assembly
Most airplanes are fully cantilever or with a minimum of external bracing so assembly is pretty straight-forward
Follow manufacturer’s instructions
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
04/10/23 Author: Harry L. Whitehead 8
Airplane AssemblyAirplane Assembly
General Assembly procedures:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
04/10/23 Author: Harry L. Whitehead 9
Airplane AssemblyAirplane Assembly
General Assembly procedures:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
Level fuselage–Laterally and longitudinally–Inside hangar to minimize wind currents
If must be outside = point into windUse manufacturer’s level point(s) and plumb bob or spirit level
04/10/23 Author: Harry L. Whitehead 10
Airplane AssemblyAirplane Assembly
General Assembly procedures:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
Install wings and torque boltsInstall Hor. Stab. And Vert. Stab. And torque bolts
04/10/23 Author: Harry L. Whitehead 11
Airplane AssemblyAirplane Assembly
General Assembly procedures:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
Perform Alignment Check (next area)
Install movable control surfaces
Install and rig control systems
Test fly to verify control responses and flight stability/attitude
04/10/23 Author: Harry L. Whitehead 12
Airplane AssemblyAirplane Assembly
Alignment Check:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
Wings•Most modern wings have very little adjustments available•Usually only angle of incidence
•Wing mounting bolts are on eccentric bushing or serrated bushings
•= rotate to change angle
04/10/23 Author: Harry L. Whitehead 13
Airplane AssemblyAirplane Assembly
Alignment Check:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
Wings
•May need to use special Incidence Board or just Universal Propeller Protractor for initial settings•Either must be installed at manufacturer specified location
04/10/23 Author: Harry L. Whitehead 14
Airplane AssemblyAirplane Assembly
Alignment Check:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
Wings with V-struts:•Piper Tri-Pacer, Piper Cub
•Can usually adjust Dihedral and Angle of Incidence•Procedure
•Level fuselage laterally & longitudinally•Check and adjust Dihedral
04/10/23 Author: Harry L. Whitehead 15
Airplane AssemblyAirplane Assembly
Alignment Check:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
Wings with V-struts:•Piper Tri-Pacer, Piper Cub
•Check and adjust Dihedral•Use Dihedral Board•Position at manufacturer specified position•Adjust length of struts until bubble is centered
04/10/23 Author: Harry L. Whitehead 16
Airplane AssemblyAirplane Assembly
Alignment Check:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
Wings with V-struts:•Piper Tri-Pacer, Piper Cub
•Check and adjust Dihedral•Some aircraft use string stretched between the wingtips at specified chord location•Adjust struts to get specified dimension between string and wing root
04/10/23 Author: Harry L. Whitehead 17
Airplane AssemblyAirplane Assembly
Alignment Check:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
Wings with V-struts:•Piper Tri-Pacer, Piper Cub
•Check and adjust Angle of Incidence•Use Incidence Board or just measure angle with Prop Protractor or Protractor Head of Combination Square•Adjust Rear strut to get proper angle
04/10/23 Author: Harry L. Whitehead 18
Airplane AssemblyAirplane Assembly
Alignment Check:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
Engines•Use manufacturer’s specs.•Usually parallel to longitudinal axis•Mounts usually just bolt on with no adjustment provisions
•Be sure to use proper shimming (washers), bolts, torques, etc. as specified
04/10/23 Author: Harry L. Whitehead 19
Airplane AssemblyAirplane Assembly
Alignment Check:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
Empennage:•General
•Most are cantilever with fixed positions•Insure all bolts are proper Part Number and torqued in proper sequence so is not cocked
Author: Harry L. Whitehead 20
Airplane AssemblyAirplane Assembly
Alignment Check:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
Empennage:•If Wire-Braced
•Uses Streamlined wires so insure have proper tension (use Datum Board) and is flat with airflow (decreases vibrations and drag)•Must replace streamlined wires with streamlined wires only
•DO NOT use round cable as replacement = vibes and different expansion rates
04/10/23 Author: Harry L. Whitehead 21
Airplane AssemblyAirplane Assembly
Alignment Check:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
Empennage:•Check Hor. Stab. Dihedral & Angle of Incidence
•Basically same as wings•May or may not be adjustable
04/10/23 Author: Harry L. Whitehead 22
Airplane AssemblyAirplane Assembly
Alignment Check:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
Empennage:•Check Vert. Stab. (Fin) Verticality
•Measure from like points on both Hor. Stabs. and should be equal measurement•Fin may be offset slightly to compensate for Spiraling Slipstream
04/10/23 Author: Harry L. Whitehead 23
Airplane AssemblyAirplane Assembly
Alignment Check:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
Empennage:•If suspicious, run string through control hinges
•Should be able to be centered in all hinges•If not = hinges are misaligned and will bind control movement•NOTE: applies to all control surface hinge lines, not just empennage
04/10/23 Author: Harry L. Whitehead 24
Airplane AssemblyAirplane Assembly
Alignment Check:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
Symmetry Check:•To insure entire aircraft is aligned properly (is Symmetrical)•Measure between specified points on aircraft•Use steel tape with 5 pound pull (for consistency)•Like measurements should be equal within manufacturer’s tolerances•May need to use plumb bob from points, mark on floor, and then measure (especially large aircraft)
04/10/23 Author: Harry L. Whitehead 25
Airplane AssemblyAirplane Assembly
Alignment Check:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
Symmetry Check:•To insure entire aircraft is aligned properly (is Symmetrical)•Measure between specified points on aircraft•Use steel tape with 5 pound pull (for consistency)•Like measurements should be equal within manufacturer’s tolerances•May need to use plumb bob from points, mark on floor, and then measure (especially large aircraft)
04/10/23 Author: Harry L. Whitehead 26
Airplane AssemblyAirplane Assembly
Flight Controls Installation & Rigging:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
Ailerons:•Be sure to only use manufacturer’s parts combinations and torque specs to prevent binding
•Should be free to pivot with no binding and no looseness
04/10/23 Author: Harry L. Whitehead 27
Airplane AssemblyAirplane Assembly
Flight Controls Installation & Rigging:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
Ailerons:
•System:•Stick or wheel connected to cables
04/10/23 Author: Harry L. Whitehead 28
Airplane AssemblyAirplane Assembly
Flight Controls Installation & Rigging:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
Ailerons:
•System:•Up cable goes to each aileron•“Through” or “Balance” cable connects down side of both ailerons
THROUGH CABLE
UP CABLES
04/10/23 Author: Harry L. Whitehead 29
Airplane AssemblyAirplane Assembly
Flight Controls Installation & Rigging:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
Ailerons:
•System:•Stick or wheel connected to cables•Up cable goes to each aileron•“Through” or “Balance” cable connects down side of both ailerons
04/10/23 Author: Harry L. Whitehead 30
Airplane AssemblyAirplane Assembly
Flight Controls Installation & Rigging:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
Ailerons:
•System:•To combat adverse yaw = differential travel•Also use Frise ailerons•Also some use Rudder-Aileron Interconnect Spring(s)
•When wheel/stick is moved = also moves rudder in appropriate direction to combat adverse yaw
04/10/23 Author: Harry L. Whitehead 31
Airplane AssemblyAirplane Assembly
Flight Controls Installation & Rigging:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
Ailerons Rigging:•Install all cables and check and adjust tension (most are cable systems)
•Lock in neutral position first•Put clamps or control locks on stick/wheel•Put clamps or battens on control surfaces•Some have holes for Rigging Pins to go into to hold in neutral position
04/10/23 Author: Harry L. Whitehead 32
Airplane AssemblyAirplane Assembly
Flight Controls Installation & Rigging:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
Ailerons Rigging:•Check and adjust travel
•Remove locks•Use Prop Protractor, Control Surface Protractor, or Protractor Head of Combination Square•Check up and down movement as specified in TCDS
04/10/23 Author: Harry L. Whitehead 33
Airplane AssemblyAirplane Assembly
Alignment Check:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
Ailerons Rigging:
Prop Protractor Review
Propeller Protractor
04/10/23 Author: Harry L. Whitehead 34
Airplane AssemblyAirplane Assembly
Alignment Check:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
Ailerons Rigging:
Prop Protractor Review
Propeller Protractor
04/10/23 Author: Harry L. Whitehead 35
Airplane AssemblyAirplane Assembly
Alignment Check:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
Ailerons Rigging:
Prop Protractor Review
Propeller Protractor
04/10/23 Author: Harry L. Whitehead 36
Airplane AssemblyAirplane Assembly
Alignment Check:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
Ailerons Rigging:
Prop Protractor Review
Propeller Protractor
04/10/23 Author: Harry L. Whitehead 37
Airplane AssemblyAirplane Assembly
Alignment Check:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
Ailerons Rigging:
Prop Protractor Review
Propeller Protractor
04/10/23 Author: Harry L. Whitehead 38
Airplane AssemblyAirplane Assembly
Alignment Check:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
Ailerons Rigging:
Prop Protractor Review
Propeller Protractor
04/10/23 Author: Harry L. Whitehead 39
Airplane AssemblyAirplane Assembly
Alignment Check:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
Ailerons Rigging:
Prop Protractor Review
Propeller Protractor
04/10/23 Author: Harry L. Whitehead 40
Airplane AssemblyAirplane Assembly
Alignment Check:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
Ailerons Rigging:
Prop Protractor Review
Propeller Protractor
04/10/23 Author: Harry L. Whitehead 41
Airplane AssemblyAirplane Assembly
Alignment Check:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
Ailerons Rigging:
Prop Protractor Review
Propeller Protractor
04/10/23 Author: Harry L. Whitehead 42
Airplane AssemblyAirplane Assembly
Alignment Check:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
Ailerons Rigging:
Control Surface Protractor:•Adjust disk to zero when surface is in neutral•Move surface to limits and read angle at pointer
04/10/23 Author: Harry L. Whitehead 43
Airplane AssemblyAirplane Assembly
Flight Controls Installation & Rigging:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
Ailerons Rigging:•Check and adjust travel
•Adjust stops at ailerons•Make sure they hit the stops at ailerons before running out of stick/wheel movement•Should have small amount of movement of stick/wheel left to give pilot “springback” feel or “cushion” so he/she knows they’re at end of travel
04/10/23 Author: Harry L. Whitehead 44
Airplane AssemblyAirplane Assembly
Flight Controls Installation & Rigging:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
Ailerons Rigging:
04/10/23 Author: Harry L. Whitehead 45
Airplane AssemblyAirplane Assembly
Flight Controls Installation & Rigging:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
Ailerons Rigging:•Check and adjust travel
•Some are “Drooped”•When in neutral position = trailing edges are slightly lower than wing or Flap trailing edges (must be equal droop on each wing)•During flight = ailerons are forced to streamlined position to take up any slack or wear in system (mostly cable systems)
04/10/23 Author: Harry L. Whitehead 46
Airplane AssemblyAirplane Assembly
Flight Controls Installation & Rigging:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
Ailerons Rigging:•After adjustment
•Move stick/wheel through entire range of movement
•Check for ease of movement, no binding, hits stops at aileron first, and AILERONS MOVE IN PROPER DIRECTION
•Check entire system for proper installation (pulleys, cables, bolts, safeties, etc.)
04/10/23 Author: Harry L. Whitehead 47
Airplane AssemblyAirplane Assembly
Flight Controls Installation & Rigging:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
Flaps:
•System:•Actuated by mechanical handle or electrical
•Handle manually positioned by pilot and connected to cables•Electric switch connected to reversible motor in wing which is connected to cables
•Both sides connected to same cables to insure equal extension and retraction
04/10/23 Author: Harry L. Whitehead 48
Airplane AssemblyAirplane Assembly
Flight Controls Installation & Rigging:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
Flaps Rigging:•Generally same as ailerons•Lock in retracted position
•Adjust cable tension•Check and adjust travel as per TCDS
•Hit stops at flaps first•BOTH MUST EXTEND EQUALLY!
•If different = extreme roll force•Check indicator system matches flap movement and positions
04/10/23 Author: Harry L. Whitehead 49
Airplane AssemblyAirplane Assembly
Flight Controls Installation & Rigging:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
Elevators:
•System:•Wheel/stick connected to cables•Cables go through belly to bellcrank on or near Elevator
04/10/23 Author: Harry L. Whitehead 50
Airplane AssemblyAirplane Assembly
Flight Controls Installation & Rigging:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
Elevators:•System:
•Most modern airplanes can be loaded with CG too far aft•Lots of seats, baggage compartments in back, etc.
•When this airplane is slowed down for landing:•Trim tab working hard to keep nose down with Elevators in slightly down position•If turbulence = Trim Tab may loose effectiveness = Elevators streamline = nose pitches up and trim tab can’t compensate = possible stall
04/10/23 Author: Harry L. Whitehead 51
Airplane AssemblyAirplane Assembly
Flight Controls Installation & Rigging:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
Elevators:
•System:•Down Spring in system puts load on Elevator working against Trim Tab•If turbulence causes loss of trim tab effectiveness = Down Spring pulls Elevator down to keep nose down until Trim tab can take over again
04/10/23 Author: Harry L. Whitehead 52
Airplane AssemblyAirplane Assembly
Flight Controls Installation & Rigging:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
Elevators:•Rigging generally same as ailerons•Lock in neutral
•Trailing edge in line with Hor. Stab. trailing edge•Clamp wheel/stick and elevator
•Adjust cable tension•Adjust travel•Check operations and system for problems
04/10/23 Author: Harry L. Whitehead 53
Airplane AssemblyAirplane Assembly
Flight Controls Installation & Rigging:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
•System:•Wheel/stick connected to cables very similar to Elevator except connects to counterweight (or Balance Arm) on front of stabilator inside fuselage
Stabilators:
04/10/23 Author: Harry L. Whitehead 54
Airplane AssemblyAirplane Assembly
Flight Controls Installation & Rigging:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
Stabilators Rigging:•Rigging generally same as others•Lock in neutral
•Must use stabilator rigging tool similar to incidence board to find neutral
•Adjust cable tension•Adjust travel•Check operations and system for problems
04/10/23 Author: Harry L. Whitehead 55
Airplane AssemblyAirplane Assembly
Flight Controls Installation & Rigging:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
Rudder:
•System:•Cables connected to pedals and through belly to rudder •On Tricycle gear aircraft = also connect to Nose Wheel steering mechanism
04/10/23 Author: Harry L. Whitehead 56
Airplane AssemblyAirplane Assembly
Flight Controls Installation & Rigging:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
Rudder Rigging:•Generally same as others•Lock in neutral
•Clamp pedals
04/10/23 Author: Harry L. Whitehead 57
Airplane AssemblyAirplane Assembly
Flight Controls Installation & Rigging:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
Rudder Rigging:•Generally same as others•Lock in neutral
•Clamp pedals•Clamp rudder in line with Vert. Stab.
•Adjust cable tension
04/10/23 Author: Harry L. Whitehead 58
Airplane AssemblyAirplane Assembly
Flight Controls Installation & Rigging:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
Rudder Rigging:•Adjust travel
•Can’t use bubble type protractors•Measure distance moved from specified point
•May need to make drawing protractor•Or measure distance from hinge to trailing edge (= radius of movement), calculate circumference of movement, divide by 360, multiply by necessary degrees of travel, measure travel
•Check operations and system for problems
04/10/23 Author: Harry L. Whitehead 59
Airplane AssemblyAirplane Assembly
Flight Controls Installation & Rigging:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
Control Tabs:•Typical System (Aileron):
•Control wheel in cockpit•Turns cable drum or chain sprockets connected to cables •Includes position indicator mechanism
04/10/23 Author: Harry L. Whitehead 60
Airplane AssemblyAirplane Assembly
Flight Controls Installation & Rigging:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
Control Tabs Rigging:•Generally same as others•Lock in neutral
•In line with control surface installed on•Adjust cable tension•Adjust travel•Check operations and system for problems•Check indicator for proper operation•Insure is moving in proper direction
04/10/23 Author: Harry L. Whitehead 61
Airplane AssemblyAirplane Assembly
Flight Controls Installation & Rigging:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
Final Check:•Test fly and readjust as necessary to fly “hands off” at cruise and most common loading•If flying with constant bank (“heavy wing”)
•Need to adjust angle of incidence of wing(s)•Need to “Wash IN” heavy wing by INcreasing angle of incidence on low side
•Turn rear bolt (if serrated or eccentric)•shorten rear strut length
•Could also Wash Out light (or high) wing
04/10/23 Author: Harry L. Whitehead 62
Airplane AssemblyAirplane Assembly
Flight Controls Installation & Rigging:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
Final Check:•If in sideslip = rudder
•Reset in-flight adjustable trim tab or bend fixed trim tab to compensate
•If nose low or high = elevator•Reset trim tab(s) accordingly
•All are Trial and Error adjustments so re-test fly to verify and keep trying until it’s right
04/10/23 Author: Harry L. Whitehead 63
Airplane AssemblyAirplane Assembly
Flight Controls Systems:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
Cable Systems:•Types of Cable
•CRES or carbon steel•Carbon steel cheaper and stronger
•Preformed•Must be at least 1/8 inch diameter for Primary Controls
04/10/23 Author: Harry L. Whitehead 64
Airplane AssemblyAirplane Assembly
Flight Controls Systems:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
Cable Systems:•Types of Cable
•Non-flexible•1x7 or 1x19•1 strand of 7 or 19 wires•Only for straight runs with no change in direction
04/10/23 Author: Harry L. Whitehead 65
Airplane AssemblyAirplane Assembly
Flight Controls Systems:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
Cable Systems:•Types of Cable
•Flexible•7x7
•Straight runs or with large pulleys for small direction changes
•7x19 (formerly Extra Flex.)•Use on any system•Is most common
04/10/23 Author: Harry L. Whitehead 66
Airplane AssemblyAirplane Assembly
Flight Controls Systems:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
Cable Systems:•Types of Cable
•Also:•3 x 7
•only used on very small cable runs for non-critical applications•usually only for control surface position indicators
•6 x 19•for larger than 3/8” diameters
04/10/23 Author: Harry L. Whitehead 67
Airplane AssemblyAirplane Assembly
Flight Controls Systems:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
Cable Systems:•Types of Cable
•Nylon-coated•Made by extruding a nylon coating over CRES cable•Increases service life as keeps clean and less vibration (= less work hardening)
04/10/23 Author: Harry L. Whitehead 68
Airplane AssemblyAirplane Assembly
Flight Controls Systems:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
Cable Systems:•Types of Cable
•LockClad•On some older aircraft for high altitude flight•Is regular cable surrounded by Aluminum tube swaged on entire length•Temperature affects length less
04/10/23 Author: Harry L. Whitehead 69
Airplane AssemblyAirplane Assembly
Flight Controls Systems:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
Cable Systems:•Termination
•Woven•Army-Navy 5-tuck splice or Roebling Roll•Very time consuming to make•Only produce 75% of cable strength
04/10/23 Author: Harry L. Whitehead 70
Airplane AssemblyAirplane Assembly
Flight Controls Systems:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
Cable Systems:•Termination
•Nicopress•Copper sleeves squeezed onto cable•Squeezes:
•1. Center•2. Terminal end•3. Cable end
•Check with Go-NoGo gauge•Develops 100% of cable strength
04/10/23 Author: Harry L. Whitehead 71
Airplane AssemblyAirplane Assembly
Flight Controls Systems:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
Cable Systems:•Termination
•Nicopress•Can use 2 sleeves in series for splice = also 100% of cable strength•Be sure to place slippage mark on edge of sleeve(s) and cable when done
04/10/23 Author: Harry L. Whitehead 72
Airplane AssemblyAirplane Assembly
Flight Controls Systems:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
Cable Systems:•Termination
•Swaged•Most common•Terminal Swaged (squeezed) onto cable•Develops 100% of cable strength
04/10/23 Author: Harry L. Whitehead 73
Airplane AssemblyAirplane Assembly
Flight Controls Systems:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
Cable Systems:•Termination
•Swaged•Use Go-NoGo gauge to check•Apply slippage marks after
04/10/23 Author: Harry L. Whitehead 74
Airplane AssemblyAirplane Assembly
Flight Controls Systems:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
Cable Systems:•Termination
•Proof Load Test•After assembly•Pull with 60% of cable strength
•see AC 43.13-1B for strengths•Apply gradually and hold for 3 minutes•OK = no slippage in terminal(s)
04/10/23 Author: Harry L. Whitehead 75
Airplane AssemblyAirplane Assembly
Flight Controls Systems:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
Cable Systems:•Termination
•Proof Load Test•After assembly•Pull with 60% of cable strength•Apply gradually and hold for 3 minutes•OK = no slippage in terminal(s)
From AC 43.13-1B
04/10/23 Author: Harry L. Whitehead 76
Airplane AssemblyAirplane Assembly
Flight Controls Systems:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
Cable Systems:•Cable Inspection
•Inspect for wear, corrosion, breakage, distortion, or any damage
•Some damage is hidden = should periodically remove cable and inspect thoroughly
•Especially look at where passes over pulleys or through fairleads or within 1 foot of swaged-on terminal
04/10/23 Author: Harry L. Whitehead 77
Airplane AssemblyAirplane Assembly
Flight Controls Systems:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
Cable Systems:•Cable Inspection
•Wear•Replace when is worn 40-50% of outer wires
•Visual to see if wear of wires is blending together = 40-50%•Gaps between wires = excess of 50% wear and must be replaced
04/10/23 Author: Harry L. Whitehead 78
Airplane AssemblyAirplane Assembly
Flight Controls Systems:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
04/10/23 Author: Harry L. Whitehead 79
Airplane AssemblyAirplane Assembly
Flight Controls Systems:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
Cable Systems:•Cable Inspection
•Don’t confuse wear with manufacturer’s splice•Splice OK
04/10/23 Author: Harry L. Whitehead 80
Airplane AssemblyAirplane Assembly
Flight Controls Systems:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
Cable Systems:•Cable Inspection
•Wear•If LockClad or Nylon Coated
•Replace if outer cover is worn through
04/10/23 Author: Harry L. Whitehead 81
Airplane AssemblyAirplane Assembly
Flight Controls Systems:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
Cable Systems:•Cable Inspection
•Damage or Corrosion•Pass rag over length and will snag on broken wires•DON’T USE HAND!
04/10/23 Author: Harry L. Whitehead 82
Airplane AssemblyAirplane Assembly
Flight Controls Systems:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
Cable Systems:•Cable Inspection
•If suspect = remove and bend in loop to make broken wires stand out = replace
04/10/23 Author: Harry L. Whitehead 83
Airplane AssemblyAirplane Assembly
Flight Controls Systems:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
Cable Systems:•Cable Inspection
•Damage or Corrosion•Corrosion is especially prevalent in battery compartments, lavatories, wheel wells•Anywhere a concentration of vapors, fumes or liquids can occur•Exterior corrosion is not bad but probably also has internal corrosion = replace
04/10/23 Author: Harry L. Whitehead 84
Airplane AssemblyAirplane Assembly
Flight Controls Systems:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
Cable Systems:•Cable Inspection
•If cable is kinked or twisted wrong•Replace as wires/strands will not return to original position and strength is less
•Make sure no splice is closer than 2 inches to any pulley or fairlead
04/10/23 Author: Harry L. Whitehead 85
Airplane AssemblyAirplane Assembly
Flight Controls Systems:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
Cable Systems:•Other Components:
•Pulleys•Are phenolic with sealed bearings
•No lubrication necessary•Replace if bearing is rough or dry
•Use for direction change over 3o
04/10/23 Author: Harry L. Whitehead 86
Airplane AssemblyAirplane Assembly
Flight Controls Systems:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
Cable Systems:•Other Components:
•Pulleys•Check for wear patterns•Periodically rotate any which don’t normally rotate much = loosens and evens wear
04/10/23 Author: Harry L. Whitehead 87
Airplane AssemblyAirplane Assembly
Flight Controls Systems:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
Cable Systems:•Other Components:
•Pulleys•Check for wear patterns•Periodically rotate any which don’t normally rotate much = loosens and evens wear
04/10/23 Author: Harry L. Whitehead 88
Airplane AssemblyAirplane Assembly
Flight Controls Systems:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
Cable Systems:•Other Components:
•Pulleys•Make sure cable or pulley guards are used to help keep cable on pulley
04/10/23 Author: Harry L. Whitehead 89
Airplane AssemblyAirplane Assembly
Flight Controls Systems:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
Cable Systems:•Other Components:
•Fairleads•To prevent cable chafing on structure•Maximum deflection allowed is 3o
•Phenolic, plastic, or nylon (= soft material) so fairlead wears instead of cable
Author: Harry L. Whitehead 90
Airplane AssemblyAirplane Assembly
Flight Controls Systems:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
Cable Systems:•Other Components:
•Pressure Seals•Used on pressurized aircraft where cable passes through pressure vessel•Are filled with special grease and shaped so cable passes through but not air pressure•Inspect for proper lube and insure all snap rings are in place (or might jam cable)
04/10/23 Author: Harry L. Whitehead 91
Airplane AssemblyAirplane Assembly
Flight Controls Systems:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
Cable Systems:•Other Components:
•Cable Connectors•Some aircraft use spring-loaded “quick disconnects”•Allows “quick” removal of cable section for inspection and/or replacement
04/10/23 Author: Harry L. Whitehead 92
Airplane AssemblyAirplane Assembly
Flight Controls Systems:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
Cable Systems:•Other Components:
•Bellcranks and Quadrants•Bellcranks transmit lateral movements
•Increase range or mechanical advantage in system
04/10/23 Author: Harry L. Whitehead 93
Airplane AssemblyAirplane Assembly
Flight Controls Systems:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
Cable Systems:•Other Components:
•Bellcranks and Quadrants•Bellcranks transmit lateral movements
•Increase range or mechanical advantage in system
•Quadrants convert cable to push-pull movement
04/10/23 Author: Harry L. Whitehead 94
Airplane AssemblyAirplane Assembly
Flight Controls Systems:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
Cable Systems:•Travel Adjustment & Tension:
04/10/23 Author: Harry L. Whitehead 95
Airplane AssemblyAirplane Assembly
Flight Controls Systems:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
Cable Systems:•Travel Adjustment & Tension:
•Tension varies with temperture as Aluminum structure changes size more than steel cable
04/10/23 Author: Harry L. Whitehead 96
Airplane AssemblyAirplane Assembly
Flight Controls Systems:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
Cable Systems:•Travel Adjustment & Tension:
•Some aircraft have chart to give proper tension (in pounds) for the ambient temperature at time of checking•Small aircraft usually give range of acceptable tensions (for flexibility of temperatures)
04/10/23 Author: Harry L. Whitehead 97
Airplane AssemblyAirplane Assembly
Flight Controls Systems:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
Cable Systems:•Travel Adjustment & Tension:
•Some aircraft have chart to give proper tension (in pounds) for the ambient temperature at time of checking•Small aircraft usually give range of acceptable tensions (for flexibility of temperatures)
04/10/23 Author: Harry L. Whitehead 98
Airplane AssemblyAirplane Assembly
Flight Controls Systems:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
Cable Systems:•Travel Adjustment & Tension:
•Use Tensiometer to check tension•Make sure Riser is proper for cable size•Hook on cable in middle of as long a run as is accessible•Squeeze trigger and read scale
04/10/23 Author: Harry L. Whitehead 99
Airplane AssemblyAirplane Assembly
Flight Controls Systems:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
Cable Systems:•Travel Adjustment & Tension:
•Use Tensiometer to check tension•Use chart to convert scale reading to pounds of tension
04/10/23 Author: Harry L. Whitehead 100
Airplane AssemblyAirplane Assembly
Flight Controls Systems:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
Cable Systems:•Travel Adjustment & Tension:
•Use Tensiometer to check tension•Some large aircraft use automatic tension devices
•Keeps tension constant regardless of temperature
04/10/23 Author: Harry L. Whitehead 101
Airplane AssemblyAirplane Assembly
Flight Controls Systems:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
Cable Systems:•Travel Adjustment & Tension:
•Use Turnbuckles to adjust•Has threaded ends into barrel•One end is left hand thread, one end is right hand thread = turn barrel to change overall length•Barrels available in short and long versions to give some flexibility in installations
04/10/23 Author: Harry L. Whitehead 102
Airplane AssemblyAirplane Assembly
Flight Controls Systems:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
Cable Systems:•Travel Adjustment & Tension:
•Use Turnbuckles to adjust•Don’t lube threads•Must have no more than 3 threads sticking out of barrel or 4 threads into barrel when properly tensioned•Safety with wire or clips
04/10/23 Author: Harry L. Whitehead 103
Airplane AssemblyAirplane Assembly
Flight Controls Systems:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
Cable Systems:•Travel Adjustment & Tension:
04/10/23 Author: Harry L. Whitehead 104
Airplane AssemblyAirplane Assembly
Flight Controls Systems:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
Push-pull Systems:
•General:•Uses all direct mechanical linkages instead of cables•Overall has less play or slop in systems than cable
04/10/23 Author: Harry L. Whitehead 105
Airplane AssemblyAirplane Assembly
Flight Controls Systems:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
Push-pull Systems:
04/10/23 Author: Harry L. Whitehead 106
Airplane AssemblyAirplane Assembly
Flight Controls Systems:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
Push-pull Systems:•General:
•Uses seamless Aluminum tubes•Each end has fitting
•Usually riveted into tube•Have replaceable bearing (rod ends) or fork•If replace make sure Witness Hole (Check Hole) is blocked
•Can’t put wire through•Insures enough threads are engaged
04/10/23 Author: Harry L. Whitehead 107
Airplane AssemblyAirplane Assembly
Flight Controls Systems:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
Push-pull Systems:•General:
•Inspect for condition carefully•Dents, scratches, gouges, etc. in tube bad as is thin walled and will then crack or fail easily (= monocoque structure)•Check bearings/rod ends for wear
•Small amount in each = large amount in system
04/10/23 Author: Harry L. Whitehead 108
Airplane AssemblyAirplane Assembly
Flight Controls Systems:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
Push-pull Systems:
•Bellcranks, Torque Tubes:•Systems use Bellcranks and Torque Tubes to change motion directions or convert from lateral motion to rotary motion
04/10/23 Author: Harry L. Whitehead 109
Airplane AssemblyAirplane Assembly
Flight Controls Systems:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
Push-pull Systems Rigging:•Rigging usually accomplished by adjusting the length(s) of various tubes in the system•Needs to be checked anytime any tube or rod end is replaced or any control surface is replaced
04/10/23 Author: Harry L. Whitehead 110
Airplane AssemblyAirplane Assembly
Flight Controls Systems:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
Push-pull Systems Rigging:•Installation of tubes:
•Center rod ends in forks and tighten check nuts•Allows tubes to rotate slightly during ops with minimal damage to rod ends and forks
04/10/23 Author: Harry L. Whitehead 111
Airplane AssemblyAirplane Assembly
Flight Controls Systems:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
Push-pull Systems Rigging:•Installation of tubes:
•If installing on a bolt or stud•Put open end of rod end away from structure or put large area washer under nut•If bearing comes out of rod end = won’t disconnect tube completely
04/10/23 Author: Harry L. Whitehead 112
Airplane AssemblyAirplane Assembly
Control Surface Balancing:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
General
04/10/23 Author: Harry L. Whitehead 113
Airplane AssemblyAirplane Assembly
Control Surface Balancing:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
General
•If surface is out-of-balance = flutter or buffeting of surface = control problems, uncomfortable ride, premature and extreme wear •Need to check after repairs or painting
04/10/23 Author: Harry L. Whitehead 114
Airplane AssemblyAirplane Assembly
Control Surface Balancing:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
General
•Basically we want the Moments fore and aft of the surface hinge line to be equal
•Think Weight and Balance with the hinge line as CG
•Generally adjusted by adding weight forward of the hinge line as most repairs and paint are aft
04/10/23 Author: Harry L. Whitehead 115
Airplane AssemblyAirplane Assembly
Control Surface Balancing:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
Procedure
•Balance is checked and adjusted Statically•= the surface is not in motion
•The surface is removed from the aircraft and installed on a balance fixture using the hinge bolts
•Usually 2 knife-edges •Must be level and in draft-free environment
04/10/23 Author: Harry L. Whitehead 116
Airplane AssemblyAirplane Assembly
Control Surface Balancing:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
Procedure
04/10/23 Author: Harry L. Whitehead 117
Airplane AssemblyAirplane Assembly
Control Surface Balancing:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
Procedure
•All trim tabs should be in a neutral position•The surface must be level
04/10/23 Author: Harry L. Whitehead 118
Airplane AssemblyAirplane Assembly
Control Surface Balancing:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
Procedure
•Measure whether is Overbalanced or Underbalanced and how much
•Overbalance = chord angles down at the leading edge (nose heavy)•Underbalance = chord angles down at the trailing edge (TE heavy or nose light)•Generally want surface to be somewhat Overbalanced
04/10/23 Author: Harry L. Whitehead 119
Airplane AssemblyAirplane Assembly
Control Surface Balancing:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
Procedure
•Measure whether is Overbalanced or Underbalanced and how much
•Manufacturer will give figures and formulas to determine value•Need to measure force and calculate moment (like Wt. & Bal. problem)•May need special tool (like Cessna 310)
04/10/23 Author: Harry L. Whitehead 120
Airplane AssemblyAirplane Assembly
Control Surface Balancing:
IV. Assembly & Rigging Rigging Specifications Airplane Assembly Flight Control Systems Control Surface Balancing Biplanes
Procedure
•If necessary to add weight, only do so at specified locations and check again after
04/10/23 Author: Harry L. Whitehead 121
Top Related