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601 Rudder light fairing fit

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paulried(at)rogers.com
Guest

Posted: Sun Apr 15, 2007 10:41 am Post subject: 601 Rudder light fairing fit

I have fitted the supplied fiberglass fairing for the  rudder nav light but it is so poorly made that the surface where the aluminum  mounting bracket sits is not flat (about 1/8" height difference on the mold line  where the two halves are joined).  Also and likely more importantly, the  edges of the fairing curl up away from the rudder skin when it is clecoed in  place.  How do you get the fairing to lay flush with the rudder  skin?

  

 I have attached a small photo in case my description  above is not clear.

  

 Any help with these two issue would be  appreciated!  Man I hate fiberglass!  My hands are  itchy.

  

  

 Paul Riedlinger

 paulried(at)rogers.com

15_04_07_Finishing_up_rudder_023.jpg

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dredmoody(at)cox.net
Guest

Posted: Sun Apr 15, 2007 11:39 am Post subject: 601 Rudder light fairing fit

Hi Paul,

  

 I haven't worked on your specific problem but in  general, if a composite part (fiberglass, plexiglas, Lexan, etc.) is not fitting  properly and passively, heat the #%!*%!!# with a paintstripper heat gun. Start  at lower temperature and work on it patiently so that you reshape the part  using the lowest temperature that will soften it  enough to overcome its memory. Let me stress that part about low  heat / long heat up time. If you get impatient and ramp up the temp too much to  get a quick response, you may screw up the part. Once the part is warm enough to  lose its shape memory, bend it just past where you want it to stay and  maintain that position while it cools. It takes time, patience, and there is a  learning curve, but it will work.

  

 Good luck. Hope that helps,

  

 Dred

 [quote]   ---

jeffrey_davidson(at)earth
Guest

Posted: Sun Apr 15, 2007 12:22 pm Post subject: 601 Rudder light fairing fit

Well Paul, your fiberglass fairing looks better than mine!  I'm just about to install it too.  For mine, I will heat it up and try to get a little better shape out of the fiberglass.  The fit as it came really is not acceptable. It is too late for me, but if this fairing is installed as the rudder is built, the fairing can be installed with the fiberglass flange on the inside giving a much cleaner installation.  

   

Jeff  Davidson  

         

  

  

   

I have fitted the supplied fiberglass fairing for the rudder nav light but it is so poorly made that the surface where the aluminum mounting bracket sits is not flat (about 1/8" height difference on the mold line where the two halves are joined).  Also and likely more importantly, the edges of the fairing curl up away from the rudder skin when it is clecoed in place.  How do you get the fairing to lay flush with the rudder skin?  

   

I     

   

  

   

   

        [quote][b]

paulried(at)rogers.com
Guest

Posted: Sun Apr 15, 2007 12:50 pm Post subject: 601 Rudder light fairing fit

Jeff:  

   

Good idea, but too late for me I think.  The one side is still open by a few rivets (per Canadian inspection reg’s).  I am going to try using a heat gun later tonight to see if that works.  

     

   

Paul Riedlinger  

paulried(at)rogers.com  

  

       

From: owner-zenith-list-server(at)matronics.com [mailto:owner-zenith-list-server(at)matronics.com] On Behalf Of Jeff 

 Sent: April-15-07 4:23 PM

 To: zenith-list(at)matronics.com

 Subject: RE: 601 Rudder light fairing fit  

  

  

   

Well Paul, your fiberglass fairing looks better than mine!  I'm just about to install it too.  For mine, I will heat it up and try to get a little better shape out of the fiberglass.  The fit as it came really is not acceptable. It is too late for me, but if this fairing is installed as the rudder is built, the fairing can be installed with the fiberglass flange on the inside giving a much cleaner installation.  

   

Jeff Davidson  

         

  

  

   

I have fitted the supplied fiberglass fairing for the rudder nav light but it is so poorly made that the surface where the aluminum mounting bracket sits is not flat (about 1/8" height difference on the mold line where the two halves are joined).  Also and likely more importantly, the edges of the fairing curl up away from the rudder skin when it is clecoed in place.  How do you get the fairing to lay flush with the rudder skin?  

   

I     

   

  

   

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TxDave

Joined: 22 Jul 2006
Posts: 168
Location: Temple, TX

Posted: Sun Apr 15, 2007 1:34 pm Post subject: Re: 601 Rudder light fairing fit

Hey Paul,



Dred's advice works well. I used the same technique on my fiberglass wingtip. I had to adjust the flanges for a good fit with the wing skin. I didn't have access to a paint stripper heat gun, so I borrowed my wife's blow dryer. It worked just fine. She never knew.



Dave Clay

bryanmmartin

Joined: 10 Jan 2006
Posts: 1018

Posted: Sun Apr 15, 2007 1:53 pm Post subject: 601 Rudder light fairing fit

On Apr 15, 2007, at 4:22 PM, Jeff wrote:



 	  Quote: 	
		   It is too late for me, but if this fairing is installed as the  

 rudder is built, the fairing can be installed with the fiberglass  

 flange on the inside giving a much cleaner installation.

That's what I did with mine, looks great.
	


-- 

Bryan Martin

N61BM, CH 601 XL,

RAM Subaru, Stratus redrive.

do not archive.

_________________
--
Bryan Martin
N61BM, CH 601 XL, Stratus Subaru.
do not archive.

paulried(at)rogers.com
Guest

Posted: Sun Apr 15, 2007 2:03 pm Post subject: 601 Rudder light fairing fit

Thanks Dave.  Now that the Nascar race is over, I am headed back to the

garage... and yes, before you ask, I am likely the only Nascar fan in

Toronto!  My excuse is I lived in NC for 11 years and caught the bug.



Paul Riedlinger

paulried(at)rogers.com

www.mykitlog.com/paulried/

--

planecrazydld(at)yahoo.co
Guest

Posted: Sun Apr 15, 2007 2:32 pm Post subject: 601 Rudder light fairing fit

I have seen this come by several times and this is just a thought:



The tail is not mass balanced but the plane flies slowly so the idea of flutter is not very alarming. Notching the rudder trailing edge to achieve a cosmetic effect is not something to do lightly as any "loosening" of the control surface will reduce whatever flutter margin there is to some degree. A nicely faired external fitting is also quite possible.

Jeff  <jeffrey_davidson(at)earthlink.net> wrote:[quote]        v\:* {behavior:url(#default#VML);} o\:* {behavior:url(#default#VML);} w\:* {behavior:url(#default#VML);} .shape {behavior:url(#default#VML);}  <![endif]-->   st1\:*{behavior:url(#default#ieooui) }  <![endif]-->       <![endif]-->       <![endif]-->     Well Paul, your fiberglass fairing looks better than mine!  I'm just about to install it too.  For mine, I will heat it up and try to get a little better shape out of the fiberglass.  The fit as it came really is not acceptable. It is too late for me, but if this fairing is installed as the rudder is built, the fairing can be installed with the fiberglass flange on the inside giving a much cleaner installation.

   

  Jeff  Davidson

   

        

  

   

  I have fitted the supplied fiberglass fairing for the rudder nav light but it is so poorly made that the surface where the aluminum mounting bracket sits is not flat (about 1/8" height difference on the mold line where the two halves are joined).  Also and  likely more importantly, the edges of the fairing curl up away from the rudder skin when it is clecoed in place.  How do you get the fairing to lay flush with the rudder skin?

   

  I 

     

  

   

   

  

        [quote][b]Ahhh...imagining that irresistible "new car" smell?

 Check out [url=http://us.rd.yahoo.com/evt=48245/*http://autos.yahoo.com/new_cars.html;_ylc=X3oDMTE1YW1jcXJ2BF9TAzk3MTA3MDc2BHNlYwNtYWlsdGFncwRzbGsDbmV3LWNhcnM-]new cars at Yahoo! Autos.[/url]  [quote][b]

amyvega2005(at)earthlink.
Guest

Posted: Sun Apr 15, 2007 6:01 pm Post subject: 601 Rudder light fairing fit

regarding the rudder light fairng,  alittle Superfill will do the trick.



Juan



--

Tim Juhl

Joined: 21 Mar 2006
Posts: 488
Location: "Thumb" of Michigan

Posted: Mon Apr 16, 2007 2:25 pm Post subject: Re: 601 Rudder light fairing fit

I would use the heat and a flat piece of aluminum to push the edges down that attach to the rudder.  As to where the light attaches.....  rough up the gel coat and apply a little superfil between the fiberglass and the metal piece.  Cover the bottom of the metal piece with duct tape as the superfil will not adhere to that.  After it sets up you can sand it conform with the rest of the piece.



You will probably use superfil or a mix of resin and microballoons in other places to fix the fiberglass pieces.   DO NOT use polyester resins.....  epoxy resin such as the west system works best.  Polyester resins will shrink with time.



Tim

_________________
______________
CFII
Champ L16A flying
Zodiac XL - Jabiru 3300A
Almost done! It'll fly in spring!

paulried(at)rogers.com
Guest

Posted: Mon Apr 16, 2007 3:49 pm Post subject: 601 Rudder light fairing fit

Thanks for the suggestions Tim.  

Paul Riedlinger

paulried(at)rogers.com



--

paulried(at)rogers.com
Guest

Posted: Mon Apr 16, 2007 6:41 pm Post subject: 601 Rudder light fairing fit

Just to finish this thread up, thanks to all of the people  who replied.

  

 I used an old heat gun I had from my model airplane days  (used to  shrink Monocote) and it took me all of 5 minutes to fix the  problem.  I left the fairing clecoed to the rudder, and in heating the part  up, it just naturally fell down to the rudder surface!  Nice.  It is  not perfect, but a whole lot better than before.  The rest can be handled  with superfil

  

  

  

 Cheers

  

  

 Paul Riedlinger

 paulried(at)rogers.com

  



   From: owner-zenith-list-server(at)matronics.com  [mailto:owner-zenith-list-server(at)matronics.com] On Behalf Of David  Downey

Sent: April 15, 2007 6:33 PM

To:  zenith-list(at)matronics.com

Subject: RE: 601 Rudder light  fairing fit

 

I have seen this come by several times and this is just a  thought:



The tail is not mass balanced but the plane flies slowly so the  idea of flutter is not very alarming. Notching the rudder trailing edge to  achieve a cosmetic effect is not something to do lightly as any "loosening" of  the control surface will reduce whatever flutter margin there is to some degree.  A nicely faired external fitting is also quite possible.

Jeff  <jeffrey_davidson(at)earthlink.net> wrote: [quote]      v\:* { 	BEHAVIOR: url(#default#VML) } o\:* { 	BEHAVIOR: url(#default#VML) } w\:* { 	BEHAVIOR: url(#default#VML) } .shape { 	BEHAVIOR: url(#default#VML) }  <![endif]-->   st1\:* { 	BEHAVIOR: url(#default#ieooui) }  <![endif]-->   (at)page Section1 {size: 8.5in 11.0in; margin: 1.0in 1.25in 1.0in 1.25in; } P.MsoNormal { 	FONT-SIZE: 12pt; MARGIN: 0in 0in 0pt; FONT-FAMILY: "Times New Roman" } LI.MsoNormal { 	FONT-SIZE: 12pt; MARGIN: 0in 0in 0pt; FONT-FAMILY: "Times New Roman" } DIV.MsoNormal { 	FONT-SIZE: 12pt; MARGIN: 0in 0in 0pt; FONT-FAMILY: "Times New Roman" } A:link { 	COLOR: blue; TEXT-DECORATION: underline } SPAN.MsoHyperlink { 	COLOR: blue; TEXT-DECORATION: underline } A:visited { 	COLOR: purple; TEXT-DECORATION: underline } SPAN.MsoHyperlinkFollowed { 	COLOR: purple; TEXT-DECORATION: underline } SPAN.EmailStyle17 { 	COLOR: navy; FONT-FAMILY: Arial; mso-style-type: personal-reply } DIV.Section1 { 	page: Section1 }     <![endif]-->       <![endif]-->      Well Paul, your    fiberglass fairing looks better than mine!  I'm just about to install it    too.  For mine, I will heat it up and try to get a little better shape    out of the fiberglass.  The fit as it came really is not acceptable. It    is too late for me, but if this fairing is installed as the rudder is built,    the fairing can be installed with the fiberglass flange on the inside giving a    much cleaner installation.

   

   Jeff    Davidson

   

            



   

   I have fitted the    supplied fiberglass fairing for the rudder nav light but it is so poorly made    that the surface where the aluminum mounting bracket sits is not flat (about    1/8" height difference on the mold line where the two halves are    joined).  Also and likely more importantly, the edges of the fairing curl    up away from the rudder skin when it is clecoed in place.  How do you get    the fairing to lay flush with the rudder skin?

   

   I    

      



   

   



 	  Quote: 	
		  Ahhh...imagining that irresistible "new car" smell? Check out

[url=http://us.rd.yahoo.com/evt=48245/*http://autos.yahoo.com/new_cars.html;_ylc=X3oDMTE1YW1jcXJ2BF9TAzk3MTA3MDc2BHNlYwNtYWlsdGFncwRzbGsDbmV3LWNhcnM-]new cars at Yahoo! Autos.[/url]



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