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Mod 77

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frans(at)privatepilots.nl
Guest

Posted: Fri Aug 10, 2012 1:01 am Post subject: Mod 77

Hi,



I just completed mod 77 (rudder drive mechanism). I was surprised to

learn that I'm the first one to apply it to a finished airplane. Here is

a couple of reasons why you could do this mod:



1) Your built has long finished and you want to retaste that nostalgic

feeling? Mod 77 has it all: Some hardware assembly with rivets,

bearings, nuts and bolts, some foam carving, floxing and BIDding, and

plenty of "I can see it, I can touch it, but not at the same time"

deja-vu's, and last but not least the occasional confusion (text and

pictures both showing different rivets, parts in the bag that are not

listed or used in the project at all). It is the entire built of your

ship in a nutshell.



2) If you, like me, have the weight of your feet resting on the rudder

pedals, consider that it is the lower rudder hinge which is carrying all

this weight, and it is even offset this pulling force. Mod 77 takes all

weight from this hinge and transfers only the differential weight of

your feet to the rudder.



3) The original rudder stop works as a lever mechanism to execute a

massive pulling force on the hinge, especially if slammed to the

starboard side. Mod 77 removes the stops from the rudder and instead has

it incorporated inside the drive mechanism with much more robust parts.



4) Always had this feeling that this control wire running outside of

your ship belongs more on a piper cub than on your sleek Europa? Mod 77

eliminates this control wire, horns and stops and improves the cosmetics

of your ship.



5) This outside control horn and wire seemed to capture all the mud and

grass that the prop and wheels are slinging to this area, and then the

control wire did its best to draw it into the wire opening in the

fuselage, waiting there to jam or freeze itself stuck. Mod 77 reduces

maintenance quite a bit, the entire rudder drive is now inside the ship.



6) The control wire, control horn angled in the airstream, stops, and

rudder bottom cut-off, must create quite some aerodynamic drag. Mod 77

removes all this clutter and as a bonus you can blend in the bottom of

the rudder with the bottom of the tailpost. Probably woth a knot or two.



Oh, for those concerned about weight: The components weigh about 500

grams. But I could remove a good 350 grams of old hardware. Remember the

absurd weight of the original rudder plate, the stacks of washers, etc?



Frans

craigb(at)onthenet.com.au
Guest

Posted: Fri Aug 10, 2012 1:19 am Post subject: Mod 77

Did mine during the build, but it was still fun and games, probably not as

much as yours though

Do not archive

grahamsingleton(at)btinte
Guest

Posted: Fri Aug 10, 2012 2:46 am Post subject: Mod 77

Frans

When I first developed this mod I had to load test it for the LAA. Because of the leverage of the rudder pedals (and our strong legs)

If one pilot pushes hard left and the other one has to overide him the total load on the hing and flange would be nearly 400 Kg.

7 years ago we sold our house and with it went my wonderful workshop. That meant I had to stop making up Mod kits so I persuaded 

David Stanbridge that it would be a good idea for Europa to sell this mod. It works for taildraggers too btw, 

We flew my Long EZ last week for the first time in too many years, it felt wonderful. I am tempted to  revalidate my lisence and fly it from the front again!

Graham

        From: Frans Veldman <frans(at)privatepilots.nl>

 To: europa-list(at)matronics.com 

 Sent: Friday, 10 August 2012, 10:53

 Subject: Mod 77

  

 

--> Europa-List message posted by: Frans Veldman <frans(at)privatepilots.nl (frans(at)privatepilots.nl)>



Hi,



I just completed mod 77 (rudder drive mechanism). I was surprised to

learn  that I'm the first one to apply it to a finished airplane. Here is

a couple of reasons why you could do this mod:



1) Your built has long finished and you want to retaste that nostalgic

feeling? Mod 77 has it all: Some hardware assembly with rivets,

bearings, nuts and bolts, some foam carving, floxing and BIDding, and

plenty of "I can see it, I can touch it, but not at the same time"

deja-vu's, and last but not least the occasional confusion (text and

pictures both showing different rivets, parts in the bag that are not

listed or used in the project at all). It is the entire built of your

ship in a nutshell.



2) If you, like me, have the weight of your feet resting on the rudder

pedals, consider that it is the lower rudder hinge which is carrying all

this weight, and it is even offset this pulling force. Mod 77 takes all

weight from this hinge and transfers only the differential weight of

your feet to the  rudder.



3) The original rudder stop works as a lever mechanism to execute a

massive pulling force on the hinge, especially if slammed to the

starboard side. Mod 77 removes the stops from the rudder and instead has

it incorporated inside the drive mechanism with much more robust parts.



4) Always had this feeling that this control wire running outside of

your ship belongs more on a piper cub than on your sleek Europa? Mod 77

eliminates this control wire, horns and stops and improves the cosmetics

of your ship.



5) This outside control horn and wire seemed to capture all the mud and

grass that the prop and wheels are slinging to this area, and then the

control wire did its best to draw it into the wire opening in the

fuselage, waiting there to jam or freeze itself stuck. Mod 77 reduces

maintenance quite a bit, the entire rudder drive is now inside the ship.



6) The control wire, control horn angled in  the airstream, stops, and

rudder bottom cut-off, must create quite some aerodynamic drag. Mod 77

removes all this clutter and as a bonus you can blend in the bottom of

the rudder with the bottom of the tailpost. Probably woth a knot or two.



Oh, for those concerned about weight: The components weigh about 500

grams. But I could remove a good 350 grams of old hardware. Remember the

absurd weight of the original rudder plate, ics.com/Navigator?Europa-List" ="http://forums.matronics.com/" target="_blank">http://forums.matronics                    &nbsptronics.com/contribution" target="_blank">http://www.matronics.com/contri================



 

 

   

 [quote][b]

frans(at)privatepilots.nl
Guest

Posted: Fri Aug 10, 2012 3:20 am Post subject: Mod 77

Hi Graham!



 	  Quote: 	
		   Because of the leverage of the rudder pedals (and our strong legs)

 If one pilot pushes hard left and the other one has to overide him the

 total load on the hing and flange would be nearly 400 Kg.


	


Wow! I didn't even think about an override and the leverage! 400Kg is a

lot for that poor hinge! Which brings up the question why the standard

construction is even certified... Or why this mod didn't get

incorporated in the standard kit long time ago.



 	  Quote: 	
		   7 years ago we sold our house and with it went my wonderful workshop:-S


	


I even don't want to think about loosing my workshop...



 	  Quote: 	
		   That meant I had to stop making up Mod kits so I persuaded 

 David Stanbridge that it would be a good idea for Europa to sell this

 mod.


	


Just putting the mod somewhere burried onto the website isn't going to

attract many customers... It took a while before I discovered its

existence, and it took me a while to realize the benefits of this mod.



 	  Quote: 	
		   We flew my Long EZ last week for the first time in too many years, it

 felt wonderful. I am tempted to revalidate my lisence and fly it from

 the front again!


	


I think as a relatively newcomer I miss some history here. So you built

a long EZ?



Thanks for inventing this mod 77.



Frans

grahamsingleton(at)btinte
Guest

Posted: Fri Aug 10, 2012 3:44 am Post subject: Mod 77

Frans

The Long EZ was the first aircraft I built, or at least the first model airplane big enough to sit in! First flew

1985 and wore out the engine in the next ten years. I've been refurbishing and upgrading ever since.

Ivan Shaw was a very early Rutan disciple and helped me get started, there were four of us building at 

the time and we used to meet up in the hills, drink beer and talk about the next great design. The goal was an airplane that would have 

Long EZ performance and short field capability and the Europa was Ivan's distillation of all our dreams and ideas.

I claim credit for demanding it should be deriggable in 15 minutes like any self respecting glider. Ivan was persuaded to 

visit one of my local  gliding clubs and see how they  carry on. He always recognises a good idea when he sees one.

Notice the similarity of the tailplane to that of a K6E? 

Graham

        From: Frans Veldman <frans(at)privatepilots.nl>

 To: europa-list(at)matronics.com 

 Sent: Friday, 10 August 2012, 13:12

 Subject: Re: Mod 77

  

 

--> Europa-List message posted by: Frans Veldman <frans(at)privatepilots.nl (frans(at)privatepilots.nl)>



Hi Graham!



 	  Quote: 	
		   Because of the leverage of the rudder pedals (and our strong legs)

 If one pilot pushes hard left and the other one has to overide him the

 total load on the hing and flange would be nearly 400 Kg.


	


Wow! I didn't even think about an override and the leverage! 400Kg is a

lot for that poor hinge! Which brings up the question why the standard

construction is even certified... Or why this mod didn't get

incorporated in the standard kit long time ago.



 	  Quote: 	
		   7 years ago we sold our house and with it went my wonderful workshop:-S


	


I even don't want to think about loosing my workshop...



 	  Quote: 	
		   That meant I had to stop making up Mod kits so I persuaded 

 David Stanbridge that it would be a good idea for Europa to sell this

 mod.


	


Just putting the mod somewhere burried onto the website isn't going  to

attract many customers... It took a while before I discovered its

existence, and it took me a while to realize the benefits of this mod.



 	  Quote: 	
		   We flew my Long EZ last week for the first time in too many years, it

 felt wonderful. I am tempted to revalidate my lisence and fly it from

 the front again!


	


I think as a relatively newcomer I miss some history here. So you built

a long EZ?



Thanks for inventi========================http://forums.matronics                    &nbsptronics.com/contribution" target="_blank">http://www.matronics.com/contri================



 

 

   

 [quote][b]

klinefelter.kevin(at)gmai
Guest

Posted: Fri Aug 10, 2012 5:20 am Post subject: Mod 77

Hi Pete,

How might we access this report?

Kevin

On Aug 10, 2012, at 4:44 AM, Peter Zutrauen <peterz(at)zutrasoft.com (peterz(at)zutrasoft.com)> wrote:

[quote]Frans (and other newer members), 

you may may want to read the great report of Ivan's presentation at the last AGM in the last newsletter - what a great read!  Quite the history lesson (with Graham's contribution included I believe).

Cheers,

Pete

A239

On Fri, Aug 10, 2012 at 8:12 AM, Frans Veldman <frans(at)privatepilots.nl (frans(at)privatepilots.nl)> wrote:

   	  Quote: 	
		  --> Europa-List message posted by: Frans Veldman <frans(at)privatepilots.nl (frans(at)privatepilots.nl)>

 Hi Graham!

 > Because of the leverage of the rudder pedals (and our strong legs)

 > If one pilot pushes hard left and the other one has to overide him the

 > total load on the hing and flange would be nearly 400 Kg.

 Wow! I didn't even think about an override and the leverage! 400Kg is a

 lot for that poor hinge! Which brings up the question why the standard

 construction is even certified... Or why this mod didn't get

 incorporated in the standard kit long time ago.

 > 7 years ago we sold our house and with it went my wonderful workshop:-S

 I even don't want to think about loosing my workshop...

 > That meant I had to stop making up Mod kits so I persuaded

 > David Stanbridge that it would be a good idea for Europa to sell this

 > mod.

 Just putting the mod somewhere burried onto the website isn't going to

 attract many customers... It took a while before I discovered its

 existence, and it took me a while to realize the benefits of this mod.

 > We flew my Long EZ last week for the first time in too many years, it

 > felt wonderful. I am tempted to revalidate my lisence and fly it from

 > the front again!

 I think as a relatively newcomer I miss some history here. So you built

 a long EZ?

 Thanks for inventing this mod 77.

 Frans

 ===========

  target="_blank">http://www.matronics.com/Navigator?Europa-List

 ===========

 http://forums.matronics.com

 ===========

 le, List Admin.

 ="_blank">http://www.matronics.com/contribution

 ===========

[b]

stephen vestuti

Joined: 05 Jul 2011
Posts: 62
Location: Wales, UK

Posted: Fri Aug 10, 2012 8:52 am Post subject: Re: Mod 77

Graham, 

I let my license lapse in 2010, ( kids, wife, spending too much money on 

myself Etc.)  I revalidated 6 Months later - I couldn't stand it any more & 

I was missing my Europa more & more everyday.



I hope to hear that you have flown your long Ez from the front, life is just too short .



Steve    #630

steven.pitt2(at)ntlworld.
Guest

Posted: Fri Aug 10, 2012 10:45 pm Post subject: Mod 77

Kevin, 

 As a Member of the Europa Club you should be  receiving the Europa Flyer in which is contained the report on Ivan's  presentation ( as well as a fantastic photo montage of Flying to Kitty Hawk by  Troy and Donna Maynor).

 I have been trying to persuade our Treasurer (who  shot a video of the presentation) to get it on You Tube or whatever but he has a  Europa to build (which we keep on nagging him to finish)so he is finding time  difficult to edit the video.

 Regards

 Steve Pitt

 Chairman, Europa Club

 [quote]   ---

g-iani(at)ntlworld.com
Guest

Posted: Sat Aug 11, 2012 12:54 am Post subject: Mod 77

Frans



How about an article for the Europa Flyer?  It would be nice to know how you

achieved the near impossible ("I can see it, I can touch it, but not at the

same time") installation of the bell-crank assembly in a completed aircraft.

If it seems possible for normal mortals (not Dutch) I can add it to the

instructions.



I need all the help  I can get to get the documentation right (as no one at

Europa can help).



The parts list, on pages 1 & 2,  should be correct so please let me know if

you have spotted any errors.  Any other parts supplied in error needs

reporting back to Europa.



As you say the rivets supplied would have been TLPD435BS.  Apologies, I

missed the reference in section 3.6 to the original (AN470-AD4-10) rivets

which they replace.  This change was made as few builders have rivet punches

to form nice heads on solid rivets.



I have already added a reference to refinishing the base of the rudder to

the latest revision.

Best wishes

Ian Rickard G-IANI XS Trigear, 300hours

Europa Club Mods Specialist

e-mail g-iani(at)ntlworld.com

grahamsingleton(at)btinte
Guest

Posted: Sat Aug 11, 2012 1:56 am Post subject: Mod 77

Steve

Maybe we should start a countdown for Nigel's lift off?!?!

How long is it now, almost as long as it took me to refurbish my EZ!

Graham

        From: Steven Pitt <steven.pitt2(at)ntlworld.com>

 To: europa-list(at)matronics.com 

 Sent: Saturday, 11 August 2012, 7:44

 Subject: Re: Mod 77

  

 

         Kevin, 

 As a Member of the Europa Club you should be  receiving the Europa Flyer in which is contained the report on Ivan's  presentation ( as well as a fantastic photo montage of Flying to Kitty Hawk by  Troy and Donna Maynor).

 I have been trying to persuade our Treasurer (who  shot a video of the presentation) to get it on You Tube or whatever but he has a  Europa to build (which we keep on nagging him to finish)so he is finding time  difficult to edit the video.

 Regards

 Steve Pitt

 Chairman, Europa Club

 [quote]   ---

peterz(at)zutrasoft.com
Guest

Posted: Sat Aug 11, 2012 3:48 am Post subject: Mod 77

I for one would really love to Watch that video!  YouTube would be fantastic!

Cheers, and if it goes up, many thanks!

Pete

a239



On Aug 11, 2012, at 2:44 AM, "Steven Pitt" <steven.pitt2(at)ntlworld.com (steven.pitt2(at)ntlworld.com)> wrote:



[quote]       Kevin, 

 As a Member of the Europa Club you should be  receiving the Europa Flyer in which is contained the report on Ivan's  presentation ( as well as a fantastic photo montage of Flying to Kitty Hawk by  Troy and Donna Maynor).

 I have been trying to persuade our Treasurer (who  shot a video of the presentation) to get it on You Tube or whatever but he has a  Europa to build (which we keep on nagging him to finish)so he is finding time  difficult to edit the video.

 Regards

 Steve Pitt

 Chairman, Europa Club

 [quote]   ---

frans(at)privatepilots.nl
Guest

Posted: Sun Aug 19, 2012 6:32 am Post subject: Mod 77

Ian,



On 08/11/2012 10:52 AM, G-IANI wrote:



 	  Quote: 	
		   How about an article for the Europa Flyer?  It would be nice to know how you

 achieved the near impossible ("I can see it, I can touch it, but not at the

 same time") installation of the bell-crank assembly in a completed aircraft.


	


That would not be too much trouble, but I didn't make any pictures of 

the installation.



 	  Quote: 	
		   If it seems possible for normal mortals (not Dutch) I can add it to the

 instructions.


	


One very important thing: I had already installed a vent opening in the 

sternpost to receive a 2" scat hose connected to the cabin. I made this 

connector removable with 3 anchor nuts in the flange. This 2" opening in 

the sternpost appeared to be handy for many things; if I ever wanted to 

take the elevator push rod out I could do it via this opening, but it is 

also handy for visual inspection of the tunnel from the rear of the 

ship, it just adds another angle to look at things. Now it came in handy 

for installation of mod 77. For the most part I could use it as a peek 

hole while working through the standard hatch, and I also used it to get 

a flexible drill extension in to drill the required holes.



Because I think it is impossible to do mod 77 without such an opening in 

the sternpost I would propose to create this opening first. You could 

install it at the approximate height where the push rod for the rudder 

will pass through, and later put a cover on the opening with a hole in 

it for the push rod. This way it is also much easier to determine where 

exactly the opening for the push rod should be. And if you are not happy 

with the result you just make a new cover; instead if you have to make 

the hole in the sternpost you only have one shot at it and it will 

likely end up larger than necessary.



 	  Quote: 	
		   The parts list, on pages 1&  2,  should be correct so please let me know if

 you have spotted any errors.


	


The confusion was mainly on part of the rivets. Not only in the docs but 

I also received a confusing set of rivets, including the dreaded 

AN470-AD4-10's. I also received too many cotter pins, too many cable 

ends, 4 very long AN525 bolts for no purpose. Oh and there is no mention 

in the document about the connection of the rudder end of the push rod. 

I received an EUR001 safety washer for it, the manual says to attach it 

similar as the other end, but as the rudder end has two lips instead of 

one the eye-bolt can't go anywhere anyway. I just put some AN416L 

washers on both ends between the lips.

I would also like to see a different way to attach the push rod to the 

rudder, as it is very difficult to tighten the nut on the AN4-bolt via 

the rudder gap. Maybe just a bolt with a cotter pin through it would do?

Anyway, you can't access it with a normal socket, and with a spanner the 

clearance is not enough to make a sufficient turn. I ended up using two 

ratcheting spanners but just one "click" is all I can get, so it takes 

hours to tighten the nut. (And no, you can't connect the push rod to the 

rudder first, as there is no way you can handle two spanners through the 

hatch to tighten the other end afterwards (I can get only one hand in it 

at the same time). Now I think of it: Maybe an anchor nut on that metal 

plate would make things easier, instead of the nut and bolt.



Oh, and I discovered that the push rod is just as heavy as the rest of 

the assembly. Is there a reason why this is from steel instead of 

aluminium? We used aluminium for all the other controls in the ship (it 

looks like the aileron push rod is the same diameter but then in 

aluminium), so why has this one to be from heavy steel?



 	  Quote: 	
		   I have already added a reference to refinishing the base of the rudder to

 the latest revision.


	


Great!



Frans

g-iani(at)ntlworld.com
Guest

Posted: Wed Aug 29, 2012 2:25 am Post subject: Mod 77

Frans



Apologies for not replying earlier to your reply of 19/08.  Andy Draper has

had a sudden attack of needing to tidy up some of the paperwork.  The result

is a new Standard Mod (for the Andair fuel selector) and the Fuel Flow SM

updated for the FT-60 (Red cube) flow sensor.  Not much use if you know what

you are doing but it makes the upgrades legal in the UK.



I think it is worth saying that on Mod 77 I inherited a partially

undocumented mess.  Graham sold Mod 77 to David Stanbridge who then

announced it as available.  The fact that nobody at Europa had ever seen one

(never mind built one) seems to have escaped David's notice.



I think the bill of materials [BOM] used when you got your parts was the old

one.  I have checked with Europa and they are now using the new one included

in the document.



 	  Quote: 	
		  > One very important thing: I had already installed a vent opening in the

sternpost <<
	




Yes as I have on G-IANI.  The pictures were taken on G-IRON which was being

rebuilt so the hole was not needed.  I will add a reference to adding this

hole for a retro fit.  If time permits I may do Mod 77 on G-IANI this winter

and can photograph the work.



 	  Quote: 	
		  > Oh and there is no mention in the document about the connection of the

rudder end of the push rod.<<.
	




There is (see section 3.7) but it is easy to miss



 	  Quote: 	
		  >I received an EUR001 safety washer for it, the manual says to attach it

similar as the other end, but as the rudder end has two lips instead of one
	


the eye-bolt can't go anywhere anyway. I just put some AN416L washers on

both ends between the lips.<<



You are right I will try and make this clearer.



 	  Quote: 	
		  >I would also like to see a different way to attach the push rod to the

rudder, as it is very difficult to tighten the nut on the AN4-bolt via the
	


rudder gap. Maybe just a bolt with a cotter pin through it would do?

Anyway, you can't access it with a normal socket, and with a spanner the

clearance is not enough to make a sufficient turn. I ended up using two

ratcheting spanners but just one "click" is all I can get, so it takes hours

to tighten the nut. (And no, you can't connect the push rod to the rudder

first, as there is no way you can handle two spanners through the hatch to

tighten the other end afterwards (I can get only one hand in it at the same

time). Now I think of it: Maybe an anchor nut on that metal plate would make

things easier, instead of the nut and bolt.<<



I think I prefer the idea of using an anchor nut on the CS33.



 	  Quote: 	
		  >Is there a reason why this is from steel instead of aluminium? We used

aluminium for all the other controls in the ship (it looks like the aileron
	


push rod is the same diameter but then in aluminium), so why has this one to

be from heavy steel?<<



I think it is just history and people being conservative.  It is 100 grams

heavier than the Al tube of this length.  The forces on this rod are

considerably higher than on the aileron rod and a structural engineer will

need to convince the LAA that the Al tube would not bend.



We make progress slowly

Ian Rickard G-IANI XS Trigear, 300hours

Europa Club Mods Specialist

e-mail g-iani(at)ntlworld.com

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