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rob(at)hyperion-ef.com
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 Posted: Sun Feb 23, 2014 3:53 pm Post subject: Mod 76 - Altitude Hold Autopilot |
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Assuming that I am not the only one foolish enough to attempt a retro-fit of Mod 76 (Dynon) to a completed airframe I would appreciate any help from others who have done so.
I am currently at an impasse. Removal of CS10 and replacing it with CS10/2 was tedious but relatively straightforward to complete, although the Europa Factory instructions manage to overlook a few essential points. I am stymied by my inability to get the nut on the bolt that attaches the rod end to the horn on CS10/2. With perseverance I managed to get the bolt through the horn on CS10/2 and the rod end, but my not very large hands cannot do both: hold the MS31042-3 nut and rotate it after I get it near the threaded end of the AN3-7A bolt. So far I have failed even to get the nut aligned so the bolt could be turned into the nut. At this point I am considering cutting another access hole in the bottom of the fuselage but only as a last resort would I start cutting.
Suggestions?
Best regards,
Rob Housman
Irvine, California
Europa XS
Rotax 914
S/N A070
Airframe complete
Avionics in progress
[quote][b]
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rparigoris
Joined: 24 Nov 2009
Posts: 796
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| Posted: Sun Feb 23, 2014 4:08 pm Post subject: Re: Mod 76 - Altitude Hold Autopilot |
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Hi Rob
I don't know exactly what you are up against, but some things I use to start difficult nuts:
Grease on finger to hold, them
Contact cement on finger to hold them
Use magnets, all sorts of possibilities like just holding the magnet, or magnet on a stick or wire or even on a wrench
Use JB KWIK weld or rapid epoxy to glue nut to piece of something, this is only temporary and you pull it off once started, like thin metal or wire or anything that makes sense
Can you glue the nut to whatever it lives on first? Then use Redux or JB
Can you permanently install a nut? Nut plate? Tack welded nut to where it lives?
Ron Parigoris
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rob(at)hyperion-ef.com
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| Posted: Sun Feb 23, 2014 5:01 pm Post subject: Mod 76 - Altitude Hold Autopilot |
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Thanks Ron; all good suggestions but unfortunately none is suitable. See
the attached photo and you'll understand why. The perspective is from the
starboard side looking through the opening for the spar. The stick is full
down elevator and anything much less than full makes it impossible even to
see the offending bolt.
Best regards,
Rob Housman
Irvine, California
Europa XS
Rotax 914
S/N A070
Airframe complete
Avionics in progress
--
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rob(at)hyperion-ef.com
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| Posted: Sun Feb 23, 2014 5:33 pm Post subject: Mod 76 - Altitude Hold Autopilot |
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OOPS, that's from the PORT side.
Best regards,
Rob Housman
Irvine, California
Europa XS
Rotax 914
S/N A070
Airframe complete
Avionics in progress
--
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nigel_graham(at)m-tecque.
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| Posted: Mon Feb 24, 2014 12:12 am Post subject: Mod 76 - Altitude Hold Autopilot |
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Hello Rob, I recently had to strip out and refit the CS10 and had to face the same problem so know exactly what you are up against. There is a solution. Ideally you need a trusty assistant - though I did succeed by myself (it took a whole afternoon though  )
I used a long socket, and filled it with spare nuts such that it prevented the nut you are attempting to tighten - sliding down into the barrel of the socket. I magnetised the socket by stroking it a few times with a strong magnet - that ensured that the nut would not drop out. Now the nut can be held precisely.
The next bit seems non-intuitive, but tighten the bolt (not the nut) from the other side of the aircraft using your assistant and a long socket drive extension.
All you need to focus on is keeping the nut in place (a long socket is easier to hold) until the thread catches. The only other thing to consider is keeping the washers in place until the bolt is inserted - this was done by sticking the washers using a blob of grease.
It is possible to achieve without resorting to an angle grinder!
Nigel
On 23/02/2014 23:52, Rob Housman wrote:
[quote] <![endif]--> <![endif]-->
Assuming that I am not the only one foolish enough to attempt a retro-fit of Mod 76 (Dynon) to a completed airframe I would appreciate any help from others who have done so.
I am currently at an impasse. Removal of CS10 and replacing it with CS10/2 was tedious but relatively straightforward to complete, although the Europa Factory instructions manage to overlook a few essential points. I am stymied by my inability to get the nut on the bolt that attaches the rod end to the horn on CS10/2. With perseverance I managed to get the bolt through the horn on CS10/2 and the rod end, but my not very large hands cannot do both: hold the MS31042-3 nut and rotate it after I get it near the threaded end of the AN3-7A bolt. So far I have failed even to get the nut aligned so the bolt could be turned into the nut. At this point I am considering cutting another access hole in the bottom of the fuselage but only as a last resort would I start cutting.
Suggestions?
Best regards,
Rob Housman
Irvine, California
Europa XS
Rotax 914
S/N A070
Airframe complete
Avionics in progress
[b]
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rparigoris
Joined: 24 Nov 2009
Posts: 796
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| Posted: Mon Feb 24, 2014 7:31 am Post subject: Re: Mod 76 - Altitude Hold Autopilot |
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Hi Rob
Hmm, it looks to me like if you put a some scotch-tape around the nut and jammed in either a box wrench or socket it may work?
If you were to use 1/4" socket with lots of extensions and universal/s could you get to the bolt?
If not how about using a short, medium or long box wrench? If not, then buy a cheap box wrench, cut, heat up and bend if needed and weld on an extension, or use a box wrench you have and bend up a metal bar and use hose clamps to hold it?
Since you are in there, get some inspection lacquer and mark the jam nut for the ball fitting.
Ron Parigoris
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rob(at)hyperion-ef.com
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| Posted: Mon Feb 24, 2014 8:48 am Post subject: Mod 76 - Altitude Hold Autopilot |
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Nigel: What you describe is almost exactly how I connected the port and starboard pitch push rods to CS10/2, the only difference being that I did not need to magnetize the socket. Both of these connections are relatively easy to reach but that (at)#$%^&* third horn on CS10/2 is (so far) not within my reach with either fingers or tools.
Ron: My problem is access. My combination of universal joints, extensions and sockets will not clear the obstructions which include the support bracket holding CS10/2 and the aileron bell crank where it mounts to the end of CS05 torque tube. In other words, I cannot manage to get the tools to align coaxially with the bolt even if I could get the nut onto the bolt manually, which I can’t.
Next up: Unless someone presents a simpler solution, I’ll remove CS10/2 and attach only the rod end to it and then after CS10/2 is reinstalled, attempt to thread the servo push rod onto the rod end already in place. Only if this fails will I resort to cutting another access port in the bottom of the fuselage.
Incidentally, prior to installing CS10/2 I used 5 minute epoxy to hold all of those washers in place and used a greased pin slightly smaller than the size of the bolt holes to maintain alignment during cure. With my many attempts to assemble the rod end to CS10/2 these washers have remained in place.
Best regards,
Rob Housman
Irvine, California
Europa XS
Rotax 914
S/N A070
Airframe complete
Avionics in progress
From: owner-europa-list-server(at)matronics.com [mailto:owner-europa-list-server(at)matronics.com] On Behalf Of nigel_graham(at)m-tecque.co.uk
Sent: Monday, February 24, 2014 12:11 AM
To: europa-list(at)matronics.com
Subject: Re: Mod 76 - Altitude Hold Autopilot
Hello Rob, I recently had to strip out and refit the CS10 and had to face the same problem so know exactly what you are up against. There is a solution. Ideally you need a trusty assistant - though I did succeed by myself (it took a whole afternoon though )
I used a long socket, and filled it with spare nuts such that it prevented the nut you are attempting to tighten - sliding down into the barrel of the socket. I magnetised the socket by stroking it a few times with a strong magnet - that ensured that the nut would not drop out. Now the nut can be held precisely.
The next bit seems non-intuitive, but tighten the bolt (not the nut) from the other side of the aircraft using your assistant and a long socket drive extension.
All you need to focus on is keeping the nut in place (a long socket is easier to hold) until the thread catches. The only other thing to consider is keeping the washers in place until the bolt is inserted - this was done by sticking the washers using a blob of grease.
It is possible to achieve without resorting to an angle grinder!
Nigel
On 23/02/2014 23:52, Rob Housman wrote:
| Quote: |
Assuming that I am not the only one foolish enough to attempt a retro-fit of Mod 76 (Dynon) to a completed airframe I would appreciate any help from others who have done so.
I am currently at an impasse. Removal of CS10 and replacing it with CS10/2 was tedious but relatively straightforward to complete, although the Europa Factory instructions manage to overlook a few essential points. I am stymied by my inability to get the nut on the bolt that attaches the rod end to the horn on CS10/2. With perseverance I managed to get the bolt through the horn on CS10/2 and the rod end, but my not very large hands cannot do both: hold the MS31042-3 nut and rotate it after I get it near the threaded end of the AN3-7A bolt. So far I have failed even to get the nut aligned so the bolt could be turned into the nut. At this point I am considering cutting another access hole in the bottom of the fuselage but only as a last resort would I start cutting.
Suggestions?
Best regards,
Rob Housman
Irvine, California
Europa XS
Rotax 914
S/N A070
Airframe complete
Avionics in progress
|
[quote][b]
| | - The Matronics Europa-List Email Forum - | | | Use the List Feature Navigator to browse the many List utilities available such as the Email Subscriptions page, Archive Search & Download, 7-Day Browse, Chat, FAQ, Photoshare, and much more:
http://www.matronics.com/Navigator?Europa-List |
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rob(at)hyperion-ef.com
Guest
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| Posted: Tue Feb 25, 2014 1:37 pm Post subject: Mod 76 - Altitude Hold Autopilot |
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UPDATE:
Before removing CS10/2 I tried once more to get the offending nut onto the bolt with the assistance of my son’s slightly smaller hands. Success! Once the nut was aligned with the bolt I could turn the bolt with one finger (through the hole in the seat back) just enough to keep the nut it in place. Then with a box wrench on the nut (again through the seat back), and access from the starboard side, used a socket on a very long assembly of extensions to turn the bolt until everything was tight.
Best regards,
Rob Housman
Irvine, California
Europa XS
Rotax 914
S/N A070
Airframe complete
Avionics in progress
From: owner-europa-list-server(at)matronics.com [mailto:owner-europa-list-server(at)matronics.com] On Behalf Of Rob Housman
Sent: Monday, February 24, 2014 8:48 AM
To: europa-list(at)matronics.com
Subject: RE: Mod 76 - Altitude Hold Autopilot
Nigel: What you describe is almost exactly how I connected the port and starboard pitch push rods to CS10/2, the only difference being that I did not need to magnetize the socket. Both of these connections are relatively easy to reach but that (at)#$%^&* third horn on CS10/2 is (so far) not within my reach with either fingers or tools.
Ron: My problem is access. My combination of universal joints, extensions and sockets will not clear the obstructions which include the support bracket holding CS10/2 and the aileron bell crank where it mounts to the end of CS05 torque tube. In other words, I cannot manage to get the tools to align coaxially with the bolt even if I could get the nut onto the bolt manually, which I can’t.
Next up: Unless someone presents a simpler solution, I’ll remove CS10/2 and attach only the rod end to it and then after CS10/2 is reinstalled, attempt to thread the servo push rod onto the rod end already in place. Only if this fails will I resort to cutting another access port in the bottom of the fuselage.
Incidentally, prior to installing CS10/2 I used 5 minute epoxy to hold all of those washers in place and used a greased pin slightly smaller than the size of the bolt holes to maintain alignment during cure. With my many attempts to assemble the rod end to CS10/2 these washers have remained in place.
Best regards,
Rob Housman
Irvine, California
Europa XS
Rotax 914
S/N A070
Airframe complete
Avionics in progress
From: owner-europa-list-server(at)matronics.com (owner-europa-list-server(at)matronics.com) [mailto:owner-europa-list-server(at)matronics.com (owner-europa-list-server(at)matronics.com)] On Behalf Of nigel_graham(at)m-tecque.co.uk (nigel_graham(at)m-tecque.co.uk)
Sent: Monday, February 24, 2014 12:11 AM
To: europa-list(at)matronics.com (europa-list(at)matronics.com)
Subject: Re: Mod 76 - Altitude Hold Autopilot
Hello Rob, I recently had to strip out and refit the CS10 and had to face the same problem so know exactly what you are up against. There is a solution. Ideally you need a trusty assistant - though I did succeed by myself (it took a whole afternoon though )
I used a long socket, and filled it with spare nuts such that it prevented the nut you are attempting to tighten - sliding down into the barrel of the socket. I magnetised the socket by stroking it a few times with a strong magnet - that ensured that the nut would not drop out. Now the nut can be held precisely.
The next bit seems non-intuitive, but tighten the bolt (not the nut) from the other side of the aircraft using your assistant and a long socket drive extension.
All you need to focus on is keeping the nut in place (a long socket is easier to hold) until the thread catches. The only other thing to consider is keeping the washers in place until the bolt is inserted - this was done by sticking the washers using a blob of grease.
It is possible to achieve without resorting to an angle grinder!
Nigel
On 23/02/2014 23:52, Rob Housman wrote:
| Quote: |
Assuming that I am not the only one foolish enough to attempt a retro-fit of Mod 76 (Dynon) to a completed airframe I would appreciate any help from others who have done so.
I am currently at an impasse. Removal of CS10 and replacing it with CS10/2 was tedious but relatively straightforward to complete, although the Europa Factory instructions manage to overlook a few essential points. I am stymied by my inability to get the nut on the bolt that attaches the rod end to the horn on CS10/2. With perseverance I managed to get the bolt through the horn on CS10/2 and the rod end, but my not very large hands cannot do both: hold the MS31042-3 nut and rotate it after I get it near the threaded end of the AN3-7A bolt. So far I have failed even to get the nut aligned so the bolt could be turned into the nut. At this point I am considering cutting another access hole in the bottom of the fuselage but only as a last resort would I start cutting.
Suggestions?
Best regards,
Rob Housman
Irvine, California
Europa XS
Rotax 914
S/N A070
Airframe complete
Avionics in progress
|
[quote][b]
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http://www.matronics.com/Navigator?Europa-List |
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