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Images showing Graham Singletons rudder drive
modification. I first saw this modification on G-CHOX and thought it was
far neater than the crank and cable arrangement.
Images below show assembled bell crank. G-SUSE is a
tri-gear so I decided to remove the lugs that connect the mono,
tail wheel drive. The other image shows the inspection hatch on the Port
side rather than the starboard side. I used Grahams idea for making the
openings, marking out the hole and tapping it out with a sharp Stanley
knife. The cover has been left in place prior to making the splash
molding in the tail.
 
A two ply bid splash mould was made over the inside of the fuselage tail
where the opening had been developed. Once cured the splash mould was
removed and trimmed to give a flange of 3/4" around the opening. The
opening insert was then finally tapped out using the Stanley knife
method. The foam was picked out to a depth of 3mm around the o/d and I/d
of the insert and the opening and then flox resin mixture was pasted in
to seal the foam. After curing the opening and the insert edges were
cleaned up using a file and emery paper until the insert was a good fit
within the opening. The splash mould and inside fuselage were then scuff
sanded and the splash mould was installed using a weak flox and resin
mixture. Three layers of bid were then laid on top of the splash mould
and covered with peel ply. After curing the insert was attached to the
opening.
 
Foam was removed from the rear bulkhead and then covered at the area
where the bell crank mounts. Two layers of bid were then used to cover
the whole area and seal the foam. 3mm plywood inserts were then made to
fit in to the openings where the foam was removed. The plywood inserts
were then floxed in to position and clamped. Once the plywood inserts
had cured the inserts were covered with a single layer of bid. The area
was cleaned up on completion and the bell crank attached.
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