Singleton Rudder Mod

 

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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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