Dave,
The pad you have identified is correct but you will have to split it
into two 83mm X 38mm pieces so that you have a piece for each quick
connect mechanism.
You must use Redux (Araldite 420) to bond them to the angle pieces after
scuffing the mating surfaces. Don't use 5 min Araldite.
A most important part of doing this job is to first ensure that the two
bolts on which the quick connects pivot on the wing spars, line up
PERFECTLY with those on the aluminium brackets. Check this by making up
a neat fitting sleeve of appropriate length to slide from one bolt to
the other when the wings are rigged. Access is possible with long nosed
pliers through the gap along the top of the wing at this stage adjacent
to the spar. The spacer used on the bolt of one spar adjacent to the
rigging cup is a suitable sleeve.
If the alignment is not correct, enlarge the hole in the spar slightly
to give the bolt in the spar a bit of free movement. Once you are able
to slide the sleeve from one bolt to the other with no force, remove the
wing in question and repot the bolt in the spar with some redux. Put
the wing back on and with the sleeve half way over both bolts to
maintain alignment and ensuring the wing spar bolt is fully home, allow
the redux to cure. (preferably overnight).
Now that you have achieved perfect alignment of the bolts, the rest is
easy. The shims can be bonded on their angle pieces away from the
aircraft.
Using the longest AN4 bolt you have, make up the quick connect assembly
on this one bolt. You will then see the gap between the two surfaces
which has to be filled with the piece of tufnol you originally asked
about. You will find this gap is slightly wider than the tufnol and the
difference is made up with a Redux (Araldite 420) and Flox mixture. By
holding the bolt in a vice, this bonding procedure can be done easily
with this set-up. When I did it, I ensured that the angle piece onto
which the tufnol is being bonded, was the upper piece (all oriented
horizontally) so that gravity helped to hold the tufnol against the
other angle piece underneath. To further ensure there will be no
residual gap, place a small piece of sponge rubber in the middle of the
bonding area (never to be seen again) and this will expand pushing the
tufnol firmly against the other mating piece while the redux cures.
When you rig the wings again, you will have perfectly matching quick
connects but ensure you get the pivot bolts aligned perfectly first,
this is imperative.
Hope this all makes sense and sorry it is so long. . . . seems to be a
problem I have !
Regards
Kingsley Hurst
Mono Classic 281 in Oz.
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