REFLECTOR: Lay up c question

[Steve Goldman]

Jack Prock wrote:
> Hey Matt,
>  
> I think you are talking about where it says in the manual (pg 2-29 of 
> xl-rg) "Keep layups forward of the rudder bellcrank cutout"
>  
> If you try and do that, the layups don't fit. What I did was to create a 
> glass shell over the bellcrank cutout and when cured,
> you can glass over the bellcrank cutout, leaving the bellcrank cutout 
> small hallow space. Before covering the bellcrank cutout
> shell, use some scrap BID and glass the foam inside of the bellcrank 
> cutout. This makes a bellcrank cavity that has glass on
> all sides.
>  
> I included some pics of what I mean with the glass shell.

Well looking at Jack's photo's contrary to what I said about that 
piece of glass not being loaded in tension it appears to be since it 
looks like it makes a straight line from winglet edge to wing bottom.
However you'll notice especially in the first photo that there would 
appear to be way to insert the bellhorn in the rudder and have it fit 
inside the cavity without cutting a slit in that glass almost its 
entire width. Take a look at comparable photos from Andy Millin,

http://www.kal-soft.com/velocity/images/pic070l.jpg

if you look closely it looks like you can see the edge of the bellhorn 
under the glass. It looks like the glass is bent as it goes over the 
bellhorn. Looking at this photo

http://www.kal-soft.com/velocity/images/pic065l.jpg you can see that 
the position of the bellhorn and it width prevents a cave from being 
straight line of glass but it must curve. So it doesn't add strength 
as the winglet tries to be bent toward the fuselage.

If you check with the factory I think you'll see that they meant it 
when they said "Keep layups forward of the rudder bellcrank cutout". 
It doesn't hurt to make the cave but you don't need it.

-- 
Steve Goldman
'77 Tiger N28531
Velocity XL5-RG (T-2762 hrs) N758SG (reserved)
Pittsboro, NC (9NC8)
http://fatcatair.com