---------------------------------------------------------- Lightning-List Digest Archive --- Total Messages Posted Sat 09/29/12: 11 ---------------------------------------------------------- Today's Message Index: ---------------------- 1. 09:51 AM - Main gear alignment (Bernard Melendez, Jr.) 2. 10:05 AM - Main gear alignment (Bernard Melendez, Jr.) 3. 10:15 AM - Gear socket drilling jig. (Bernard Melendez, Jr.) 4. 10:41 AM - Canopy fittin' (Bernard Melendez, Jr.) 5. 10:48 AM - Oil return bottle (Bernard Melendez, Jr.) 6. 11:00 AM - Gear drill jigs (Bernard Melendez, Jr.) 7. 11:05 AM - Control stick pivot bolts. (Bernard Melendez, Jr.) 8. 11:19 AM - Rudder cable attach (Bernard Melendez, Jr.) 9. 11:26 AM - Wing tip mods (Bernard Melendez, Jr.) 10. 11:33 AM - More wing tip mod pics (Bernard Melendez, Jr.) 11. 11:39 AM - Exttended wing tip progress (Bernard Melendez, Jr.) ________________________________ Message 1 _____________________________________ Time: 09:51:17 AM PST US From: "Bernard Melendez, Jr." Subject: Lightning-List: Main gear alignment Hi guys, For those interested in the method I used for aligning the main gear, I submit these pics. Two 1/2" diameter aluminum rods were inserted into the axle sockets such that they met in the middle of the fuselage and were aligned with each other. This told me that the wheels were parallel with each other. Then, deciding how much toe-in I wanted, and using the magical math of trigonometry, I offset one gear to the length of the short leg of the triangle. The gear tube was drilled and the other gear was turned so that the 1/2" rod ends were together again, and the other gear leg was then drilled. It's easier done than explained. More than one way to skin a cat. Hope this helps. Bernardo ________________________________ Message 2 _____________________________________ Time: 10:05:35 AM PST US From: "Bernard Melendez, Jr." Subject: Lightning-List: Main gear alignment Hi guys, Here's my method for aligning the main gear. Of course, it helps to have a machinist buddy to make my drilling jig(s). First, two 1/2" aluminum tubes are inserted in the axles so that they meet in the middle. That tells me that the wheels are parallel with the fuselage center line. Then using trigonometry to determine and rotate the gear to match the short leg of the triangle, twist one gear leg to the desired toe-in (I used 1 1/2 degrees toe-in). The gear socket is then drilled, preferably using a drill jig. Once that's done, twist the other gear leg so that the end of the aluminum rods again meet and drill the second leg. Easy peachy, lemon squeezy. Hope this helps. Bernardo ________________________________ Message 3 _____________________________________ Time: 10:15:20 AM PST US From: "Bernard Melendez, Jr." Subject: Lightning-List: Gear socket drilling jig. Guys, Sorry that the basic same message got sent twice, that was my boo boo. I have AutoCAD drawings of the drilling jigs for both the main gear and the nose gear sockets. If you have access to ACAD, I can forward the drawings, for those that want it, or contact me offline and send me a SASE and I'll send a copy. Bernardo ________________________________ Message 4 _____________________________________ Time: 10:41:01 AM PST US From: "Bernard Melendez, Jr." Subject: Lightning-List: Canopy fittin' Infidels! Here's a couple or three (or four) canopy fitting pics for your review and consideration. Enjoy. Bernardo ________________________________ Message 5 _____________________________________ Time: 10:48:35 AM PST US From: "Bernard Melendez, Jr." Subject: Lightning-List: Oil return bottle Guys, Some mods that I made to the oil return bottle. The fiberglass top and bottom were removed and replaced with 1/16" aluminum. The internal baffle was also welded to the new top. Just because, no other reason. Looks more better, less worse. Bernardo ________________________________ Message 6 _____________________________________ Time: 11:00:08 AM PST US From: "Bernard Melendez, Jr." Subject: Lightning-List: Gear drill jigs Guys, A couple more pics of the main and nose drill jigs. The hardened steel guide is the only way to go. Enjoy. Bernardo ________________________________ Message 7 _____________________________________ Time: 11:05:25 AM PST US From: "Bernard Melendez, Jr." Subject: Lightning-List: Control stick pivot bolts. Infidels! I personally don't like to use plain bolts on moving surfaces. Soooo, I used drilled head bolts. Of course, I had to drill the assembly someplace to attach the safety wire. Gives me peace of mind. Bernardo ________________________________ Message 8 _____________________________________ Time: 11:19:06 AM PST US From: "Bernard Melendez, Jr." Subject: Lightning-List: Rudder cable attach Guys, I had a little issue with the way the rudder cables were attached at the bell crank behind the panel. Basically, the cable needed to be sandwiched between two parts (like a hinge.) The way it's designed puts a twisting load on the pin or bolt. Not a good thing, IMHO. My solution is to make tabs from 4130 .062" steel and rivet them in place. Voila! the cable no longer puts an asymmetrical load on the pin. Smart them Chinese, huh? Bernardo ________________________________ Message 9 _____________________________________ Time: 11:26:29 AM PST US From: "Bernard Melendez, Jr." Subject: Lightning-List: Wing tip mods Group, A couple of early pics of my extended wing tip mods. Modifications are now complete and all of the parts behind the firewall are now ready for primer and paint. More pics coming.... Bernardo ________________________________ Message 10 ____________________________________ Time: 11:33:40 AM PST US From: "Bernard Melendez, Jr." Subject: Lightning-List: More wing tip mod pics guys, Since I decided to extend the ailerons by 10", this meant that the tips also would need a "little" work (yeah, right! a little). The rear spar had to be extended as well. I'm very glad that's over, it was a bunch of work! Bernardo ________________________________ Message 11 ____________________________________ Time: 11:39:16 AM PST US From: "Bernard Melendez, Jr." Subject: Lightning-List: Exttended wing tip progress Infidels! And so it goes.... 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