12.0 CONTROLS 3/3/2006. Page 1

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3 SR3500 Rudder Pedal Parts List ITEM DESCRIPTION PART NUMBER QTY 1 MASTER BRAKE PEDAL RP SLAVE BRAKE PEDAL RP PUSH ROD RP SLAVE BRAKE TORQUE TUBE RP MASTER TORQUE FITTING RP RUDDER PEDAL (CC0102L SHOWN) CC0102 1L+1R 7 RUDDER BLOCK RP MASTER CYLINDER MC-4A 2 9 COTTER PIN MS BOLT AN3-24A 8 FIBER NUT AN BOLT AN CASTLE NUT AN BOLT AN CASTLE NUT AN BOLT AN CASTLE NUT AN WASHER AN WASHER AN COTTER PIN MS MASTER CYLINDER STANDOFF BRK Page 3

4 Page 4

5 SR3500 Control Column Parts List ITEM DESCRIPTION PART NUMBER QTY 1 CONTROL COLUMN TORQUE TUBE CC CONTROL STICK BASE CC PUSH TUBE CC STAINLESS STEEL RIVET RR TUBE END PLUG CC JAM NUT AN MALE ROD END BEARING MM-4M 2 7 2" WASHER A-M2W 2 8 TUBE DOUBLER (2.25 x 0.5 x 0.12 RND TUBE) CC STAINLESS STEEL RIVET RR BOLT AN4-14A 2 10 FIBER NUT AN WASHER AN BOLT AN4-26A 2 13 BOLT AN3-14A 2 14 WASHER AN FIBER NUT AN CONTROL STICK (not shown) CC Page 5

6 Controls 1) Make an elevator push pull tube as shown in Figure 1. The threaded portion of the end plug must be completely filled with the rod end thread. 2) Slide the push pull tube through the carrythroughs and bolt to the two FUS0304 horns at station 8. Use an AN5 bolt, washers, and AN nut. 3) Make up another push pull tube for the control column torque tube. Figure 2. Adjust the hole to hole length to be exactly the same as the hole to hole length of the CC0104 control column torque tube. Page 6

7 4) Bend four T12-HT4 tangs to have a 3/16 offset. Figure 3. 5) Cut two 94 lengths of S-4 1/8 cable. 6) On one end of each attach two tangs as in Figure 4. 7) Assemble the torque tube, CC0036 control stick base, push pull tube and cables as in Figure 5. The side holes in the torque tube may need to be made larger with a file. Use appropriate AN 4 bolts. Page 7

8 AN3-6A bolts with washers under the heads are installed into the stop tubes on the column. Adjust with washers so bolt head contacts torque tube to give desired deflections during rigging. 8) Slide the trimmed CC0037 Delrin bearings on each end. They should turn freely but have no slop. Position the assembly in the shear webs and bolt into place. 9) Slide an A-M2W 2 washer and CC0054 over each end. Center the torque tube and drill four #11 holes through each CC0054 are tight against the washers to keep side to side movement to a minimum. 10) Connect the elevator push pull tube to the control column torque tube with an AN5 bolt. 11) From RAWST0025 ( T6) fabricate and rivet a doubler to the front face of the FUS0396L pulley bracket. Figure 6. Page 8

9 12) Bolt a 3 pulley temporarily to the backside of the FUS0396 L pulley bracket. 13) Remove the left FUS0305 inside post skin. 14) Two doublers per side must be made from raw stock to add bearing surface to the pulley bolt hole. One is positioned inside the outside skin, and one spanning the inside channel flanges, riveted to the inside of these flanges with countersunk rivets. The inside skin can then be cut to form an inspection cover, easily removed by undoing the pulley bolt nut and retaining screws. This cover is structural, and supports the pulley bolt in addition to the doubler. Bolt a 3 pulley to the inside of the outside post skin. Figure 7. Page 9

10 15) Install the FUS0396 L on the front shear web at a right angle so that when the cable is pulled tight around the 3 pulley it will be tangent to the pulley on the post. Rivet FUS0396 L to the shear web with RV1410 rivets. Figure 8. Page 10

11 16) Mark the post upright and post spacers where the cable will have to pass. Cut the slots out. Make them as small as possible. They can always be enlarged later. 17) Feed the cable through the slots and secure over the upper pulley. 18) From RAWST0010 ( T6) make a support bracket to attach the pulley to the Carrythrough flange. Use 4412 avex rivets to attach to the Carrythrough to prevent interference with floor panel. Figure 9. Page 11

12 19) Repeat for right side. 20) Drill a #30 hole in the root rib in the location shown in Figure 10. This hole is for the eyebolt that will hold the top 3 pulley. 21) From RAWST0007 cut two lengths of angle that will pick up the bulkhead and root rib. Drill equally spaced holes to #30 (Fig. 11). Back drill the #30 eyebolt hole to 1/4. Figure 11. Rivet in place with 1/8 avex rivets. Page 12

13 Fig.11 22) Install a AN43B-5A eyebolt with the head to the inside. 23) From CC0142 pulley swivel insert, cut a 1 5/8 length. Drill a #11 hole crossways at the center. Assemble a 3 pulley, FUS0375 pulley swivel, two tangs and 1 5/8 length of tubing together as in Figure 12. Attach to the eyebolt with an AN3 bolt. Figure 12. Page 13

14 24) Wrap a piece of string around the pulley. Hold one end parallel with the cabin top and straight across to the other side. Hold the other end tangent with the post pulley. Mark where the cable will go through the root rib, bulkhead, upright and corner gusset. 25) Cut out slots as small as possible. 26) Thread cable through holes and around the pulley. 27) Repeat for other side. 28) Install the two FUS0399 R & L flap slider supports between the two forward bulkheads joining the fuselage root ribs. Figure 13. Tie the supports and bulkheads together with clips. Use a nominal spacing in the cabin top of 1 1/4. Do not rivet bulkheads or clips at this time. 29) From T6 cut a slider block mounting plate 4 1/16 wide and long enough to span both bulkheads. At each bulkhead location drill five #30 holes. Do not drill into the two FUS0399s at this time. NOTE: The #11 hole shown is for an F nutplate. Install the nutplate on the inside of the Bulkhead flange. Figure 14. Page 14

15 30) Drill two holes in CC0136 slider plate as in Figure ) Clamp the slider plate between two CC0137 slider blocks and position on the mounting plate as in Figure 16. Drill the six mounting holes to 3/16. The thin flanges of the slider blocks go to the bottom. Figure 16. Page 15

16 32) Drill #30 holes in mounting plate and FUS0399 flap slider supports. Figure ) Remove the assembly. Rivet the mounting plate to the slider supports. Install six anchor nuts on the inside of the slider supports for the slider blocks. Also install a 3/16 anchor nut in the front bulkhead which was drilled to #11 in step ) Rivet the slider supports and mounting plate in place. 35) Install a MI-25 bell crank bearing to the CC flap horn. Figure 17. Page 16

17 36) Bolt the horn to the slider plate. Bolt a tang also to the slider plate. Figure ) Bolt the slider plate and blocks to the mounting plate. 38) Move the slider plate so it s flush with the front edges of the slider blocks. Figure ) Cut a 2 piece of 3/4 x 3/4 x 1/8 angle for a horn stop. Drill to #11 and rivet in place.. Figure 19 40) Connect the control cables to the horn as in Figure 20. The four tangs must be drilled out to 1/4 on one end. Assemble with appropriate bolts and nuts. Page 17

18 41) From each FUS0065 L & R flap control stiffener rib cut a section to go between the root rib center bulkhead and station 5 bulkhead. 42) Transfer the position of the FLAP0011 bushing installed in the Fuselage root rib in step 34, page 12, chapter 9.4, Fig. 8, to one of the FUS0065 s. Remove and install bearing. Repeat for other side. 43) Mount the sections with bearings installed as in Figure 21. Make gussets and clips from T6. Use a 1 1/4 nominal rivet spacing in cabin top. 44) Insert CC0140 pivot assemblies on one side. Slip an AN washer up against each bearing. Measure the distance between the washers. Figure 22. Page 18

19 45) From CC0155 cut a length 1/32 short of the dimension taken in step ) Install the tube. Ensure the horns on each end are vertical. Drill one #40 hole into each CC0140 to maintain alignment. Figure ) Remove the assembly. Cleco together. Ensure horns are in line then at each end drill three rows of four #11 holes 7/8 apart. Figure 24. Page 19

20 48) Replace the assembly and rivet with 3/16 avex rivets. 49) Repeat for other side. 50) With the Control Stick in Neutral measure and make up two push pulls tubes to go from the flap horn to the pivot assembly horns. Use an AIL0026 to cut bushings to space the rod ends away from the Flap Horn (Bellcrank) to prevent any conflict between these parts due to the angle change. Figure Page 20

21 51) Connect the flap horn return spring ( compression spring) as in Figure 27. Use an AN3-4 bolt. Bend the front tang to suit as you did previously in figure ) To install the CC0135 control tube assembly the wings without the flaps must be on the aircraft. 53) Insert a long 1/4 drill bit through the root flap hinge pivot point. Mark the pivot points on to the fuselage root ribs. Drill a 2 1/2 diameter hole in the fuselage root ribs at the pivot points. 54) Install the flaps. 55) Rivet two CC0110 horns to two EL0031 end plugs. Ream out the center hole of each assembly to 9/16. Figure 28. Page 21

22 56) Install one end plug and horn assembly to each flap. One AN4 bolt will pick up the anchor nut installed in the flap root rib, the other will require a new hole in both the horn and the root rib 1 ½ forward of the existing hole in the horn. Figure ) Measure the distance A from the flange of one end plug to the other. Figure 30. Page 22

23 58) Bolt an EL0031 end plug to one end of the CC0135 control tube assembly. Back drill the four #11 holes into the end plug. Remove the end plug and install four 3/16 anchor nuts on the inside. Figure ) Repeat for other end. 60) Measure the distance B from the inside flange of one end plug to the other. Figure 32. Page 23

24 61) Subtract measurement B from measurement A from step 57. Divide the result by two to get dimension C. Example A-B = C 2 62) From RAWST0017 cut two lengths to dimension C. These will become attach tubes. 63) Rivet one attach tube to each EL0031 at the flap root hinge with eight 3/16 S.S. rivets. 64) Cut a slot in the cabin top for the upper horn of the control tube. 65) Slip the other two EL0031 into the attach tubes. 66) Position the control tube and bolt to the EL0031 s. 67) Ensure the flaps are level with the cabin top and the end horns of the control tube are vertical. Figure 33 Page 24

25 68) Drill one or two #40 holes into each EL0031 and attach tube to maintain the control tube position. 69) At the control tube center hinge location install the two hinge brackets CC0081 L and R. Rivet to the carrythrough bulkheads with four RV-1613 avex rivets in each. Figure 35. Page 25

26 70) Remove the control tube assembly and rivet the EL0031 to the attach tubes with eight 3/16 S.S. rivets. 71) Reassemble. 72) Bolt CC0149 center arm to the control tube drive horn. At the other end install a HM-4M rod end and CC0028 end plug. The tube will have to be trimmed to length. Figure ) Install two angles made from RAWST0005 and two packers made from RAWST0009 as in Figure 37. Page 26

27 74) Cut two Spacers from EL0032 ¼ wider than the Flap Handle. Bolt the CC0146 flap handle between the two CC0116 flap handle brackets using the Spacers you cut. Figure 38. Page 27

28 75) Drop the flap spring (C-740) down the flap handle. Insert the inner flap handle (CC0147) ( made in figure 38a) turn the inner handle so the end hole is visible through the slot in the flap handle. Push the spring down and insert the 1/4 bolt with a penny washer under the head of the bolt and one spacer made from an AIL0026 cut in half, the same length as the distance from the side of CC0148 to the outside of the assembly. Do the same under the nut. Install the Flap Handle End Cap CC0156 in the end of CC ) Bolt the assembly to the two angles as in Figure 39. Page 28

29 77) Install 3 pulleys, FUS0375 pulley swivels, tangs and eyebolts at bulkhead D as in Figure 40. Page 29

30 78) Install the flap return spring C0333 as in Figure 41. Page 30

31 79) Install the 1/8 flap cable with a turnbuckle. Figure 42. It is necessary to drill holes through bulkheads A, B, and C. Use RG0001 cable guides on bulkheads where necessary. 80) Rivet a CC0110 horn to an EL0031 end plug with eight 3/16 S.S. rivets. 81) On each wing cut the torque tube off 1 1/8 from the root edge of leading edge skin. Page 31

32 82) Before you can install the end plug with the horn, you will need to make two Aileron push pull tubes 35 long. Use the diagram in step 1 with a 35 dimension, and CC0028 end plugs. Install the push pull tubes. With the ailerons in their neutral position (bottom leading edge flush with bottom of wing, trailing edge in 5 degrees reflex). Insert the end plug with the horn and set at 0 degrees to the main spar. Rivet in place with eight evenly spaced 3/16 S. S. rivets. Figure ) Install the wing. Ensure the ailerons are in neutral and controls are in neutral. Measure the distance from the CC0140 to the CC0110. Make up a push pull tube to fit. Figure 44. Page 32

33 84) Bolt the push pull tubes in place with An4 bolts through the horn and AN365 nuts. 85) Place one of the FUS0305 inside post skins on to a piece of RAWST T6. Drill the holes shown in Figure 45. Trace around the edges. This part will become the post pulley access panel. 86) Trim the access panel and inside post skin as in Figure ) Make a doubler to fit on the inside of access panel as you did for the outside post skin in step ) In both the outside post skin and the pulley access panel drill a safety hole for a bolt or cotter pin to prevent the cable from coming off the pulley. 89) Dimple the outside post skin in the area where the windshield will go. 90) Rivet together with 1/8 avex rivets and bolt the pulleys permanently in place with the correct hardware. Page 33

34 CONTROL RIGGING NOTE: You will need to make and install a channel to support the cables running down your Tailcone. Make the channel the same length as the width of the midpoint bulkhead. Place and rivet the channel to the bulkhead after installing cables. RUDDER PEDALS-PLEASE REFER TO BRAKE UPGRADE MOD. IN CHAPTER 22 91) As shown in Figure 47, connect a cable to each CC0102. Page 34

35 Run the cable FWD. around the pulley you in stalled on the Firewall and back down through the holes you drilled in the Bulkheads to the Horns on the Rudder. Use RG0001 cable guides to secure the cable in the center of the holes in the Bulkheads. FIGURE ) Install an AN3 bolt with a T12-HT6 tang under the bolt head and AN365 nut to retain the cables inside the rudder pedal horns. 93) Attach the cables to the Rudder Horns with AN111-4 cable bushings. NOTE: When installing cable bushings be sure that rudder peddles are centered and in alignment with each outer. 94) Drill and bolt a T12-HT6 tang to the midpoint of FUS0325 shear web far enough AFT of CC0102 to give good spring tension. Bend the tang slightly so it points toward a second tang you bolt to the rudder pedal cable horn using the cable retaining bolt. Install the spring between these two tangs. Do this for both horns. ELEVATOR RIGGING 95) Bolt an AN130-22S Turnbuckles to the upper and lower holes in the FUS0304 Horns. Feed the cable through the bulkheads and RG0001 cable guides to the rear of the Aircraft. Try to keep the angle changes from cable guides equal. Use an AN100-4C cable thimble to connect the cables to the turnbuckles and an AN111-4 cable bushings at the elevator horns. NOTE: Make sure Elevator and Control Stick are in Neutral. Page 35

36 MOOSE CONTROL DEFLECTIONS Flaps.. 1st Notch : 13 degrees 2nd Notch: 26 degrees 3rd Notch: 39 degrees Ailerons..Min Up: 12 degrees Min Down: 12 degrees Elevator..Up: 25 to 28 degrees Down:12 to 15 degrees Elevator Trim.Nose Up: 14 degrees Nose Down: 4 degrees AIRSPEED INDICATOR MARKINGS Flap Speed-White Arc MPH Normal operating rang-green Arc MPH Caution-Yellow Arc (Super Rebel 3000) (3500 Moose) RED LINE (Super Rebel 3000) 189 (3500 Moose) Page 36

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