Following on from my last post I reacquainted myself with the build manual
sections
34 and 35.
The part DL07 is the guide mounted in the door, this gives the shoot bolt an
axis
to follow - hence it needs to be aligned accurately such that DL06 (shoot bolt)
and the operating rod DL11(F and R) do not bind.
Doing the above should ensure the shoot bolts protrude equally and follow a
longitudinal
axis.
Drilling and opening up the door-side holes is covered in manual 35. It states:
"In this step you will be cutting the holes in the door rebates to accept the
shoot
bolts, but first reinforce the area where the holes will be by applying 4
plies of bid 30 mm x 30 mm at the back of the door rebates (unmoulded side).
Once this layup has fully cured apply a small dab of wet ink, or paint to the
very
end of the shoot-bolts. With the door fully pushed home, move the door handle
towards the closed position until the end of the bolt strikes and, hopefully,
leaves a witness mark on the door reveal.
This is your starting point; drill a 1/4" hole and then with a round file
carefully
open up the hole just enough to allow a shoot bolt guide to fit in the door
recess, so that when the shoot-bolts are fully extended, the doors are fully
secured and flush with the outside of the fuselage. Use dabs of paint on
the shoot-bolt each time you want to enlarge the hole so that you can see which
areas need filing. Shorten the shoot bolt guides so that they protrude only 10
- 12 mm (3/8" - ") through the door frame and, ensuring that there is a gap
of only 1 - 2 mm between the guides in the door and the frame, bond them in with
Araldite 420 and flox."
I would suggest that there should be another bush (like DL07) that goes into the
doorframe moulding. This could be CNC machined (or 3D printed in a durable
material). The initial opening would 'collect' the DL06 shoot-bolt taper and
guide it into the new bushing.
An enlarged flange on this new bushing could be made to act in a similar way to
the UglyMod moulding - i.e. preventing the shoot-bolt from moving rearwards if
misaligned.
In summary
1. There seems to be a wide tolerance on shoot-bolt length.
2. Physical examination of Europa shoot-bolts suggests that the end taper and
radius
of the bolt is highly variable.
3. The locking mech in the door has a nice bushing/guide.
4. The shoot-bolt on the doorframe locates into a plain hole that has no
dimensional
tolerances (ref build manual 35). The dimension given has no datum and
may be open to misinterpretation.
5. A doorframe mounted bushing - correctly designed, should enable more accurate
engagement of the shoot-bolt.
6. Are the shoot-bolts installed in aircraft sufficiently long?
Discuss.......
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John Wighton
Europa XS trigear G-IPOD
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