||Continue cross-checking fuel system printouts.
||With Dorothy's help, take fuselage top out of garage to drive. Roll lower fuselage out on dolly and set it level thwartwise. Get tailplanes out of trailer and rig them after re-fitting TS05 link rod. Wire up trim servo cable to the trim controls on the radio panel. With digital level, measure port tailplane trailing edge angles. With stick fully forward, 15.5 degrees down. With tailplane in line with root fairing, 11.7 degrees down. With stick fully aft, 1.0 degrees up. That gives up travel of 12.7 degrees and down travel of 3.8 degrees. Page 19-7 of the manual calls for 12 degrees up and 4 degrees down. Not sure that the digital level was sitting square enough, so place it on a small wooden wedge to help keep it more secure. Also ask Dorothy to read the level while I hold the stick firmly at the extremes this time, as it seems to relax slightly when I let go of the stick and go aft to read the level. With stick fully forward, 2.6 degrees down. With tailplane in line with root fairing, 1.3 degrees up. With stick fully aft, 13.7 degrees up. That gives up travel of 12.4 degrees and down travel of 3.9 degrees. Strange, less overall travel than the first time! Repeat once more, making sure that the level is in a stable position and this time being very careful not to lean on the fuselage while holding the stick. With stick fully forward, 3.3 degrees down. With tailplane in line with root fairing, 0.6 degrees up. With stick fully aft, 13.0 degrees up. That again gives up travel of 12.4 degrees and down travel of 3.9 degrees. Slide the mass-balance weights out of the way and with a scalpel trim back the bead of silicon sealer on the top bump stop until the stick-forward position shows 3.5 degrees down, thus giving a down travel of 4.1 degrees. Clamp the level to the port trim tab and after confirming that the trim is in the neutral position (centre 2 LEDs lit on the indicator) measure the angles. With stick fully forward, 21.7 degrees down. With tailplane in line with root fairing, 12.8 degrees down. With stick fully aft, 15.6 degrees up. That gives up travel of 28.4 degrees (16 degrees relative to the tailplane) and down travel of 8.9 degrees (4.8 degrees relative to the tailplane). Page 19-7 of the manual calls for between 14.4 and 18 degrees relative up movement and page 19-8 calls for between 4.8 and 6 degrees relative down movement. Repeat the measurements on the trim tab. With stick fully forward, 21.8 degrees down. With tailplane in line with root fairing, 12.7 degrees down. With stick fully aft, 15.8 degrees up. That gives up travel of 28.5 degrees (16.1 degrees relative to the tailplane) and down travel of 9.1 degrees (5.0 degrees relative to the tailplane). With tailplane in line with the root fairing, motoring the trim servo in each direction gives maximum deflections of 6.6 degrees down (6.1 degrees from neutral) and 19.9 degrees down (7.2 degrees from neutral). Page 19.8 of the manual calls for a trim range of 6 degrees in each direction. Notice that the pitch pushrod is rubbing slightly on the restraining bulkhead at the forward end of its travel. Remove the bolts securing the bottom of the bulkhead, and those on the constraint plate. Ease the holes slightly with a needle file in the appropriate direction. Re-fit and try again. Better, but still just touching at end of travel. Remove bulkhead again and file the edge of the aperture in the bulkhead slightly to give more clearance. Re-assemble and all seems to be well now. Re-apply inspectors lacquer to all stiffnuts. Note that the TS05 link rod is rubbing slightly on one side of the bulkhead installed to restrain it from sideways movement. Remove the link rod and file the bulkhead to give more clearance. Return tailplanes to trailer and put away fuselage parts in garage.
||Finish updating database and drawing for fuel system. Check AN fittings etc in stock against list to confirm what's outstanding.
||Start amending fuel system drawing to reflect latest thoughts on the vent connection to the top of the filler pipe.
||Order a 5/8" x 18 TPI (AN10) tap for fitting the fuel pressure sender, and a few other taps & dies to fill gaps in the inventory, from Tracy Tools. Lift out fuselage top onto drive. Roll out lower fuselage on dolly and set roughly level thwartwise (0.1 degree port down). Confirm tailplane torque tube is at the same angle. Get tailplanes out of trailer and rig them. Check deflections with digital level positioned on a wedge at the TE of the port tailplane. Neutral is 0.3 degree up, stick forward (TE down) is 3.7 degrees down and stick aft (TE up) is 12.5 degrees up. That gives travel of 4.0 degrees down from neutral and 12.2 degrees up, very similar to the last set of measurements. No need to re-check tab angles as that geometry has not changed. Slide tailplanes out a bit and remove TS05 link rod assembly. File down the port side of the slot in the link rod restraint bulkhead to improve clearance. Re-rig tailplanes to check and link rod is now well clear of the slot. Wire up trim circuit and check the movement. Mark one each of the white wires from the 5-core cable and the Matronics Governor with a piece of yellow heatshrink for correct orientation (push top of rocker switch for nose-down trim, push bottom for nose-up trim). The forward edge of the fuselage side slots need relieving at max nose-up trim (tabs down). Slide the tailplanes out and file back the appropriate areas. Re-rig and check clearance - OK now but tailplane flanges are rubbing slightly on the fuselage fairing near the leading edge, with TE full up. Remove the tailplanes and file back the appropriate areas. Re-rig and now seems much better. Not happy with the movement of the mass balance weight - it's just touching the starboard rubbing strip in the upper part of its travel. Loosen all 4 bolts holding the containment bulkhead, adjust it slightly towards starboard and re-tighten bolts, checking the vertical alignment with the digital level. Mass balance now clears rubbing strips throughout travel, but an annoying squeak has appeared when exercising the sticks fore and aft. Seems to be coming from the stick pivot bolts - a drop of 3-in-1 oil on the starboard one gets things silent again. Re-check tailplane travel as before. Neutral is 0.9 degree up, stick forward (TE down) is 3.3 degrees down and stick aft (TE up) is 13.0 degrees up. That gives travel of 4.2 degrees down from neutral and 12.1 degrees up. Remove tailplanes and return to trailer. Put a drop of 3-in-1 oil on the tailplane torque tube bushes. Check level of tailplane torque tube - it measures 0.1 degree port down, same as the level at the datum. Re-check tailplane torque tube squareness with centre-line. TT is 940mm wide; from the starboard end to the datum between the headrests is 2380mm; from the port end to the datum between the headrests is 2385mm. Starting to rain so disconnect battery from trim system, pull lower fuselage back into garage and with Dorothy's help carry the fuselage upper moulding back inside. Drawing the dimensions of the torque tube tips from the datum in CADintosh again shows that the torque tube is 0.3 degree away from true orthogonality with the fuselage centre-line.
||Taps & dies arrive from Tracy Tools. Finish amending the fuel system drawing and database. Print out for cross-checking.
||Fit MS21042-4 stiffnut to fork-end on TS05 assembly. Apply inspectors lacquer to that and to the checknut locking the fork in alignment.