Builder Tips, Tricks, and Modifications

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This page will contain your Builder Tips and Tricks. Please share your thoughts on how best to organize this information. I think by aircraft system is probably best, rather than by submitting user, but I'm flexible. Here are some beginning categories.


CLICK THE TEXT, not the picture, to get to the article!!!'

Specific Tips

Find data on Velocity Props
Velocity Glossary
Current Events

NACA or Nose Cooler or Heat Mods



Keelseal.jpg

Keel Seal

Cooler blower 001 a.jpg

Nose Heat Control

1naca.jpg

NACA Inlets


Velocity Building 020 143.jpeg

Nose_Oil_Cooling

NACA FlowTest 0150.jpg

NACA_Ducts

NACA-LR.jpg

Updraft to Downdraft Conversion


225px

Cabin_Heater


Cowling Mods



Cowl inlet thumb.jpg

Cowl Inlet Door

Screwless cowl.jpg

Screwless Cowl

Cowling5.jpg

Custom Cowling


Jp plenum 6.jpg

Air Filter Installation

Vent1.jpg

Ground Hot Air Vent



Door Mods



Splitdoor1.jpg

Air Stair/Split Door

N173EX 017.jpg

Really Big Hatch

IMG 8975.JPG

Hendricks door latch


N87br brim.jpg

Forward Hinged Doors

Door latch.jpg

Door Latch Safety

Door pins smooth.jpg

Smoother Door Latch


Doors open.jpg

Door Gas Springs

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Strake or Fuel Mods



VP03EPq.jpg

Fuel Sump Sensor

XLRG strake.jpg

Fuel Strakes

Image003.jpg

Extended_Strake_Elbow






Prop and Spinner Tips



Hub.gif

MT_Prop_Rebuild

Spinner15.JPG

Spinner#Ferrell_Hersey_Kiss_Spinner






Engine and Exhaust Tips



Jp plenum 6.jpg

Engine#Prudhomme_Air_Cleaner

Augment 10.JPG

Engine#Ferrell Exhaust Augmentors






Fuselage Mods



Hid lamp.jpg

HID Landing Light

Mcmaster studs.png

Mounting Studs great for spar

[[Image:|225px]]

[[]]





Control Mods



Bushings Installed.jpg

Center Stick Reinforcement

N74gp sticks.jpg

Side_Sticks

Yokes.jpg

Yokes






Misc Mods



Draggage.jpg

Draggage Pod

Free track.jpg

Aircraft Tracking

FLIR.jpg

FLIR Forward Looking Infrared


Condition inspection.jpg

Condition Inspection







Trim or Control Modifications



MS20271-BS.jpg

Aileron Improvements

Elevator bearing upgrade.jpg

Elevator Bearing

TEFence2.jpg

Trailing Edge Fences


N77ly sidestick.jpg

Side Sticks

Vg.jpg

VG Installation

N2059u3.jpg

Yokes


N2059u3.jpg

Throttle Quadrants

Strong sm 2.jpg

Strong Pitch Trim

Trimbraking.jpg

Elevator Trim Braking Circuit


Tfxtreme4.jpg

Aileron Cable Replacement

Aft aileron.jpg

Preventing Roll Trim Cord Slippage


Aileron balance2.jpg

Aileron Balancing


Trim spring1.jpg

Improved Pitch Trim

Elevator1.jpg

Elevator Balancing

Strainer1.jpg

Adjustable Sparrow Strainer

Shimmy Damping Mods



Nylon nut.jpg

Nylon Belleville Anti-Shimmy

Noselock3.jpg

Mishler Nose Lock

Rene Shimmy Small.JPG

Millin Factory Shimmy Damper


Shimmy1.jpg

Nose Wheel Shimmy Damper



Brake Mods



823414.jpg

SE "Old Style" Brake Parts

Various pad states.jpg

Brake Relining/Pads


Landing Gear Mods



Lg SLM8IY76615BBVZ CoP.jpg

Landing Gear Cylinder Rebuild

Bumper.jpg

Fixed Gear Replacement Bumper

Misler mech doors.jpg

Mishler nose gear


113-1309 IMG.JPG

Main Gear Booties

Wilhelmson 006.jpg

Retractable Nosewheel

225px

Fixed Gear Fairing Modification


Seals.jpg

Retract Pump and Cylinder Rebuild

Rene Heatshield.jpg

Gear Leg Heatshield


Franklin Tips



Franklin oil system.jpg

Franklin Oil Bypass

Franklin Split Plenum.jpg

Other Franklin Information






Painting



Wing paint1.jpg

Paint#Wing Painting Jigs - Ferrell







Building Space or Shop or Moving Tips



Wing Supports 3.JPG

1 Man Wing Support

Strakeout.jpg

Move fuselage with Spar installed

Wing-Rack.jpg

Wing & Canard Rack new



HT52008-2.jpg

Wing Jacks



General Tips

General Controls Paint Fuselage NACA Ducts Emergency Procedures
Wings Engine Avionics Interiors Test Flying Tow/Tug
Prop Spinner Finishing Landing Gear Electrical Power Nose_Wheel_Shimmy_Damper

Engine Installations

V8 Engine V6 Engine Subaru Engine Mazda Engine TIO-540 Franklin Engine

Oil Cooler Turning Vanes

Not great pictures but I managed to stick my phone into the nose of the airplane to get pic of each side of the oil duct.

What I did was remove the duct, do a micro fill & sand job on the inside to smooth it up. Mine was really rough and had numerous bumps and edges inside..

Then carve curved matching slots in the two sides of the oil duct. Just thick enough to slide thin aluminum through.

Then cut out aluminum vanes. Each aluminum piece slides through both sides of the duct slots creating turning vanes. Slots are about 1 inch apart. I left tabs on the ends of the vanes that were then folded against the sides of the oil duct. Then a few layers of bid over the tabs and sides of the duct to seal the slots to the vanes and restore the oil ducts strength.

The shiny squares you see in the pic are the aluminum tabs

Scott

Toe Brakes

We've retrofitted our XL to use the toe-brake option from the factory. We will eventually add the cast aluminum pedals, but currently have the two separate pedals on both sides. The pilot side master cylinders go to the brakes on the lower end, and the tops go to teh copilot lower master cylinder connections, and the copilot upper connections run to the new resevoir. Note also that the new system requires Mil-Spec 5606 fluid (like the retracts use in the hydraulics).
Installation Instructions


Construction

Builders tips by section of the builders manual

1 - Introduction 2.1 - Wing Core

    2.1.1 - Joining Leading Edge Wing Cores to Spar
    2.1.2 - Joining Trailing Edge Wing cores to Spar.
    2.1.3 - Navigation (VHF) Antenna

2.2 - Wing Skins

    2.2.1 - Lower Skin
    2.2.2 - Wing Leading Edge Rib
    2.2.3 - Wing Root Ribs
    2.2.4a - Glassing
    2.2.4b - Top Wing Skin
    2.2.5 - Rudder Conduit Installation
    2.2.6 - Wing Attach Bolt Access Holes

2.3 - Winglets

    2.3.1 - Preparing Winglets for Glassing
    2.3.2 - Glassing Inboard surface
    2.3.3 - Glassing Outboard Surface
    2.3.4 - Winglet Trimming

2.4 - Wingtip Trimming 2.5 - Winglet to wing attachment

    2.5.1 - Overview of Winglet to Wing Attachment
    2.5.2 - Winglet and Wing Preparation
    2.5.3 - Setup and alignment
    2.5.4 - Winglet Attachment Lay-Ups

2.6 - Filling and Sanding Wings and Winglets 2.7 - Ailerons

    2.7.1 - Aileron Cutouts
    2.7.2 - Aileron Wells
    2.7.3 - Glassing Aileron Well and Ribs
    2.7.4 - Aileron Construction
    2.7.5 - Torque Tube and Hinge Backing Plates
    2.7.7 - Balancing the Ailerons

2.8 - Rudders

    2.8.1 - Rudder Cut-Outs
    2.8.2 - Rudder and Rudder Wells
    2.8.3 - Rudder Hinge Installation
    2.8.4 - Rudder Horn Installation
    2.8.5 - Rudder Return Spring

2.9 - Winglet Bottom

    2.9.1 - Prepare Winglet Bottom
    2.9.2 - Attaching Winglet Bottom to Wing

3.1 - Canard

    3.1.1 - Reference list

3.2 - Canard Core Preparation

    3.2.1 - Installation of Lift Tabs
    3.2.2 - Foam Cores
    3.2.3 - Preparation for Skinning

3.3 - Glassing the Canard

    3.3.1 - Canard Lay-up Schedule
    3.3.2 - Canard Lay-up A
    3.3.3 - Canard Lay-up B
    3.3.4 - Canard Lay-up C

3.4 - Elevator Construction

    3.4.1 - Assemble Cores
    3.4.2 - Lay-up Procedure - Side One
    3.4.3 - Lay-up Side Two
    3.4.4 - Elevator to Canard Fit
    3.4.5 - Elevator Hinge Installation
    3.4.6 - Hinge Arm Installation

3.5 - Canard Final Preparation for Elevators

    3.5.1 - Positioning the Elevator
    3.5.2 - Positioning torque / counterweight arms
    3.5.3 - Elevator Balancing

4.1 - Bulkhead Preparation

    4.1.1 - Locate Bulkhead Placement 

4.2 - Install Bulkheads

    4.2.1 - Preliminary Fitting of Parts 
    4.2.2 - Bonding Procedures 
    4.2.3 - Glassing Bulkheads
    4.2.4 - Engine Bulkhead 
    4.2.5 - Engine and Gear Bulkheads 
    4.2.6 - Cowl 
    4.2.7 - Canard Bulkhead Notes 
    4.2.8 - Battery Shelf 
    4.2.9 - Landing Light 

5.1 - Windows

    5.1.1- Window Cutouts 
    5.1.2 - Fit Windows 
    5.1.3 - Install Windows 

5.2 - Fuselage Top Installation

    5.2.2 - Door Cutout 
    5.2.3 - Fuselage Door Hole Treatment 
    5.2.4 - Door Hinge Installation 
    5.2.5 - Install Door with Hinges to Fuselage 

5.3 - Latches

    5.3.1 - Install Door Latch Mechanism 
    5.3.2 - Latch Base Assemblies 
    5.3.3 - Pilot Door Security Lock 
    5.3.4 - Installing Door lock 
    5.3.5 - Install Windows in Doors 
    5.3.6 - Install the Latch Pin Tubes in Fuselage 

5.4 - Carbon Beams

    5.4.1 - Install Carbon Beams 
    5.4.2 - Install Door Seal 

5.5 - Finishing the Doors

    5.5.1 - Install Door Gas Springs 

6.1 - Keel

    6.1.1 - General 
    6.1.2 - Forward Keel Access Hole 
    6.1.3 - Aft Keel Access Holes 
    6.1.4 - Fitting the Keel 
    6.1.5 - Keel Hard points 

6.2 - Seats and Hardpoints

    6.2.1 - Fuselage Hardpoints 
    6.2.2 - Seat Belt Hardpoints 
    6.2.3 - Front Seats 
    6.2.4 - Rear Seats 

6.3 - Keel Controls

    6.3.1 - Keel Control Assembly Locations 
    6.3.2 - Forward Aileron Torque Tube Bearing 
    6.3.3 - Rear Aileron Control Bracket 
    6.3.4 - Mid-bearing Support 
    6.3.5 - Control Stick Assembly 
    6.3.6 - Aileron Torque Tube Support 
    6.3.7 - Keel Installation 
    6.3.8 - Keel Stiffening Lay-ups 

6.4 - Forward Fuselage Treatments

    6.4.1 - Nose Access Cover 

6.5 - Pedal System / Brake Cylinders

    6.5.1 - Mount Master Cylinders 
    6.5.2 - Assemble Rudder Pedals 
    6.5.3 - Mount Pedals 
    6.5.4 - Install Nylaflow Tubing for Rudder Cables 

6.6 - Instrument Panel

    6.6.1 - Locate Panel 
    6.6.2 - Install Panel 

6.7 - Installing Main Spar

    6.7.1 - Spar Positioning 
    6.7.2 - Spar Installation 
    6.7.3 - Lay-ups 
    6.7.4 - Triax Reinforcement 

6.8 - Canard Reinforcements

    6.8.1 - Canard Attachment Reinforcement 
    6.8.2 - Canard Top Attachment Points 

6.9 - Overhead Fresh air Duct 6A.1 - Keel Controls

    6A.1.1 - Keel Cut out 
    6A.1.2 - Upper Aileron Torque Tube Bearings 

6A-1.3 - Control Stick Assembly

    6A.1.4 - Lower Aileron Torque Tube 

6A.2 - Rear Seat installation

    6A.2.1 - Bottom Seat Pan Installation 
    6A.2.2 - Seat Back Installation

6A.3 - Rudder Pedal / Toe-Brake

    6A.3.1- Installing Toe-Brake Assembly 

6A.4 - Cleveland Brake Install 6A.5 - Main Gear Leg Torsional Reinforcement

    6A.5.1 - Gear Leg Preparation 
    6A.5.2 - Carbon Bid Gear Leg Torsional Reinforcement 

7.1 - Nose Gear Door Installation

    7.1.1 - Nose Gear Door Cutout 

7.2 - Nose Gear Installation

    7.2.1 - Nose Gear Bushings
    7.2.2 - Overcenter Linkage 
    7.2.3 - Sequence Valve 
    7.2.4 - Gas Spring 
    7.2.5 - Nose Gear Guides

7.3 - Main Gear Preparation

    7.3.1 - Gear Leg Preparation 
    7.3.2 - Gear Leg Torsional Reinforcement 

7.4 - Fuselage Preparation

    7.4.1 - Gear leg cut out 
    7.4.2 - Drilling Holes for Main Gear Bushings 
    7.4.3 - Transverse Bulkhead Install 

7.5 - Installation of Main Gear Bushings 7.6 - Main Gear Pulley Installation

    7.6.1 - Pulley Assembly 
    7.6.2 - Main Gear Overcenter Linkage and Sockets 
    7.6.3 - Hydraulic Cylinder 
    7.6.4 - Cables 

7.7 - Installing the Main Gear

    7.7.1 - Gear Legs
    7.7.2 - Brake Lines 
    7.7.3 - Main Gear Doors 

7.8 - Hydraulic System

    7.8.1 - Hydraulic Power Pack and Nose Gear Door Cylinder 
    7.8.2 - Plumbing 
    7.8.3 - Pressure switch adjustment. 
    7.8.4 - Electrical 
    7.8.5 - Final System Adjustments 

7.9 - Emergency Extension

    7.8.1 - Basics 
    7.8.2 - Nose Gear Safety Stick 

8.1 - Wheels and Axles

    8.1.1 - Install Main Gear Axles 

8.2 - Nose Wheel Installation 9.1 - Fuel System

    9.1.1 - Transfer Template 

9.2 - Lower Fuel Strake

    9.2.1 - Wheel Well Measurements 
    9.2.2 - Preparation 
    9.2.3 - Lower Strake Alignment 
    9.2.4 - Cut out Lower Baggage Access Openings 
    9.2.5 - Lower Strake Half Glassing 

9.3 - Internal Strake Structures

    9.3.1 - Fitting Wheel Well 
    9.3.2 - Baffles and Bulkheads 
    9.3.3 - Install Strake Baffles 
    9.3.4- Bulkhead Fuel Fittings 
    9.3.5 - Fuel system venting 

9.4 - Upper Strake Half

    9.4.1 - Fuel Cap Installation 
    9.4.2 - Fitting the Upper Strake Half 
    9.4.3 - Upper Strake Half Installation 
    9.3.4 - Outboard End Strake Reinforcement 

9.5 - Sump Tank and Fuel Lines

    9.5.1 - Fuel lines 
    9.5.2 - Install the Sump Tank Cover 
    9.5.3 - Install Mounting Tabs 
    9.5.5 - Sump Tank Installation 

9.6 - Wing Strake Cutout

    9.6.1 - Wing Strake Cutout 
    9.6.2 - Wing Strake to Beam Support 
    9.6.3 - Installing Leading Edge of Strake onto Door 

9.7 - Fuel System Plumbing

    9.7.1 - Solid fuel line Installation 

10.1 - Elevators

    10.1.0 - Introduction 
    10.1.1 - Installing Control Stick Push-Tube Assembly
    10.1.2 - Elevator Trim 
    10.1.3 - Aerodynamic Trim (Sparrow Strainer) 

10.2 - Rudders

    10.2.1 - Rudder Cable Installation 

10.3 - Ailerons

    10.3.1 - Rigging of the Roll System (Ailerons) 

11.1 - Cowl Treatments

    11.1.1 - Cowling Relief Hole for Wing 
    11.1.2 - Cowling Joint Flanges 
    11.1.3 - Upper Cowl-to-Wing Flanges 
    11.1.4 - Lower Cowling Flanges 
    11.1.5 - Premolded NACA Scoop Installation 
    11.1.6 - Oil Access Door 
    11.1.7 - Cowl Attachment 

11.2 - Canard Tips

    11.2.1 - Installation 
    11.2.2 - Counterweight Fairings 

12.1 - Engine Installation

    12.1.1 - Introduction 
    12.1.2 - Engine Mounts 

12.2 - Fluid Lines

    12.2.1 - Aluminum Oil Lines 
    12.2.2 - Fuel Plumbing 

12.3 - Controls, Cooling and Prop

    12.3.1 - Throttle, Mixture, and Prop Controls 
    12.3.2 - Pressure Checking Fuel System 
    12.3.3 - Fuel Sight Gauges 
    12.3.4 - Cooling Plenum Chamber 
    12.3.5 - Propeller 
    12.3.6 - Nose Mounted Cooler 

12.4 - Exhaust Installation

    12.4.1 - Overview 
    12.4.2 - Cowling Cutout 
    12.4.3 - Exhaust Stack Trimming 

13.1 - Electrical system and Avionics

    13.1.1 - Introduction 
    13.1.4 - Glideslope Antenna 
    13.1.5 - Marker Beacon 
    13.1.6 - Transponder 
    13.1.8 - GPS 
    13.1.9 - ELT 

13.2 - Instrument Panel

    13.2.1 - Instrument Panel 
    13.2.2 - Engine Instruments 

13.3 - Electrical System Completion

    13.3.1 - Introduction 
    13.3.2 - Basic Electrical System 
    13.3.3 - Trim, Speed Brake, & Speed Brake Warning 
    13.3.4 - Switches and Circuit Protection 
    13.3.5 - Avionics 
    13.3.6 - P-Leads 

13.4 - Pitot - Static and Vacuum Instruments

    13.4.1 - Vacuum System 
    13.4.2 - Static Port 
    13.4.3 - Pitot Tube 

14.1 - Final Assembly Procedures

    14.1.1 - Canard / Elevators 
    14.1.2 - Aircraft Tie Downs 
    14.1.3 - Wings to Aircraft
    14.1.4 - Ailerons 
    14.1.5 - Control System
    14.1.6 - Rudder Pedals, Cables,
    14.1.7 - Vortilon Installation
    14.1.8 - Brake Bleeding 
    14.1.9 - Landing Gear, Wheels, Brakes, Fairings 
    14.1.10 - Fuel System
    14.1.11 - Powerplant / Propeller
    14.1.12 - Pitot / Static System 
    14.1.13 - Electrical System 
    14.1.14 - Alternator 
    14.1.15 - Vacuum Pump System

15.1 - Interior

    15.1.1 - Headliner 
    15.1.2 - Carpet 
    15.1.3 - Upholstery 
    15.1.4 - Seat Foam 
    15.1.5 - Glue for Installation 
    15.1.6 - Trim and Weather-stripping 

15.2 - Installation

    15.2.1 - Fuselage Headliner 
    15.2.2 - Window Frames 
    15.2.3 - Carpeting 
    15.2.4 - Side Panels 
    15.2.5 - Interior Door Cover 
    15.2.6 - Glare shield 
    15.2.7 - Rear Cover Panel

New Articles

Placeholder File:Fixing Prop Nicks and Dings.docx