AILERON AND FLAP ASSEMBLIES

TABLE OF CONTENTS

PAGE
A. TRAILING EDGE PREPARATION......................................F-3
B. AILERON AND FLAP HINGE LAYOUT AND REINFORCEMENT................F-4
C. AILERON AND FLAP LAYOUT AND REINFORCEMENT......................F-8
D. AILERON AND FLAP HINGE CONSTRUCTION AND ATTACHMENT.............F-13
E. AILERON RIB CONSTRUCTION AND CLOSEOUT..........................F-24
F. AILERON COUNTERWEIGHT INSTALLATION.............................F-30
G. FLAP RIB CONSTRUCTION AND CLOSEOUT.............................F-41
H. FLAP ACTUATOR INSTALLATION.....................................F-52
I. FLAP LINKAGE INSTALLATION......................................F-54
J. AILERON INSTALLATION AND LINKAGE CONSTRUCTION..................F-57
K. FLAP STOP INSTALLATION.........................................F-64

STODDARD-HAMILTON
AIRCRAFT, INCORPORATED

A SSEMBLY NAME REVI SION DATE VOLUME PAGE

MODEL

GLASAIR III AILERON & FLAP ASSEMBLIES II F-1

 AILERON AND FLAP ASSEMBLIES

INTRODUCTION

Aileron and flap construction, installation, control linkage hook-up, and

aileron counterbalance fabrication are described in this section. The
ailerons and flaps are cut from full-length upper and lo wer aileron/flap
panels. The forward shear webs are integral parts of the lower aileron/flap
panels. FIGURE (F-1) shows the major components of the flap and aileron
assemblies.

NOTE : The wing tip must be fit to the wing prior to beginning this section .

UPPER Al LE RON
PANEL

UPPER FLAP
PANEL
LOWER AILERON
SHEARWEB

LOWER Al LERON
PANEL

LOWER FLAP
SHEARWEB
LOWER FLAP
PANEL

FIGURE (F-1)
-------------------1

STODDARD-HAMILTON
AIRCRAFT. INCORPORATED

ASSEMBLY NAME REVISION DATE VOLUME PAGE

MODEL

GLASAIR III AILERON & FLAP ASSEMBLIES II F-2

 CONSTRU CTION PROCEDURE

Before beginning construction of each alphabetical division in this section,

read the entire section and study each step in order to have an understanding
of the complete assembly process .

A. TRAILING EDGE PREPARATION

STEP A-1
WITH WING IN JIG
SANO UPPER TRAILING EDGE
UNTIL IT IS PERPENDICULAF�
ABOVE LOWER TRAILING EDGE
FOR ENTIRE WING SPAN.

PLUMB BOB

FIGURE (F-2)

The lo wer wing panel has had its trailing edge sanded straight in Section A
WING PREPARATION of the WING ASSEMBLY chapter of this manual. For proper fit
of the ailerons and flaps, the trailing edge must be perpendicular to the wing
chord line while in the wing jig, as sho wn in FIGURE (F-2), and the upper
surface trailing edge must also be straight. Refer to STEP E-2 (WING ASSEMBLY
section) if any adjust ments are needed.

NOTE: Masking tape (stretched for straightness) along the forward side of a
chalkline makes a more permanent and more visible reference line for sanding.

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STODDARD-HAMILTON
AIRCRAFT, INCORPORATED
ASSEMBLY NAME REVISION DATE VOLUME PAGE
MODEL
GLASAIR III AILERON & FLAP ASSEMBLIES II F-3
 B. AILERON AND FLAP HINGE LAYOUT AND REINFORCEMENT

STEP B-1 AILERON AND FLAP HINGE LOCATIONS

<t_

1-1/4"
II

24
11
10
::..i,\, 2
II

\2

AILERON
i.......--FLAP LOCATION ___.......-.-LOCATION

[I::> 42" (STANDARD FLAPS)

41-1/2" (SLOTTED FLAPS)

FIGURE (F-3)

Lay out the flap and aileron hinge locations on the lower trailing edge of the wing on both sides, as
shown in FIGURE (F-3). All measurements are referenced from the wing tip attach flange joggle.

NOTE: For slotted flap installations, make the ailerons 41-1/2" long, instead of 42". This provides
more space for installing the outboard slotted flap hinge. Refer to your slotted flap instructions for
more information.

STODDARD-HAMILTON
AIRCRAFT. INCORPORATED
MODEL ASSEMBLY NAME REVISION DATE VOLUME PAGE

GLASAIR III AILERON & FLAP ASSEMBLIES J 12/15/94 II F-4

 STEPB-2

,
1,

�- ,, I 11
1 i 14 FOR Al LERONS
26 FOR FLAPS
11

-<, f�
L�
-
· �----,:-·-._ ,-.:,.;-,"
-

=S=E=C=T=IO=N=A=-=A=
i.--1-11s+I

FIGURE (F-4)
From the supplied 1" thick foam make (4) wedges 1" x 1-1/8" x 14" and (4) wedges 1" x 1-1/8" x
26" as shown in FIGURE (F-4). The 14" long wedges are for the aileron hinge reinforcements.
The 26" long wedges are for the flap hinge reinforcements. Cut a 1" bevel at each end of each
foam wedge, as shown in FIGURE (F-4), Flag #1.
NOTE: The inboard flap wedges may be relieved or interrupted where the landing gear
hydraulic line bulkhead fittings come through the aft spar shearweb. f

�
STODDARD-HAMILTON
AIRCRAFT. INCORPORATED

GLASAIR III AILERON AND FLAP ASSEMBLIES H 7/01/91 II F-5

MODEL ASSEMBLY NAME REVISION DATE VOLUME PAGE
 STEP B-3
�-WOOD BRACES

FOAM REINFORCEMENT
WEDGE

AFT LOWER EDGE

OF WING

FIGURE (F-5)

Mix a thick batch of Q-cell mixture and bond the foam wedges into the aft
lower corner of the rear spar at the hinge locations shown in FIGURE (F-3).

Hold the foam wedges in place with small pieces of wood while the Q-cell
mixture cures, as sho wn in FIGURE (F-5). Cut-to-length tongue depressors
work well for this. After the Q-cell mixture has cured, rereove the wood
braces .

NOTE: The 1" bevel on each end cf the foam wedges is to facilitate the
installation of the t wo layer laminates to follow. The hinge is located
between the bevels on the foa m wedges. The foam wedges have been fabricated
2" longer than the hinges to allow the 1" bevel to extend 1" past each end
of t he hin ge .

NOTE: The lo\\·er wing panel must have a 3/4" wide flat area exposed aft of the
foam wedge prior to the installation of the (2) layer cover laminate, as shown
in FIGURE (F-6), to allow room for installation of the flap and aileron
hinges. If this condition is not met, sand the foam wedge to provide adequate
space for installation of the hinge.

STODDARD-HAMILTON
AIRCRAFT, INCORPORATED
REVI SION DATE VOLUME PAGE
MODEL A SSEMBLY NAME
GLASAIR III AILERON & FLAP ASSEMBLIES II F-6
 Apply a wet Q-cell mixture to the exposed portion of the foam wedges. Radius
the corners using a thick Q-cell mixture. Let cure.

STEP B-4

From the fiberglass cloth stock cut strips on the 45 ° bias to the following
dimensions.

QUANTITY (8) 4" x 16" (for the aileron hinge reinforcements)

(8) 4-3/8" x 28" (for the flap hinge reinforcements)

STEP B-5

2 LAYER LAMINATE

FIGURE (F-6)

Lay up (2) layers of the �, x 16' cloth on each aileron foa m hinge
reinforcement. Make sure the cloth extends all the way to the trailing edge
of the lower wing panel. Keep the laminates smooth in order to provide a flat
surface to secure the hinges. (See Flag #1, FIGURE [F-6].) Lay up (2) layers
of the 4-3/�' x 2�' cloth on each flap foam wedge. Use standard laminating
procedures. Let cure.

COMPLETED [ ]

STODDARD-HAMILTON
AIRCRAFT, INCORPORATED
REVISION DATE VOLUME PAGE
MODEL ASSEMBLY NAME
GLASAIR III AILERON & FLAP ASSEMBLIES II F-7
 C. AILERON AND FLAP LAYOUT AND REINFORCEMENT
STEP C-1

WING
TIP
3/ 11
/16 GAP
L
I ----:-·

AILERON-FLAP
PANEL SHEARWEB

AFT EDGES
OF W I NG
SKINS

:::2 FROM
11

FOAM CORE

--Al LERON-FLAP
LOWER PANEL

FIGURE (F-7)

STODDARD-HAMILTON
AIRCRAFT. INCOR('ORATED
MODEL ASSEMBLY NAME REVISION DATE VOLUME PAGE

GLASAIR III AILERON & FLAP ASSEMBLIES II F-8

 Install the wing tips onto the wings with appropriate screws .

Examine the aileron-flap upper and lower panels or shell halves. The lower
panels have the shearweb built right into them. The upper panel's forward
edge curves downward. Each panel has a foam composite core. There is
excess material on the ends and trailing edges of the panels to allow for
fit-up to the wing and fuselage.

Trim the inboard end of the aileron-flap panel along the scribe line on the
underside of the panel.

NOTE: Early serial number kits may not have a scribe line on the inboard end
of the lower aileron/flap panel. If the scribe line is missing, measure
inboard 1-3/�' from the inboard corner of the lower aileron/flap panel
shearweb and lower surface , end mark a line to the most inboard trailing edge
point on the panel (about 80 to the shear web). Trim this triangular section
off.

NOTE: The root ends of the flaps will be trimmed further to fit the wing root
notch in the wing to fuselage fairing later during FINAL ASSEMBLY.

"\ I

---c-.------
1---�: -
J ·1
L·
21·1/2"

I
I

I ·.

f
�TRIM NOTCf TO CLEAR
1

�AILERON /FLAP PANEL

FIGURE (F-8)

Measure outboard from the wing centerline along the wing trailing edge 21-1/2"
and make a mark , as shown in FIGURE (F-8 )

STODDARD-HAMILTON
AIRCRAFT, INCORPORATED
MODEL ASSEMBLY NAME REVISION DATE VOLUME PAGE

GLASAIR III AILERON & FLAP ASSEMBLIES II F-9

 There must be a 3/16' gap between the wing tip and the outboard end of the
aileron, as shown in FIGURE (F-7). With the wing tips installed, have a
helper hold the lower aileron/flap panels in place against the lo wer wing
panel trailing edge with the inboard corner of the aileron/flap panel shearweb
lined up with the 21-1/�' mark. Using the wing tip as a guide, mark a line on
the outboard end of the aileron/flap panel. Remove the panel and mark a
second line 3/16" inboard and parallel to the wing tip line. Trim the
aileron/flap panel off along this second line.

Trim the wing panel trailing edge notch to clear the inboard end of the
aileron /flap panel , as shown in FIGURE (F-8) .

NOTE: The trailing edges of the aileron and flap panels may come with excess
material that will require tri mming when the lower panels are attached with
the piano hinge. The trailing end of the wing tip may extend farther aft than
the final width of the aileron at the outboard end. Trim the trailing edge of
the wing tip after the ailerons are mounted to the wing, keeping the length of
wing tips equal.

STEP C-2 LAYING OUT THE AILERON-FLAP SEPARATION LINE AND CUTTING THE LOWER
AILERON-FLAP PANEL

MARK
WING
HERE

3 II
�6
AILERON-FLAP
PANEL SEPARATION
LINE
FIGURE (F-9)

Layout the aileron-flap separation line onto the lower aileron-flap panels
as sho wn in FIGURE (F-9). Cut the lower panels in two along this line,
using a saber saw. Be careful not to chip the primered surface. Sand the
cut ends of the panels to remove saw marks.

Hold the aileron-flap lo wer panel in place 3/16' from the wing tip as shown,
and transfer the hinge locations from the wing onto the lower panel. Also,
mark the location of the aileron-flap separation line onto the wing.

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STODDARD-HAMILTON
AIRCRAFT. INCORPORATED
MODEL ASSEMBLY NAME REVISION DATE VOLUME PAGE
GLASAIR II AILERON & FLAP ASSEMBLIES D 3/7 /88 II F-10
 STEP C-3

The aileron and flap lower panels require reinforcement at the hinge attach
points. Cut (16) pieces of cloth 2-1/2" x 25" on the 45 ° bias for the flap
hinge reinforcements. Cut (8) pieces of cloth 2-1/2" x 13 11 on the 45 ° bias
for the aileron hinge reinforcements.

STEP C-4

1-LAYER(AI LE RONS)
3-LAYERS (FLAPS)
" --(MASKING TAPE
13�

I
---,� %".... 1---

FIGURE (F-10)

Set the aileron shearwebs at 90 ° to the lower surfaces with masking tape as
shown in FIGURE (F-10) before lamination.

NOTE: The shearweb angles on the ailerons must be equal at 90 °. The aileron
travel will differ if not set equally on both ailerons.

Lay up (1) layer of 2-1/2 11 x 1311 cloth at each hinge location for the
aileron. Center the 13 11 pieces of cloth over the 12 11 hinge area. Lay up (3)
layers of the 2-1/2" x 25 11 cloth at the hinge location for the flaps in the
same manner as done for the ailerons. Let the layups cure and then remove
the masking tape.

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STODDARD-HAMILTON
AIRCRAFT, INCORPORATED
MODEL ASSEMBLY NAME REVISION DATE VOLUME PAGE
GLASAIR III AILERON & FLAP ASSEMBLIES G 4/26/90 II F-11
 STEP C-5

From the supplied .032 11 thick 2024-T3 aluminum sheet cut strips to the
following dimensions:

QUANTITY (4) 1/2" x 24 11 (for flaps)

(4) 1/2 11 x 12 11 (for ailerons)

Remove any sharp burrs and sand both sides with 60 grit sandpaper to prep
them for bonding. These strips will reinforce the aileron and flap
shearwebs where the hinge rivets are installed.

STEP C-6

r X
_[_2
II
1-LAYER
LAMINATE

<t-- ,111

.032" 2024-T3 REINFORCEMENT PLATE

CROSS-SECTION (TYPICAL FLAP-AILERON)

FIGURE (F-11)

Mix a small batch of body putty. Apply a small bead of the putty along the
backside of each strip to bond them to the aileron and flap shearwebs.
Center the strips 1/2 11 above the lower inside surface of the panels at the
hinge locations, as shown in FIGURE (F-11). Use the 12 11 pieces for the
aileron hinges and the 24" piece for the flap hinges. Clamp the strips in
place with some long wood or metal strips. After' the body putty has cured,
sand the excess putty smooth and lay up one more layer of cloth over each
reinforcing strip, using the remaining pieces in the same manner as was done
previously.

COMPLETED [ ]

�
STODDARD-HAMILTON
AIRCRAFT. INCORPORATED
MODEL ASSEMBLY NAME REVISION DATE VOLUME PAGE
GLASAIR III AILERON & FLAP ASSEMBLIES G 4/26/90 II F-12
 D. AILERON AND FLAP HINGE CONSTRUCTION AND ATTACHMENT

I
STEP D-1

.,..________ 12" FOR Al LERONS__________

24" FOR FLAPS

....-1/4"

'8I "R (TYP)

4 Pl
FIGURE (F-12)

From the supplied MS20001-P4 hinge stock cut (4) pieces 12" long and (4) pieces 24" long as shown in
FIGURE (F-12). For kits delivered after 8/1/94 cut these pieces from the two 63" long (335-2000-163)
I
and one 26" long (335-2000-126) pieces ofMS20001-P4 hinge stock. Do not drill any mounting holes
at this time.

NOTE: Cut the hinge pins 1-1/2" longer than the hinge halves. The extra length will be used to secure
the hinge pin later. On one end of each hinge pin grind a (dull) point approximately 1/4" in length to aid
in inserting the hinge pin. On the opposite end form a locking arm by bending the last 3/4" of the hinge
pin 90 ° .

STEP D-2

FIGURE (F-13)
(See FIGURE (F-15) for View A-A)

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STODDARD-HAMILTON
AIRCRAFT. INCORPORATED
MODEL ASSEMBLY NAME REVI SION DATE VOLUME PAGE

GLASAIR III AILERON & FLAP ASSEMBLIES J 12/15/94 II F-13

 On the lower surface of the wing, lay out hole patterns for attaching the
forward hinge halves. Lay out the hole patterns 3/8" forward of the lower
wing panel's trailing edge, as shown in FIGURE (F-16). Space the rivets l"
apart and 1/2" from the end s of the hinge halves , as shown in FIGURE (F-15).

NOTE: Make sure the laminate thickness on the wing lower trailing edges is
uniform at the hinge locations. If the laminates are not flat and of uniform
thickness the ailerons will bind up when rotated. Use a sanding block to sand
any irregularities smooth, if necessary. The hinge halves must be straight to
insure freedom of movement.

CAUTION: If too much material is removed, the hinge attach point may be
weakened . Add laminates if necessary.

Using a long straight sanding board (3 to 4 feet long if possible), bevel the
wing lower trailing edge to at least a 45 ° angle. Position each hinge half in
its proper location with the bulb facing down, as shown in FIGURE (F-13).
Using a long straight edge, held against the bulb portion, align the hinges
both fore and aft and up and down.

NOTE: A sharp angle is necessary, when beveling the trailing edge, to

minimize the wing-to-aileron/flap gap. (See FLAGNOTE #3, FIGURE (F-13).)

Shim the hinges up , if necessary, with laminates or mill-fiber mixture.

Once the hinge halves are properly shimmed (if necessary) and aligned, clamp
the hinges securely in place and mark their position. Drill through the lower
wing panels and hinge halves with a #30 drill bit, insert a cleco into each
hole after drilling to keep the hinge halves from shifting. Remove the
clamps, leaving the hinge halves clecoed to the wing panel.

FIGURE (F-14)
--------------------t
�
STODDARD-HAMILTON
AIRCRAFT, INCORPORATED
REVISION DATE VOLUME PAGE
MODEL ASSEMBLY NAME

GLASAIR III AILERON & FLAP ASSEMBLIES II F-14

 As accurately as possible, measure the height of the hinge bulb off the lower
surface of the wing ("X"), as sho wn in FIGURE (F-14). Place the aileron-flap
lower panel on a flat table. Use a straight edge to mark a line (use a fine
line for accuracy) on the forward side of the shearweb equal to height ("X")
of the hinge bulb off the lower surface of the wing.

Attach the aileron-flap hinge halves (with the hinge pins) to the wing hinge
halves. Align the hinges with the lines previously marked on the shear webs of
the aileron-flap lower panels. Use C-clamps to secure the aileron-flap lower
panels to the hinges. Mark the hinge locations on the shearwebs and pull the
hinge pins. Be certain the hinge locations do not shift once the hinge pins
have been removed.

TRAI LING EDGE

OF WI NG
THESE SURFACES
VIEW A-A SHOULD BE PARALLEL

FIGURE (F-15)

With the hinge halves clamped to the Aileron-Flap lower panels, as shown in
FIGURES (F-13) and (F-15), lay out the rivet hole patterns on the shearweb
hinge halves. Space the rivets 1" apart 1/2" from the end of the hinge
halves. Position the holes so that they go through the center of the .032"
aluminum reinforcement strips. (See Flag #2, FIGURE [ F-13 ].)

Drill through the hinge halves and lower aileron and flap panels with a #30
drill bit at these hole locations.

NOTE: Initially drill only the holes at each end of the hinges. Install
clecos in these holes , then remove the C-clamps. Assemble the lower aileron­
flap panels to the wing and check for lo wer surface alignment and freedom of
movement throughout the panel's full range of travel. If satisfactory, remove
the hinge pins and continue to drill the rest of the holes.

�
STODDARD-HAMILTON
AIRCRAFT, INCORPORATED
REVISION DATE VOLUME PAGE

MO't;tASAIR III ASSA1tEf� & FLAP ASSEMBLIES II F-15

 NOTE: Insert a cleco into each hole after drilling to keep the hinge half
from shifting.

Remove the aft hinge halves, deburr the holes, and rivet the hinge halves to
the shearwebs of the aileron-flap lower panels, using the supplied AN470AD4-6
rivets.

When riveting the 24" hinge halves for the flaps, countersink the hinge halves
and use flush head AN426AD4-6 rivets for the (3) rivets on the inboard end of
the inboard flap hinge so that the flap actuator fitting will mount flush and
not conflict with rivet heads. (See FIGURE [F-43].)

STEP D-3 TRIMMING THE WING TRAILING EDGE TO ALLOW ADEQUATE AILERON-FLAP
DOWN TRAVEL
EXTENDED STRAIGHT
LINE OFF LOWER
WING SKIN
AN470AD4-6.
AN426AD4-6 AN426AD4-6 RIVETS,*
EUSE ONLY FOR 3 INBOARD RIVETS1
R I V ETS
OF THE INBOARD FLAP HINGE j

----
--- L-- ·3 0

�' 1
.�' �":::- , '-
3r. ' ' 19 ° FOR AILERONS
8 ', '-, 34° FOR FLAPS

°
158 FOR AILERONS ',:::" ' '
/
'
/ ,,
" ',,
143 ° FOR FLAP� '"'-

,,�
�"'

FIGURE (F-16)

The ailerons and flaps require downward travel of 19 ° and 34 ° respectively.

With the hinge pivot point above the lower surface of the wing, gaps are
required between the lower aft edge of the wing and forward lower edge of the
control surfaces to allow proper downward travel. (See Flag #1, FIGURE [F-
16].) If necessary, remove material from the lower wing panel trailing edge
to allow full downward control surface travel.

�
STODDARD-HAMILTON
AIRCRAFT. INCORPORATED
MODEL ASSEMBLY NAME REVISION DATE VOLUME PAGE
GLASAIR III AILERON & FLAP ASSEMBLIES G 4/26/90 II F-16
 NOTE: These control travels are measured from the lower surface of the wing to the lower surface of
the aileron/flap lower panel. The neutral position (faired with the wing tip) of the lower surface of the
lower aileron/flap panel is approximately 3° below an extended straight line off the lower skin of the
lower wing panel, as shown in FIGURE (F-16).

STEP D-4

EX C E S S MAT'L TRA I L I N G E DG E
EXAGG E RATE D NOTCH 1 0 � '<:1]
FOR C L AR I T Y (ADD 1 . 1 " I F WING
LOWER TRAILING EDGE HAS
LOWE R BEEN TRIMMED
A I L ERON F LAP FOR SLOTTED F LAPS)
PAN E L PAN E L
[:::> ±1FOR18"STANDARD
TOLERANCE
FLAPS
+O", -1 /8" TOLERANCE
FOR S LOTTED FLAPS

LOWER WING SURFACE - VIEW LOOKING UP

FIGURE (F-17)

Attach the flap and aileron lower panels to the wing with the forward hinge halves, hinge pin, and
clecos, as shown in FIGURES (F-1 7) and (F-1 8). With the wing tips in place, snap a chalk line onto the
lower aileron and flap panels from the 5-7/8" dimension at the tip to the 1 0-1/4" dimension at the root
(both dimensions measured from the wing trailing edge), as shown in FIGURE (F-1 7). Remove the
panels and cut along these lines with a saber saw if enough excess material is available.

�
STODDARD-HAMILTON
AIRCRAFT. INCORPORATED
MODEL ASSEMBLY NAME REVISION DATE VOLUME PAGE

GLASAIR III AILERON & FLAP ASSEMBLIES J 12/1 5/94 II F-1 7

 NOTE: For builders installing slotted flaps, the 5-7/8" and 10-1/4" dimensions determine the proper
angle of the aileron trailing edge even though the original flap panel shown in FIGURE (F-1 7) is not
used. The 1 0-1/4" dimension at the inboard end of the flap will be 1 . 1 " larger (1 1 . 3 5") after the wing
lower trailing edge is trimmed for slotted flap installation. Refer to the slotted flap instructions for
details.

NOTE: The 5-7/8" dimension at the outboard end of the ailerons can vary ±1/8" (+O" or -1/8" if slotted
I
flaps are used), but should be equal from one side to the other.

NOTE: The control surfaces will have to be propped up from below while snapping the chalk line.

When trimming the control surface trailing edges, leave a little excess material to allow for sanding.
Use a long sanding block to sand the cut edges of the aileron and flap panels smooth and straight. Trim
the aft ends of the wing tips at this time, if necessary, to match the 5-7/8" ±1/8" dimension (+O" or -1/8" I
if slotted flaps are used) given for the ailerons in FIGURE (F-1 7).

�
STODDARD-HAMILTON
AIRCRAFT. INCORPORATED
MODEL ASSEMBLY NAME REVISION DATE VOLUME PAGE

GLASAIR III AILERON & FLAP ASSEMBLIES J 1 2/1 5/94 II F-1 8

 2 4°

--
___ :::::i
�T;AL
� ���I T I O N

F U L L U P A I L E R O N POS I T I O N

NEUTRAL POS I T I O N

FIGURE (F-18 )

�
STODDARD-HAMILTON
AIRCRAFT, INCORPORATED
MODEL ASSEMBLY NAME REVISION DATE VOLUME PAGE
GLASAIR III AILERON & FLAP ASSEMBLIES G 4/26/90 II F-19
 Reattach the flap and aile ron lowe r pane l s to the wing with the fcrward hing e
halves, hinge p in, 2nd clecos, aE: 1=:how n irl FIGURE ( F-18). Remove the win g
tips. Pivot the cont rol surface s until they touch the u r per aft edge of the
wing (see Flag #1, :FIGURE [F-18 ]). Mark a line on the shearwebs along this
edge. Ma rk anot her line pa rallel t o and the app roximat e thickness of the
upper panels below the fi rst. (See Flag #2, F l ClRE [ D-18].) The uppe r panels
will have to be measu red to determine the placement of the lo wer lines.
Remove the lower cont rol surface panels and t rim the shearwebs to the uppe r
lines .

NOTE: Large heavy duty scisso rs or ai rc raft sheet metal shea rs work well fo r
cutting the shearwebs. Be very accurate when t rimming the shearwebs.

With a long sanding block, bevel the uppe r trailing edges of the wing in the
locality of the cont rol su rfaces. (See Flag #3, FIGURE [F-18].) The bevel
should be app roximately 30°.

NOTE: Do not shorten the uppe r wing panels when beveling the uppe r trailing
edges, and avoid sanding them to razor sha rpness. Leave them slightly dull.
If they are too thin and pointed, they become fragile and more prone to
chipping.

Place the uppe r aile ron-flap panels onto the lowe r panels while they are cleco
clamped in place. Transfer the aile ron-flap sepa ration line from the lower
panels to the uppe r ones, remove the upper panels, and use a saber saw to cut
both upper panels in two along the marked lines. Sand the cut ends of the
uppe r panels smooth and straight. Place the uppe r aile ron panels onto the
lower ones and t rim both the inboard and outboa rd ends of the upper panels to
match the lowe r ones.

The aile rons should be able to rotate freely up 24 ° and down 19 °. The flaps
should rotate f reely downwa rd 34 °.

Fit the uppe r control surfaces to the lowe r ones. When doing this the idea is
to sand the shea rwebs until the upper panels fit in place with a minimum gap
at point A, F IGURE (F-18), with free movement and full up and down travel.
The upper panels will be re moved and installed many times to get the p rope r
fit. The upper panels may be shifted slightly forwa rd or aft when fitting to
get the best results. The curve in the upper panel should be just hidden
inside the t railing edge "pocket" when the control surfaces are neut ral to the
wing.

NOTE: Make sure the cu rved po rtions of the uppe r panels a re pa rallel or
aligned to the trailing edges of the wing. Be careful , when sanding the
shea rwebs, not to remove too much mate rial at once. Be patient and use a long
sanding block for this. The upper edges of the shea rwebs should be parallel
to the uppe r wing su rfaces. Use the lowe r (p reviously ma rked) lines as
refe rences.

NOTE: To obtain full upwa rd aileron travel , trim mate rial off the forward
edges of the uppe r aile ron panels, as necessa ry, if they interfe re wit h the
rea r spa r shea r web or hinge reinfo rcement foa m angles.

�
STODDARD-HAMILTON
AIRCRAFT. INCORPORATED
MODEL ASSEMBLY NAME REVISION DATE VOLUME PAGE
GLASAIR III AILERON & FLAP ASSEMBLIES D 3/7/88 II F-20
 Once the upper panels are properly fit , their trailing edges need to be
trimmed to length. Place the upper panels in position and m ark a line from
below onto the upper panels, using the trailing edges of the lower panels as
guides. Remove the upper panels and cut their trailing edges w ith a saber
saw. Sand any saw cut roughness smooth and match the trailing edges of the
upper panels to the lower ones .
NOTE: Clamp the upper and lower panels together and align their trailing
edges before sanding . Use a long sanding block for this .

STEP D-SA RIVETING HINGE HALVES TO WING PANELS

At this time, the flap and aileron hinge halves may be riveted to the lower
w ing panel trailing edge. Use standard procedures, as described in the
FABRICATION TECHNIQUES section on pages A-18 through A-20, to countersink the
rivet holes in the w ing panel and to rivet the hinges.

AN426AD4-6 rivets are specified in FIGURE (F-16) , but make sure that , before
driving , the rivets extend throught the rivet holes about 1-1/2 times the
rivet dia meter. Substitute longer rivets, if necessary, or trim them if they
are to o lo ng .

Once the flap and aileron hinge halves are riveted on, the hinge pins must be
removed to disassemble the flaps and ailerons from the w ing panel.

�
STODDARD-HAMILTON
AIRCRAFT. INCORPORATED
MODEL ASSEMBLY NAME REVI SION DATE VOLUME PAGE
GLASAIR III AILERON & FLAP ASSEMBLIES F : 1/1 5/891 II F-21
 STEP D-6 HINGE PIN SAFETYING
;-i AI L E RON SHOWN ,
< F L A PS SI M I L A R )
/ 1

---
A
A
. 0 3 2 S A FE T Y
W I R E (TYP )
�------1 LOW E R WI N G
S KI N T RAI L I N G
EDG E

� 11
3/8' �
1 /1 6 HOL E ( 2 P L S .)

0 0 0 0
I
O U T BOA RD
L O W E R W I NG \ -----1
SK I N "
1 /4

VI EW A-A
FIGURE (F-19)

Prior to flight, the aileron an d flap hinge pins must be safetied to the lowe r
wing pa nel with 0.032" safety wire to prevent the m from workin g their way out
of the hinge. The hinge pins are safetie d to the lower panel with the 90 °
ben ds facing each other, between the two mounting hinges, as shown in FIGURE
(F-19). Two 1/ l e' holes for the safety wire must be drille d thr ou gh the lower
wing skin, as shown in FIGURE (F-19), View A-A. The hinge pin is inserte d
into the hinge, the bent locking arm of the hinge pin is place d between the
1/ 16" holes , an d a loop of safety wire is run through the holes an d over the
locking ar m. The safety wire is drawn tight an d the en ds woun d together
inside the trailing e dge of the wing.

�
STODDARD-HAMILTON
AIRCRAFT, INCORPORATED
MODEL ASSEMBLY NAME REVISION DATE VOLUME PAGE
GLASAIR II AILERON & FLAP ASSEMBLIES D 3 / 7 /88 II F-22
 NOTE: The control surface actuating linkage must be disconnecte d to allow
access to insert and safety the hinge pins.

There may be several alternative metho ds to secure the hinge pins without
having to drill through the wing panels. Securing or laminating a small wire
loop in place next to the hinge pin location may be a suita ble way to
accomplish this.

Glasair Ne wsletter #14 also showe d a metho d of fa bricating a small aluminum

angle piece with a hole drille d in the en d. This aluminum angle was then
attache d to the end of the hinge with the en d rivet.

The hinge pins are installe d in the hinges with the locking arms of the hinge
pins nearest the center of the control surface. This is done to allow a
control surface to be remove d without distur bing the other control surfaces.

NOTE: The hinge pins must be safetie d with 0.032 11 safety wire before flight.

COMPLETED [ ]

�
STODDARD-HAMILTON
AIRCRAFT. INCORPORATED
MODEJ.. ASSEMBLY NAME REVISION DATE VOLUME PAGE
GLASAIR III AILERON & FLAP ASSEMBLIES D 3/7 /88 II F-23
 E. AILERON RIB CONSTRUCTION AND CLOSEOUT

The aileron is fabricated with two ribs; an inboard rib, which stiffens the aileron in the area of
the aileron pushrod attach point, and an outboard rib, which has the aileron counterweight
secured to it.

The inboard ribs are fabricated from a 3" x 6" piece of (2) layer precured laminate, and the
outboard ribs are fabricated from a 3" x 6" piece of 1 / 4" thick 20 lb. foam.

STEP E-1 AILERON RIB TEMPLATE FABRTCATION

1 /4" 20# FOAM R I B

( 2) LAY ER P R EC U R E D
LAMJ N A T E

OUTBOARD
IN-BOARD
END
END

flGURE (F-20)
Each aileron is "custom fit" to the wing; the rib size, therefore, must be determined by the
builder. Make a template for each rib out of cardboard. Place the cardboard templates inside
the aileron 3/ 4" from each end, as shown in FIGURE (F-20). Place the upper panels on top of
the lower ones and trim the cardboard temrlates until the upper panels fit flush.

Save these cardboard templat1:'S. They will be 1.,se<l to cut otht?r d1)th pieces later.

STODDARD-HAMILTON
AIRCRAFT, INCORPORATED
MODEL
GLASAIR lil
ASSEMBLY NA�
A ILERuN & FLAP ASSEMBLIES
REVISIO
NH
DA ;rI Ol / 9 1 VOLU
M_n:
PAlt-24
 STEP E-2 AILERON RIB FABRICATION

I N BOA R D A I LERO N R I B S O U T BOA R D A l LE RON R I B S

2-LA YER P RE-C URE D LAM I N A TE 1 / 4 " 2 0 L B . FOAM

6 11
V I EW A
_, I· 6 11
V I EW B
.. ,

FIGURE (F-21)

B oth the inboard and outboard a ileron r ib s w ill be fabricated in this step,
but, only the inboard a ileron r ib can be in stalled at th is tim e. The outb oard
a iler on r ib w ill be in stalled later (Step F-5) t o match the a iler on
c ounterwe ight arm which mu st be posit ioned f ir st.

Trace the inboard a iler on r ib tem plate tw ice ont o a p iece of 3" x 6" (2) layer
precured lam inate, a s shown in FIGURE (F-21) View A, and cut out. Sand the
sm ooth surface c om pletely dull w ith 60 gr it sandpaper.

NOTE: Large heavy sc is sor s work well f or cutting the lam inate. The r ibs d o
n ot extend t o the tra il ing edge of the panel s, but st op where the gap between
the panel s narr ows t o 1/8". (See Flag #1, FIGURE [F-20].)

Trace the outboard r ib template tw ice onto a 3" x 6 11 p iece of 1/4" thick 20
lb. f oa m , a s shown in FIGURE (F-21) View B, and cut out. C oat both side s of
the outboard ailer on r ib p iece s w ith a thin Q-cell m ixture.

__,,-
STODDARD-HAMILTON
AIRCRAFT, INCORPORATED
MODEL ASSEMBLY NAME REVISION DATE VOLUME PAGE
GLASAIR II AILERON & FLAP ASSEMBLIES D 3/7/88 II F-25
 STEP E-3 INBOARD AILERON RIB INSTALLATION

Using small dabs of hot glue or body putty, bond the pre-cured lam inate
inboard rib in place, as sho wn in FIGURE ( F-20) .

NOTE: Make sure the rib is perpendicular to the lo wer surface and spaced
3/ 4" fro m the end of the aileron.

M ix a thick Q-cell/resin m ixture and use this to form a 1 /8" radius on both
the inboard and outboard sides of the rib .

STEP E-4 CUTTING INBOARD AND OUTBOARD AILERON RIB INSIDE LAMINATES

OUTL I NE
�

T
FIGURE (F-2 2)

Cut (10) pieces of cloth (2 per inboard rib , 3 per outboard rib) on the 45 °
bias , 1 /2" oversi ze , as shown in FIGURE ( F-22) , using the previously made
cardboard aileron rib tem plates.

NOTE: Save the tem plates. They will be used to cut the fiberglass cloth
reinforcing pieces later.

STEP E-5 INBOARD RIB INSIDE LAMINATES

Lay up ( 2) layers of cloth on the inside surface of the inboard aileron rib ,
using the appropriate pieces as shown i n FIGURE (F-24). Use standard
lam inating procedures. Let cure.

�
STODDARD-HAMILTON
AIRCRAFT. INCORPORATED
MODEL ASSEMBLY NAME REVISION DATE VOLUME PAGE
GLASAIR II AILERON & FLAP ASSEMBLIES D 3/7 /88 II F-26
 STEP E- 6 FABRICATING THE AILERON TRIM TAB

"
1 /4 H O L E ( 6 P LS)

TH I S A R EA TO B E
B O N D E D T O A I L E RON
B EN D LINE

3/4

_L I------
II
1-1/ 2

A I LERON TRIM TA B
1 11
( M AT L : . 02 5 2024-T :3 A L U M . S H E E T )

FIGURE (F-23)

To correct any t endencies for the airplan e to roll to the right or l eft during
flight, a fix ed trim tab is incorpo rat ed into one aileron. Cut a pi ec e of
0.025" thick 2024-T3 aluminu m sheet 1-1/2" x 4", as sho wn in FIGURE (F-23).
Round th e co rners and fil e any sa w cut roughness smooth. Drill ( 6) 1/4" hol es
on th e half to b e bond ed to th e ail eron. Rough sand the tab on both bonding
su rfac es to prep it f or bonding and painting. M ount th e tab to th e l eft
ail eron only.

FIGURE (F-24) shows the l ocation of th e ail eron trim tab. The tab will be
bonded betw een th e t railing edges of the ail eron in St ep F-9.

NOTE: If, during flight t esting, th e airplan e rolls to th e left in lev el

f light, bend the tab up. If the airplane rolls to th e right , bend the tab
down. Depending on how accu rately th e plan e was constructed and jigged, th e
t rim tab may not b e needed and could be l eft st raight. B e su re to firmly
clamp the trailing edg e of th e aileron with blocks of wood wh en bending th e
tab so that th e tab does not b r eak loose or damage th e trailing edge.

_,,-
STODDARD-HAMILTON
AIRCRAFT, INCORPORATED
MODEL ASSEMBLY NAME REVISION DATE VOLUME PAGE

GLASAIR II AILERON & FLAP ASSEMBLIES D 3 /7 /88 II F-2 7

 I N BOARD A I L E R O N RIB r-
2 L AYER L A M I N ATE r--

/
-- - - - ----
I A I L E RON
I
TR I M TA B
,I __ 3
�
II

li-•------ 1 8 Y 81 1 ---.-i
T
P L A N V I EW OF A I LERON
I NBOARD
..
A FT V I EW OF A I L E R O N
II
I NB OA RD A I LE R O N R I B
( TY P I C A L ) 2 L AYE R LAM I N ATE .

I NB OARD END OF A I L ERON

( L E FT A I LERON S H OW N )
FIGURE (F-24)

�
STODDARD-HAMILTON
AIRCRAFT, INCORPORATED
REVISION DATE VOLUME PAGE
MODEL ASSEMBLY NAME
GLASAIR II AILERON & FLAP ASSEMBLIES D 3/7 /88 II F-28
 F. AILERON COUNTERWEIGHT INSTALLATION
STEPF-1 INTRODUCTION

B O LT

COUN TER W EIG H T ARM

COUNTERWEIGHT
CUTOUT

( LEFT HAND SIDE I N N EU TRAL POSITI ON )

FIGURE (F-25)
To aid in control surface flutter prevention, the ailerons on the Glasair are counterweighted.
These counterweights come with the kit but require some fitting. The counterweight
installation is shown in FIGURE (F-25).
WARNING: When handling the lead counterweights, observe the safety precautions described
in the Lead Warning on page 1-7A of the General Infonnation section of the Instruction
Manuals.

�
STODDARD-HAMILTON
AIRCRAFT. INCORPORATED

GLASAIR III AILERON & FLAP ASSEMBLIES H 7/01/91 II F-29

MODEL ASSEMBLY NAME REVISION DATE VOLUME PAGE
 STEP F-2 HOLE FOR COUNTERWEIGHT AR M IN THE AILERON SHEARWEB

LOW E R AILERON
PAN E L

....
1 / 211
S Q UA R E
H O LE

A I LE R ON H I N G E

FIGURE (F-26)

Remove the lower aileron panels from the win g and cut 1/2" square holes in the
aileron shearwebs to allow the aileron counter wei ght arms to pass throu gh , as
shown in FIGURE (F-26) . Locate the 1/2" square holes with their outboard
edges 1/4" inboard of the outboard aileron ends and their lower ed ges 11 /16"
from the hin ge centerline, as shown .

NOTE: To make the square holes, drill a series of small holes around the
periphery of the square, and cut out.

�
STODDARD-HAMILTON
AIRCRAFT. INCORPORATED
MODEL ASSEMBLY NAME REVI SION DATE VOLUME PAGE
GLASAIR II AILERON & FLAP ASSEMBLIES D 3/7 /88 II F-30
 R O L L P I N S I N S TA L L E D
D U R I NG L E A D C A S T I NG

COUNTERWE I G H T
A S S EM B LY

( R I G H T S I DE SHOWN )

FIGURE (F-27)
NOTE: The lead weights are held in place on the counter weight arms by roll
pins installed through the arm prior to the lead being molded onto the
counterweight arm.

�
STODDARD-HAMILTON
AIRCRAFT. INCORPORATED
MODEL ASSEMBLY NAME REVISION DATE VOLUME PAGE
GLASAIR II AILERON & FLAP ASSEMBLIES D 3/7 /88 II F-31
 STEP F-3 COUNTERWEIGHT ARM CLEARANCE SLOT IN WING REAR SP AR

WI NG
REAR SPA R
S H E AR WE B SLOT

'------1
AI L E RON
COUNTERW E I GH T

FIGURE (F-28)

Mount the lower aileron panel to the wing and support it in the neutral position.

NOTE: To determine the aileron neutral position, align the aileron trailing edge with the Hoerner wing
tip trailing edge.

Cut a slot in the rear spar shearweb to allow the lead weight portion ofthe aileron counterweight to rest
on the inside surface of the lower wing panel with its outboard edge parallel to the end of the wing
while the counterweight attach arm extends through the 1/2" square hole in the aileron shearweb.

NOTE: When cutting the slots for the counterweight arms, it is normal and acceptable to cut through
the ends of the outboard aileron hinge reinforcement wedges.

STEP F-3A COUNTERWEIGHT CLEARANCE OPENING IN WING

Position the aileron counterweight in a chordwise direction with the forward aileron counterweight
attach bolt hole 5/8" aft of the aft face of the aileron hinge, as shown in FIGURE (F-30).

�
STODDARD-HAMILTON
AIRCRAFT. INCORPORATED
MODEL ASSEMBLY NAME REVISION DATE VOLUME PAGE

GLASAIR III AILERON & FLAP ASSEMBLIES J 12/1 5/94 II F-32

 Trace the forwar d and aft en ds of the lead weight onto the insi de surface of
the lower wing panel. Transfer an d mark the location of the wing tip attach
joggle onto the insi de of the lower wing panel. To determine the spanwise
location of the aileron counterweight cutout, center the lea d portion of the
counterweight bet ween the wing tip attach joggle (just marke d) and the
outboar d face of rib J. With the counter weight hel d in this position, trace
its inboar d an d outboar d e dges onto the insi de of the lower wing panel.

Using the marks just ma de, cut the initial aileron counterweight clearance
hole in the wing lower surface. Cut insi de the lines first and then sand out
to the lines to achie ve smooth e dges. Check the fit of the counterweight in
the cutout an d a djust the si ze an d shape of the cutout, if necessary, to allow
the lea d portion of the counter weight to fit through with the lo wer wing
surface .

NOTE: The final size an d exact shape of the wing counterweight clearance hole
will not be co mplete d until the aileron has been completely assemble d and the
aileron counterweight can be more per manently installe d. The counterweight
will be san de d, coate d with bo dy putty an d shape d smooth in a later Step.

STEP F-3B INSTALLING THE OUTBOARD AILERON RIB

I N BOARD A I LE R O N R I B
----------1 A I L E RO N
COU NTER WE I G H T
3 - L AY E R
LAM I N AT E S

A I L E RON
TR I M TA B

.__� 2- L AY E R P REC U R ED
LAM I NATE
SH I M
PLA N VI E W OF A I LERON
I NBOARD
FIGURE (F-29)

Reinstall the aileron counterweight in the wing with the lo wer surface of the
counterweight no w flush with the lo wer outsi de surface of the wing.

�
STODDARD-HAMILTON
AIRCRAFT. INCORPORATED
MODEL ASSEMBLY NAME REVISION DATE VOLUME PAGE

GLASAIR II AILERON & FLAP ASSEMBLIES D 3 / 7 /88 II F-33

 NOTE: Enlarge the 1 /2" aileron shearweb counterweight clearance hole as
required to allow the aileron counterweight lead to fit flush and square with
the lower surface of the wing.

Cut a small strip of 2-layer pre-cured laminate to act as a te mporary shim

between the counterweight attach arm and the outboard aileron rib. (This shim
simulates the 2-layer closeout laminate which will be applied later on the
outboard face of the outboard aileron rib J
With the aileron counterweight positioned in its cutout in the wing and with
the 2-layer temporary shi m positioned on the inboard side of the counterweight
attach arm, position the outboard aileron rib snugly against the inboard side
of the shimmed counter weight arm. Use dabs of hot glue to temporarily hold
the outboard aileron rib in place.

Remove the aileron counterweight.

Mix a thick Q-cell /resin mixture and use this to form a 1/8" radius on both
side s of t he r ib .

Install the outboard aileron rib using the cloth pieces cut earlier and the
same techniques used in Step E-5. Apply the (3) layer la minates on the
inboard side of the rib. Let cure.

STEP F-3C DRILLING AILERON COUNTERWEIGHT BOLT HOLES

Reinstall the aileron counterweight in position in the wing cutout.

Temporarily install the hoerner wing tip, and align the trailing edge of the
aileron with the trailing edge of the hoerner tip. This sets the aileron
neutral position. Support the aileron in this position and remove the hoerner
tip .

Verify that the lower surface of the aileron counterweight lead is flush with
the lower surface of the wing.

With the aileron and counterweight positions now set, use the existing 3 /16"
mounting holes in the aileron counter weight arm as guides to drill matching
holes in the aileron outboard rib.

NOTE: Use hot glue and shims to hold the counter weight arm accurately in
position while drilling the 3 /16' attach holes. Insert a bolt into the first
hole to maintain alignment while drilling the second hole.

Remove the aileron counterweight .

NOTE : Revision D deletes FIGURES (F-30) and (F-31) .

�
STODDARD-HAMILTON
AIRCRAFT. INCORPORATED
MODEL ASSEMBLY NAME REVISION DATE VOLUME PAGE

GLASAIR II AILERON & FLAP ASSEMBLIES D 3/7 /88 II F-34

 STEP F-4 INSTALLING AILERON COUNTERWEIGHT NUTPLATES

____ /
I

K1 000 -3 N UTPLATE OUTBOAR D

F I LL FLU S H AILERO N
RIB
K 1 000-3 W I T H M O DEL I N G
N UTPLATE CLAY PLAN VIEW

K 1000-3 N UT PLATE
B A B 3-2A
POP - R I VET
T RO UG H 4 ( PLC S )

..
I N B' D .
'. ;
OUTBOARD
AILE RON
.. RI B
:,
I•

V I EW B-B SID E V I EW

FIGURE (F-32)

The nutplates for the counterweight attach points are secured to the outboard
aileron rib with AB3-2A pop rivets, as shown in FIGURE (F-32) .

NOTE: Fill the holes flush with modeling clay to prevent them from being
filled with resin when laying up the (2) closeout layers of rib cloth .

�
STODDARD-HAMILTON
AIRCRAFT, INCORPORATED
AS REVISION DAT E VOLUM E PAG E
MO�tAsArn III xitt'k�� II F-35
E
& FLAP AssEMBLIEs 4/26/90
 •
STEP F-5

II
2�
1

FIGURE (F-33)

Cut (4) 1-1/4" x 41" pieces of cloth on the 45 ° bias . Also, cut ( 4) pieces of
cloth on the 45 ° bias to the dimensions shown in FIGURE (F-33) . This is
enough cloth for both ailerons .

STEP F-6

HERE RESIN/
M I L L- FI BER

SH I M HERE
IF REQU I RED

---<£P- S T RA I G HT WORKBENCH
- ------- -:;;- Q �

TYPI CAL CROSS - SEC T ION

O F AI LERON

FIGURE (F-34)

�
STODDARD-HAMILTON
AIRCRAFT, INCORPORATED
MODEL ASSEMBLY NAME REVISION DATE VOLUME PAGE
GLASAIR III AILERON & FLAP ASSEMBLIES G 4 / 26/90 II F-36
 Take care to fin d a strai ght an d flat surface on which to bon d the control
surfaces to ge ther.

Form a 1/4" deep trough in the outboar d foam rib, as shown in F IGURE (F-32)
View B-B. A Dre mel tool with a pointe d rotary file is probably the best tool
for this job .

Prep san d any expose d shiny surfaces to be lam inate d on the aileron shearwebs
as sho wn in F IGURE (F-34). Mix a 40 gram com bination resin an d mill-fiber
m ixture. Apply a 1/�' bea d of this m ixture to the upper aileron panel on the
trailin g e dge surface as shown in F IGURE (F-34). Position the aileron trim
tab between the trailin g e dges of the upper an d lower left aileron panels in
the location shown in F IGURE (F-25). Sprea d an a dditional amount of the
m ixture at the tab location on both si des of the tab. Also, fill the trough
in the outboar d aileron rib with this m ixture. Place the lower panel into
position on the upper panel, lay a strai ght 2" x 4" boar d alon g the len gth of
the aileron 's trailin g e d ge as shown, an d distribute wei ghts evenly the len gth
of the boa r d. Let cu re .

NOTE: Use the m inim um am ount of wei ght necessary to hol d the trailin g e dges
together. Too much wei ght can cause dimplin g.

NOTE: Some shim m ing will be require d between the workbench an d upper panel as
note d in F IGURE (F-34). This is because the upper panels are curve d instea d
of flat. The shearwebs on the lower panels may ten d to lift off the upper
panels when clam pe d in place. Wei ght if necessary. Be careful to not disturb
the tab while curin g.

Repeat Step F-6 for the other aileron.

·· 1 � ·;, x 4 1 " S T R IP S
STEP F-7

I N BOA R D E N D "L" SHA PED

P I ECES

FO RWA RD V I EW S I D E V I EW
F IGURE (F-35)

Lay up one strip of 1-1/4" x 41" cloth (cut in Step F-5) onto the seam, as
shown in F IGURE (F-35). Follo w this with an ''L" shape d piece , then a 1-1/4" x
41" strip, and finally one more ''L" shape d piece. (See the Si de Vie w in
FIGURE [F-35].) Trim any excess cloth durin g the green cure state.

STODDARD-HAMILTON
AIRCRAFT. INCORPORATED
REVISION DATE VOLUME PAGE
MODEL ASSEMBLY NAME
GLASA IR III A ILERON & FLAP ASSEMBL IES II F-37
 NOTE: Avoid getting resin onto the hinge halves by covering them with tape.
Apply weights to the ailerons to keep the shearwebs flush to upper panels , if
needed.

Let cure , then remove the panels from the workbench.

STEP F-8

F-< I B C
- ----- LOTH
----- -
__ _ _ _

AC T U AT O R
�,___------•...i-.-- - - - R E I N FO RCE ME N T
CLOTH

OU TLI NE

FIGURE (F-36)

Using the aileron rib cardboard templates as guides, cut (8) pieces of rib
cloth (2 per rib) on the 45 ° bias for the aileron inboard and outboard ribs,
as shown in FIGURE (F-36). Also cut ( 1 0) actuator reinforcement pieces on
the 45 ° bias (5 per aileron) for the inboard aileron actuator ribs , as shown
in FIGUR ES ( F- 36) & ( F-37 ).

STODDARD-HAMILTON
AIRCRAFT, INCORPORATED
REVISION DATE VOLUME PAGE
MODEL ASSEMBLY NAME

GLASAIR III AILERON & FLAP ASSEMBLIES II F-38

 STEP F-9

IN BOARD AIL E R O N

TRIM H E RE
2 LAYER R I B
L AM IN ATE

5 LAYE R
AC TUAT O R
REI N FORCEMENT
LAM I NAT E

SIDE VIEW OF FRO N T V I EW OF

I N B OARD E N D I N BOARD E N D
O F AI LE RON OF AI LERON

I N BOARD E N D
O F AILE RON

RIB

ACTUATOR
REINFORCEMENT
CLOTH

FIGURE (F-37 )

�
STODDARD-HAMILTON
AIRCRAFT, INCORPORATED
ASSEMBLY NAM E REVISION DATE VOLUME PAGE
MODEL
GLASAIR III AILERON & FLAP ASSEMBLIES G 4/26/90 II F-39
 Apply (2) layer laminates on the outboard and inboard ribs of each aileron
panel, as shown in FIGUR E (F-37), using the previously cut pieces. Now
laminate the (10) actuator reinforcement pieces (5 per aileron) on the
inboard rib only of each aileron , as shown in FIGUR E (F-37).

NOTE: Do not cut the cloth at any of the corners. The cloth pieces are small
enough to be able to be formed to the compound curves in the corners.

When the laminates reach the green cure state, use a sharp knife to trim any
excess cloth that protrudes beyond the ends of the aileron panels. Also, trim
the la minates even with the edges of the square holes for the counterweights.
Redrill the 3/ 16" diameter holes that are plugged with modeling clay in the
outboard ri bs .

NOTE: Be very careful to only drill far enough to open the holes. Do not
damage the nutplates. This is very important since major rework will be
required to replace a damaged nutplate. Wrap multiple layers of masking tape
tightly around the drill bit to form a depth stop when drilling these holes .

NOTE: For temporary installation of the counterweight ar ms, install the m with
several washers under the heads of the bolts so that the bolts do not extend
through the locking portions of the nutplates. Running the bolts through the
locking portions of the nutplates several times will destroy the locking
feature. Tag the ailerons as a reminder to remove the extra washers upon
final assembly.

COMPLETED [ ]

STODDARD-HAMILTON
AIRCRAFT. INCORPORATED
DATE VOLUME PAGE
REVISION
MODEL ASSEMBLY NAME

GLASAIR III AILERON & FLAP ASSEMBLIES II Ii' -40

 G. FLAP RIB CONSTRUCTION AND CLOSEOUT
STEP G-1

34 5 / 8 11

I
1--- - - ---- -

- - --- - - ---Iii--- -
- ---

I I
ct ct <t
RIB © R I B (e)
RI B @
L E F T LOWE R
F L A P PANEL

FIGURE (F-38)
Lay out and mark the rib centerlines onto the lower flap panels as shown in
FIGU RE (F -38) .

�
STODDARD-HAMILTON
AIRCRAFT, INCORPORATED
MODEL ASSEMBLY NAME REVISION DATE VOLUME PAGE

GLASAIR III AILERON & FLAP ASSEMBLIES II F-41

 STEP G-2
F LA P R I B C

F OAM T EM P L A T E

F LA P R I B A F LA P R I B B

F O A M T EM P LA T E
FOAM T EM P LA T E
FIGURE (F-39)
----------------.....;
STODDARD-HAMILTON
AIRCRAFT, INCORPORATED
MODEL ASSEM BLY NAME REVISION DATE VOLUME PAGE

GLASAIR III AILERON & FLAP ASSEMBLIES II F-42

 From 1/2" thick 4.5 l b. foam cut out (2) sets of flap ri bs as shown full size
in F IG URE ( F -3 9).

NOTE: Cut these foam ri bs slightly oversize to allow for final fit up .

STEP G-3

Fit the foam ribs to the flap panels in the locations shown in FIGURE (F-38).
This will require several sequences of putting the foam ribs in place,
installing the upper panels, checking for fit , and then removing the upper
panels to sand the ri bs.

NOTE: Ri b B is the hardest to fit. Use a flashlight to check for fit,

leaving the end ri bs out to be a ble to see inside the flap.

STEP G-4
1"
�

,<

TY PI CAL R I B C LO T H
D I M E N SI ONS

A C T UATO R
RE I N FORCE M E NT
C LOTH

F IGURE (F-40)

�
STODDARD-HAMILTON
AIRCRAFT, INCORPORATED
MODEL ASSEMBLY NAME REVISION DATE VOLUME PAGE

GLASA IR II A ILERON & FLAP ASSEMBLIES D 3/7 /88 II F -43

 Using the foa m ribs as guides , cut (8) pieces of rib cloth on the 45 bias for
°

each flap. Four of these pieces are required for the ''B" rib and t wo each for
the "A" and 't" ribs . Cut the rib cloth pieces to the dimensions shown °
in
FIGURE (F-40). Cut (4) actuator reinforcements (2 per flap) on the 45 bias
for rib A as shown in FIGURE (F-40) .

STEP G-5

FLAP R I B
T Y P I CA L )
� " D I A. Q- CELL
D OWE L M I XT U R E

( AFT VI EW)

FIGURE (F-41)

Mix up a s mall , wet batch of resin/Q-cell mixture and apply a thin coating to
both sides of each of the foam flap ribs. Let cure. Mix a thick 30 gram Q­
cell m ixture for bonding the flap ribs in place. Apply a bead of this mixture
to the bottom and forward edge of each rib and press the ribs into their
appropriate places as shown in FIGURE (F-38) . Use a 1/4" diameter do wel to
radius the excess Q-cell mixture as it oozes out from belo w , as sho wn in
FIGURE (F-41) . Remove any excess mixture so that only 1/8" radius fillet of
Q-cell mixture remains in the corners. Let cure.

�
STODDARD-HAMILTON
AIRCRAFT. INCORPORATED
MODEL ASS�r,i.s.L:)'..,t,J.%:)� REVISION DATF. .• VOLUME PAGE
GLASAIR III AlL�KUN & FLAP ASSEMBLIES F 1/15/89 , II F-44
 STEP G-6

2 L AY E R R I B L AMINATE

--- - - -
RIB© RIB@
R I B@

LEFT LOWER 2 LAY E R

FLAP PA N E L ACTUATOR
RE I N FO RCEME NT
T R I M H E RE L AM I NAT E
F LU SH TO
FOAM

S ECTION A- A

FIGURE (F-42)

Lay up (2) layers of rib cloth on the inside surfaces of ribs A and C, as
shown in FIGURE (F-42). Lay up (2) layers of rib cloth on each side of rib B
as shown. Use standard la minating procedures. Lay up (2) layers of the
actuator reinforcement cloth onto the inside of each A rib as shown. Tri m and
le t cure .

NOTE: Let excess cloth extend above the foam ribs so that the cloth can be
trimmed flush w hen in the green cure state. (See Section A-A, FIGURE [ F-42].)

�
STODDARD-HAMILTON
AIRCRAFT, INCORPORATED

SS REVISION DAT� VOLUME PAGE

MOD{;LASAI R III A A�E�� & FLAP ASSEMBLIES 1/1 5/89 ; II F-45
 STEP G-7

S I DE V I EW P L A N V I EW

K1 000-3
N UT P L ATES

A,.

..
T
( LE FT FLAP S H OW N ) I N B OA R D

E N D V I EW
FIGURE (F-43)

STODDARD-HAMILTON
AIRCRAFT, INCORPORATED
MODEL ASSEMBLY NAME REVISION DATE VOLUME PAGE

GLASAIR III AILERON & FLAP ASSEMBLIES II F-46

 NOTE: The flap actuator fitting is mounted on top of the inboard flap hing e
as sho wn in FIGURE (F-43). This condition cr eat es a gap betw een th e actuator
fitting and the flap sh earweb . (See Flag #1, FIGURE [ F-43].) Aft er the upper
flap panels hav e b een bonded in plac e and just befor e mounting the actuator
fittings to the flaps for the last tim e, fill th ese gaps with about a (4)
layer thick laminate so that th e fittings mount to a solid flat surfac e.

Clamp the (2) flap actuator fittings to the flaps centered at rib A. Position
th e holes for th e rod end b earings 2" from th e hinge c enterlin es, as shown in
FIGURE (F-43). Using the fittings as drill guides, drill the (2) outboard
3/16" mounting holes through th e flap sh earwebs .

Install (2) Kl000-3 nutplates, as shown in FIGURE (F-43). Count ersink th e

forward side of th e sh earweb for the AN426AD3-4 riv ets befor e riv eting th e
nutplat es .

STEP G-8

Install th e flap actuator fittings with th e AN3-5A bolts, and AN960-D10

wash ers, as shown in the Plan View of FIGURE (F-43).

STEP G-9

Using th e sp ecially made foam rout er tool (bent nail) bev el th e foam ribs on th e
flaps as shown in FIGURE (F-44). A knif e and sandpap er also work w ell for
this .

NOTE: Make sur e to remove all th e foam fro m th e insid e surfac es of th e

laminat es as shown in FIGURE (F-44) , Flag #1.

STODDARD-HAMILTON
AIRCRAFT. INCORPORATED
REVISION DATE VOLUME PAGE
MODEL ASSEMBLY NAME

GLASAIR III AILERON & FLAP ASSEMBLIES II F-4 7

 A
•• J A

�-lJ.--
FOAM
PLAN V I EW _..l1 RO U T E R
TO O L

3 / 1 6" DIA .
VE N T H O L E

SECT I O N C- C S ECTI O N B -B SECTION A- A

FIGURE (F-44)
STEP G-10

FIGURE (F-45)
-------------------1

STODDARD-HAMILTON
AIRCRAFT. INCORPORATED
MODEL ASSEMBLY NAME REVISION DATE VOLUME PAGE

GLASAIR III AILERON & FLAP ASSEMBLIES II F-48

 Cut (4) pi eceE. of "L" shapE d cloth on th e 45 c bias to th e dim en sions sh own in
FIGURE (F-45) to form the flap actuator fittir: g mc untiq; r,a ds. Cut (4) 1-
1/4" x 71" strips of cloth on th e 45 ° bias to form th e clos eout laminates for
the forward flap pan el seam.

Drill 3/1 8' diam eter v ent holes through th e flap B ribs (shown in section B-B
of FIGURE [F-44]) to v ent the outboard bays of the flaps prev enting structural
damage du e to pr essur e chang es with altitud e. Wh en th e flap panel is
compl eted, drill anoth er 3/1 8' hole through the low points of the inboard flap
ribs (A ribs) to both v ent th e flap pan els and provide drains for moistur e
that might oth erwis e be trapp ed insid e.

STEP G-11

Th e flap upp er pan els ar e bonded in plac e in a mann er si milar to th e ail eron
pan els. Lik e the outboard ail eron ribs, all of the foam rib troughs in th e
flaps ar e filled with mill fiber mixtur e just prior to bondin �

NOTE: Mak e sure to prep sand any la minating or bonding surfac es , if requir ed,
b efor e bonding. Do only one flap at a tim e.

M I LL FI BER
MIXTURE

TYP I CA L R I B

FIGURE (F-46)

M ix up a w et 25 gram mill fib er mixtur e and "overfill" th e rib troughs

slightly as shown in FIGURE (F-46). Mix a 30 gram combination resin/mill ­
fib er mixtur e and apply a bead along th e inside trailing edge of th e low er
pan el.

NOTE: These mixtur e quantities ar e only enough for bonding on e flap tog eth er.

Plac e the upp er pan el onto the low er one and th en turn the (2) pan els ov er and
clamp togeth er in th e sam e manner as th e ail erons (see FIGURE [F-34]). Shim
and w eight as r equir ed.

Remov e th e flap actuator fitting and fill the bolt holes with modeling clay.
Lay up the "L" shap ed and 1-1/4" x 71" strips of cloth in th e sam e mann er as
was done on th e ail eron. (See FIGURE [F-35].)
________________.,
.,.;._,

�
STODDARD-HAMILTON
AIRCRAFT. INCORPORATED
REVISION DATE VOLUME PAGE
MODEL ASSEMBLY NAME
GLASAIR III AILERON & FLAP ASSEMBLIES II F-4 9
 r-
•
F LAP u �• &1 1 c RI B
G...CEEOJf l....Nv'1J NAlES

"
1

RIB
.----, O U T L I NE

R I B C LOT H D I M EN S I O N S

3- 1 / 4 11

5 / 8"�
ACT UATOR
R E I N FO R C EM EN T
C LO T H I N B OA R D
SI DE

RIB A

, ..
V I EW B

FIGURE (F-47 )

Cut (8) pieces of bidirectional cloth (two per rib) on a 45° bias to the
dimensions shown in FIGURE (F-47), vie w A , to close out the A and C ribs on
both f la ps .

I n addition , cut (4) pieces o f bidirectional cloth (two per rib) on a 45 ° bias
to the dimensions shown in FIGURE (F-47) view B for the actuator r einforcement
laminates on both "A" ribs .

STODDARD-HAMILTON
AIRCRAFT, INCORPORATED
MODEL ASSEMBLY NAME REVISION DATE VOLUME PAGE

GLASAIR III AILERON & FLAP ASSEMBLIES II F-50

 Lay up the (8) p ie ce s of r ib cloth (2 pe r ri b) t o cl ose ou t ri bs A and C. La y
up the (2) actuat or reinf orcement cloth pieces on the inb oard side of rib A in
a similar manner as the five reinf orcement pieces on each ailer on actuator
rib. Refer t o Step F-9. Trim any excess cl oth while in the green cure state
and let cure. Repeat the ab ove pr ocedure f or the other flap.

COMPLETED [ ]

�
STODDARD-HAMILTON
AIRCRAFT, INCORPORATED
MODEL ASSEMBLY NAME REVISION DATE VOLUME PAGE

GLASAIR IIJ AILERON & FLAP ASSEMBLIES II F-51

 H. FLAP ACTUATOR INSTALLATION

STEP H-1

FL A P S H EARW EB
<t
RI B@

PLAN V I EW

FIGURE (F-48 )

Trim the upper panel of each flap in the curved portion as shown in FIGURE ( F-
48) for the flap actuator fitting. The extra cutout on the inboard side is
for removing the bolt. Sand any saw cut roughne ss sm ooth.

STODDARD-HAMILTON
AIRCRAFT, INCORPORATED
MODEL ASSEMBLY NAME REVI S ION DATE VOLUME PAGE

GLASAIR III AILERON & FLAP ASSEMBLIES II F-52

 STEP H-2

Redrill the 3/16" diameter holes for the actuator fitting that were filled
with modeling clay.

NOTE : Drill only far enough to open up the holes. Be very careful not to
damage the threads of the nutplates.

Temporarily install the actuator fittings to the flaps with the AN3-5A bolts.
Use the two inboard holes in the flap actuator fitt ing to drill the two
inboard m ount ing holes through the flap shearweb . Rem ove the actuator
fitting. Install (2) K l000-3 nutplates on the shearweb (sim ilar to the
nutplates installed in Step G-7 and FIGURE (F-43)). Countersink the rivet
ho les for the nutplate, and install them on the shearweb using AN426AD3-4
ri vets. If necessary, apply additiona l lam inates in the actuator fitting area
to provide a f lat m ounting surface for the f itting, as shown in FIGURE (F-43).
Re install the actuator fitting with the suppl ied AN3-5A bo lts and AN960-Dl0
washers.

NOTE : The inboard ends of the flaps will be capped in a later step after the
wing to fuselage asse mbly. The inboard end caps will be formed to m atch the
fuselage contour and the lower surfaces at the inboard ends of the flaps wi ll
be contoured to m atch the shape of the wing r oot fa irings.

COMPLETED [ ]

STODDARD-HAMILTON
AIRCRAFT, INCORPORATED
A SSEMBLY NAME REVI SION DATE VOLUME PAGE
MODEL

GLASAIR III AILERON & FLAP ASSEMBLIES II F-53

 I. FLAP LINKAGE INSTALLATION

STEP 1-1

F LAP HAN DLE

AN3- 11A BOLT

A N 364- 1 03 2 A NUT
AN960- D1 0
A N 960- D l OL
(TYP. ) 0
(::)

AN3 93 - 1 1 C L EVIS PIN

AN960 - D10L WASHER
AN3 8 0 - 2 -2 COT T E R PIN

C ROS S - SECT ION TH RU WI N G

FIGURE (F-49)

Install the flaps to the wing with the MS20253-P2 hinge pin as shown in FIGURE
(F-49) . In this section the flap actuator linkages are installed and
adjusted . Cut holes in the rear spar shearweb to allow the linkages to pass
through . (See Flag #1 , FIGURE [F-49] . ) Cut the holes 3/4" wide and slightly
oblong to allow free movement of the flap actuator linkages .

CAUTION: Do not damage the rear spar caps when cutting the flap linkage holes
through the rear spar shearweb .

Access to the flap actuator arms , for attachment of the forward end of the
linkages , is gained through the main gear wheelwells .

�
STODDARD-HAMILTON
AIRCRAFT. INCORPORATED
MODEL ASSEMBLY NAME REVISION DATE VOLUME PAGE
GLASAIR III AILERON & FLAP ASSEMBLIES G 4/26/90 II F-54
 STEP 1-2 ASSEMBLING AND RIGGING THE FLAP LINKAGE

....-----t A N 3 1 6 - 4 R
NUT AN486-4 P C LE V I S
( TYP. 2 P LAC E$)

I
0

1 70-341 6-001
ROD END I N S PECTI ON HOLE
BEARING

FIGURE (F-50)
· Thread the AN316-4R nuts, the 170-3416-001 rod end bearings, and the AN486-4P clevises onto I
the flap actuator linkages, as shown in FIGURE (F-50).
Install the flap actuator linkages between the flap actuator arms and the flap actuator fittings.
Fasten the clevis ends of the linkages to the flap actuator arms with the AN393-11 clevis pins,
the AN960-D10L washers, and the AN380-2-2 cotter pins. Place the washers under the cotter
pins. Fasten the rod end bearing ends of the linkages to the flap actuator fittings using AN3-
11A bolts, AN960-D10 washers (below the nut), and AN364-1032A nuts.
NOTE: It may be necessary to insert an AN960-D10L thin washer between the 170-3416-001 rod
end and the actuator fitting, if a gap exists.
Adjust the lengths of the flap actuator linkages until the conditions shown in FIGURE (F-49) are
met:
A. When the flaps are extended fully to 34°, the flap handle must be positioned in the
uppermost notch of the ratchet plate.
B. When the flaps are in the retracted (neutral) position, the handle must be in the lowest
notch of the ratchet plate.

�
STODDARD-HAMILTON
AIRCRAFT. INCORPORATED

GLASAIR III AILERON & FLAPASSEMBLIES 7/01/92 II F-55

MODEL ASSEMBLY NAME REVISION DATE VOLUME PAGE
 NOTE: In the n eutral position the flap trailing edge is ev en (faired) with
th e aileron and wing tip trailing edg e.

NOTE: Mak e sure the rod end b earings and cl evises ar e thr eaded onto th e
actuator linkages past th e insp ection holes sho wn in FIGURE (F-50). Ins ert a
pi ece of stiff wir e into the insp ection hol es to ch eck and be sure th e rod
ends ar e thr ead ed past th e hol es. If th e conditions called out abov e and in
FIGURE (F-49) for the position of the flaps and flap handle cannot b e m et with
both rod end b earings and th e cl evises thr eaded onto th e linkages past th eir
insp ection holes, contact us to arrange r eplac em ent of the linkages with
long er ones.

Adjust th e linkages so that both flaps travel equally up and down .

C OMPLETED [ ]

�
STODDARD-HAMILTON
AIRCRAFT, INCORPORATED
REVISION DATE VOLUME PAGE
MODEL ASSEMBLY NAME

GLASAIR III AILERON & FLAP ASSEMBLIES II F-56

 J. AI LERON INSTALLATION AND LINKAGE CONSTRUCTION

STEP J-1

1
3 // D I A .
6 D R I LL T H I S
H O LES HOLE LAT E R

A I LERON
A C T UA T O R
FITTING

5 , , RAD. (REF. )
r,6
{}> �6 1
DIA.

HOLE
�8 ,,

DR I LL T H I S
HOL E L AT E R
FIGURE (F-51)

Enlarge the lower pilot hole in the base of the aileron actuator fitting to
3/16" dia mete r as sho wn by Flagnote #2, FIGURE (F-51). Also drill the 3/16 11
diameter hole for the rod end bearing as shown by Flagnote #3, FIGURE (F-51).

NOTE : Do not drill the uppe r 3/16" diamete r mounting hole as refe renced by
Flag #1 in FIGURE (F-51). This hole will be drilled late r.

STEP J-2

In a simila r manne r as was done on the flaps, the aile rons need to be trimmed
for the actuator fittings. Trim the curved portion back on the inboard ends
of the aile rons as shown in FIGURE (F-52).

NOTE: Leave approximately 1/4" of the curved portion of the uppe r skin intact
as shown.

STODDARD-HAMILTON
AIRCRAFT. INCORPORATED

MODEL ASSEMBLY NAME REVISION DATE VOLUME PAGE

G LASAIR III AI LERON & FLAP ASSEMBLIES II F-57

 STEP J-3 AILERON ACTUATOR FITTING INSTALLATION

AN3 -1 1A BOLT
AN960 - 10 WASHER (3)
A N 364 -1032 A NUT

I NBOARD END OF A I LERON A N 960- 1 0

W A S H E R,
PLA N V IEW
( LE F T Al LERON SHOWN)

\ --11 .3
AN 3 -5 A BOLT
AN365-1032A NUT
AN960 � 1 0 L WASH ER ( UN D E R N U T ) � HINGE PI VOT POINT
S I DE VIEW

FIGURE (F-52)

Install the ai leron actuator fittings as shown in FIGURE (F-52) . Make sure
the fittings are f lush against the root end of the ailerons and that they are
posit ioned so the 1 .3 11 dimens ion is achieved . Use the supp lied AN3-SA bolts
and AN365-1032A nuts . Radius the fitting as needed for fit . (See F lag #2 ,
FIGURE [F-52 ] .)

NOTE : When dri lling the mounting holes for the fittings in the ai lerons ,
drill the lower ho les first . Dri ll through the ai leron shearweb , using the
actuator fittings as drill guides . Make sure the f ittings are he ld proper ly
so the 1 .3 11 dimension is maintained . Fasten the fittings to the ai lerons with
the AN3-5A bo lts , and AN365-1032A nuts . Now dri ll the upper mounting ho les
through the fittings and ailerons so that the nut is as close to the upper
aileron pane l as possible . (See F lag #1 , FIGURE [F-52 ] .) F inish securing the
a i leron fittings with the AN960-D10L washers under the nuts .

NOTE : Center punch ing the ho le locations before dri lling wi ll pre vent the
dri ll from s lipping and possibly damaging the part .

�
STODDARD-HAMILTON
AIRCRAFT. INCORPORATED
MODEL ASSEMBLY NAME REVISION DATE VOLUME PAGE
GLASAIR III AILERON & FLAP ASSEMBLIES G 4/26/90 II F-58
 STEP T-4 ASSEMBLING THE AILERON LINKAGE ROD
Thread the AN316-4R nuts and the 170-3416-001 rod end bearings onto the aileron linkage rods. I
Install the linkage rods between the aileron bellcranks and the aileron actuator fittings using the
AN3-10A bolts at the bellcrank end and the AN3-11A bolts at the aileron end, as shown in
FIGURES (F-52) and (C-42).

STEPT-5 INSTALLING THE AILERON LINKAGE ROD

Install the ailerons to the wing with the MS20253-P2 hinge pin. The aileron actuator linkages
are installed in the same way as the flap actuator linkages. Access to the aileron bellcranks is
through the outboard inspection holes. An oblong hole must be cut in the rear spar shearweb to
allow the linkage to pass through.
CAUTION: DO NOT cut into the rear spar caps.
Adjust the lengths of the aileron linkages such that:
A. The control sticks are in their neutral (perpendicular) positions.
B. The outboard aileron bellcranks are neutral (Step N-4, page C-66).
C. The ailerons are aligned with the wing tips.
NOTE: Check that all (4) rod end bearings are threaded onto the linkage rods past the
inspection holes as was done with the flap actuator linkages.
NOTE: When assembling the aileron linkage for the final time, install washers between the rod
end bearings and the insides of the aileron actuator fittings to eliminate play in the control
system.
Grind the aileron control travel !Stops (located on the left side of the pilot's control stick yoke
and the right side of the passenger's control stick yoke) so that the aileron control system will
allow the aileron to move to its 19° down position. (Measured using the aileron rigging jig
shown in FIGURE [F-52B].) I

STODDARD-HAMILTON
AIRCRAFT. INCORPORATED

GLASAIR ill AILERON & FLAP ASSEMBLIES 7/01/92 II F-59

MODEL ASSEMBLY NAME REVISION DATE VOLUME PAGE
 '·.

WING

A I LERON R I G G I N G J I G

FIGURE (F-52B)
NOTE: A simple jig can be made for rigging aileron travel. Cut a 4" x 11" piece of plywood, as
shown in FIGURE (F-52B). Cut a 22° bevel on one side of the plywood piece, as shown. Use the
beveled plywood piece to set the proper aileron down travel, as shown in FIGURE (F-52B). The 1
wing will need to be resting on saw horses to use this jig.
NOTE: The aileron travel is measured only on the lower side. If both left and right ailerons are
adjusted to yield 19° down, the internal geometry of the aileron bellcrank will yield
approximately a 21 ° up position.

�
STODDARD-HAMILTON
AIRCRAFT. INCORPORATED

GLASAIR ill AILERON & FLAP ASSEMBLIES 7/01/92 II F-59A

MODEL ASSEMBLY NAME REVISION DATE VOLUME PAGE
I
 INTENTIONALLY LEFT BLANK

�
STODDARD-HAMILTON
AIRCRAFT. INCORPORATED
MODEL ASSEMBLY NAME REVISION DATE VOLUME PAGE
GLASAIR II] AILERON & FLAP ASSEMBLIES D 3/7/88 II F-59B
 STEP J-6

T Y P I C A L C O N T R O L S U R F A C E ,J: N DF C A P I N ST A L LA T I O N
( O U T B OA R D A I L E R O N S H OW N )
C O U N T E RW E I G H T B O LT S EN D CAP
r - --- - - -
--- ---
---
5 / 81 1 D . H O L E S 1 / 8 11 H O L E
O U T B OA R D A I L E R O N O N LY

R ES I N /M I LL F I B E R C O N T R O L S U R FA C E
MI XTURE

1 / 4" 4 . 5 LB . F O A M
EN D CA P

'L
3 / ,1 6 " I I 3 - LA Y E R
LA M I N A T E

S EC T I ON A-A

FIGURE (F-53)

The fabrication procedures for the end caps, as described in a general manner
in this step , are the same for both the ailerons and the flaps.

NOTE: The end caps for the inboard ends of the flaps cannot be installed
until the wing is fitted to the fuselage and the flaps are trimmed to match
the sides of the fuselage.

NOTE: The end caps for the ailerons must be installed before the ailerons are
balanced .

To for m the end caps, cut 1/4" thick 4.5 lb. foam 1/4" larger than the opening
at the end of the control surface. Seal both sides of the end cap foam cores
with a thin Q-cell mixture. Let cure.

STODDARD-HAMILTON
AIRCRAFT. INCORPORATED
MODEL ASSEMBLY NAME REVISION DATE VOLUME PAGE

GLASAIR II AILERON & FLAP ASSEMBLIES II F-60

 Mark the end caps to indicate their intended positions.

Lay up a (3) layer 45 ° bidirectional cloth lam inate on the outside face of
each end cap, as sho wn in FIGURE (F-53).

NOTE: Body putty can be used to fill the weave of the end cap lam inates,
after they have cured, to achieve a sm ooth finish.

Press the foam side of each end cap blank against the end of the control
surface it is to cap, making an impression the size of the cap opening. Cut
the end caps to rough size by trim m ing them about 1/8" outside of the
im pression. Trim away the foa m outside of the wing tip impression so the foam
of the end cap blank can fit into the control surface opening. Fit the end
cap into place and trim the end cap laminates flush with the outside surfaces
of the aileron or flap. Remove the end cap and trim the foam back 3/16" from
the trimm ed edges of the lam inates all around, as shown in FIGURE (F-53).
Apply a resin/m ill-fiber mixture in the area around the foam core, as shown,
tape the cap to the wing tip, and let cure. Drill a 1/8" hole for water
drainage in the location shown in FIGURE (F-53).

The outboard end caps for the ailerons require (2) 5/�' diam eter holes
centered over the aileron counterweight bolts, as shown, to provide access for
installation and rem oval of the aileron counterweights.

NOTE: When the installation of the counterweight is complete, seal around the
heads of the counterweight bolts with silicone sealant to keep moisture and
debris from entering the aileron .

�
STODDARD-HAMILTON
AIRCRAFT, INCORPORATED
REVISION DATE VOLUME PAGE
MODEL ASSEMBLY NAME
GLASAIR III AILERON & FLAP ASSEMBLIES II F-61
 STEP J-7 SHAPING THE AILERON C OUNTERWEIGHT

WARNING: The ailer ons must be balanced t o prevent aerodynamic flutter.

Balancin g the ailer ons will be completed durin g final assembly, after the
aircraft has been painted. Paint adds a si gnificant am ount of wei ght t o the
c ontrol surfaces , so it is imp ossible to achieve the c orrect balance before
paintin g.

In this step , the shapes of the counterwei ghts will be finalized and the
c ounterwei ght h oles will be cut in the l ower win g panel .

First , use a file t o round all the sharp c orners of the lead c ounterwei ght t o
about a 1/8" radius. Then , sand the lead surfaces of the counterweight and
fill any irre gularities with b ody putty t o obtain a sm ooth final finish.

Temp orarily fasten the c ounter wei ght arm t o the nutplates built into the
ailer ons using AN3-11A bolts. Add a AN960-10 washer between the counterwei ght
arm and the ailer on rib t o av oid dama gin g the nutplate l ockin g feature.

A N 3-11A B O L T S
A N 9 6 0- 1 0 L
WASHERS

FIGURE (F-54)

With the c ounterwei ghts in place , turn the win g upside d own. Place the win g
on (2) padded sawh orses. Appr oximate where the c ounterwei ght cutouts in the
l ower win g panel will be and mark the appr oximate outlines of the cutouts onto
the l ower win g panel. (See Fla g #1 , FIGURE [ F-54].)

�
STODDARD-HAMILTON
AIRCRAFT. INCORPORATED
MODEL ASSEMBLY NAME REVISION DATE VOLUME PAGE

GLASAIR III AILERON & FLAP ASSEMBLIES D 3/7/88 II F-62

 To deter mine how far aft the cutout slot will e xtend, remove the
counterweights. Simulate the full downward travel of the counter weights by
rotating the ailerons to the full up position, as sho wn in FIGURE (F -54).
Place the counterweights alongside the ailerons, aligning the mounting holes
in the counterweight ar ms with the mounting holes in the ailerons. Determine
how far aft the slots need to e xtend and draw a line on the wing. Layout the
slots for the counter weight arms onto the lower surface of the wing. Cut out
the slots , using a hacksaw blade or small Dremel cutting bit.

NOTE: Since the shape of the counterweight cutout has only been appro ximated,
cut inside the marked lines first, and then slowly enlarge and smooth the
cutout by sanding to the proper size.

NOTE: It is permissible and will be necessary to cut into the lower rear spar
cap to form the counterweight clearance slot in the lower wing panel.

Reinstall the counterweight ar ms to check your progress while tri mming the
counterweight cutouts. Trim the rear spar shearweb to allow full downward
movement of the counter weight arms and enlarge the counterweight cutouts to
provide 1/16" clearance from the counterweight arm all around.

NOTE: The lower surface of the lead weight should be as flush as possible to
the lo wer skin surface when the aileron is in the neutral position. When the
aileron is in the full down position, the counterweight should be just shy or
very lightly touching the upper wing panel.

If the lower surface of the counter weight is not flush with the lo wer wing
panel in the neutral aileron position, build up the lower surface of the
counterweight with body putty to achieve a flush surface. Sand any additional
body putty to smooth contours in preparation for painting.

COMPLETED [ ]

�
STODDARD-HAMILTON
AIRCRAFT, INCORPORATED

MODEL ASSEMBLY NAME REVISION DATE VOLUME PAGE

GLASAIR III AILERON & FLAP ASSEMBLIES II F-63

 K. FLAP STOP INSTALLATION

STEP K-1

REAR SPAR SH EARWE B

( F I GURE
STOP
- - = ==

Ir-"
� -= - -=I/ J
t__.\
A� 11 -- 76 5 / 8
1-
11 ------
--,

W I NG

FIGURE (F-55)

To provide a p ositive st op f or the flaps when in the fully retracted p osition

and als o t o unload the pressure on the flap c ontr ol linkage in flight , (2)
flap st ops are used, one per flap. Lay out the flap st op l ocations on each
side of the wing as sh own in FIGURE (F-55 ). These st ops are located 7 6-5/8"
fr om the wing tip attach flange j oggle on each side at a p oint c oincident with
the center flap rib B. The flaps will need to be rem oved t o install the
flap s t ops.

Cut (6) piec es of cl oth 1- 1/ 2" x 1 -1/2" on t he 4 5° b ia s. L ay up (3) piec es of

cl oth centered over the B rib on each flap shearweb, creating a (3) layer pad
laminate f or the flap stop bolt , as sh own in FIGURE (F-56) Views A-A and C-C.
Make (2) tw o-layer precured laminates t o be used as supp orts f or the remaining
(4) layers of the (6) layer web laminates. (See View A-A in FIGURE [F-56] f or
the shape of the (6) layer web laminate.) Prep sand the shiny surfaces of the
(2) layer support laminates until dull in preparation for la mination. Use hot
glue or body putty to b ond the (2) layer supp ort laminates to the aft surface
of the rear spar shearweb 7 6-5/8" fr om each wing tip attach flange joggle, as
sh own in FIGURE (F-56) View B-B. Apply a Q-cell radius in all c orners t o be
laminated. F or the web laminates, cut (8) pieces of cl oth on the 45 ° bias
large enough to allow a l" overlap onto the rear spar shearweb and spar caps,
as sh own in FIGURE (F-56) Vie ws B-B and D-D. Lay up (2) pieces of cloth on
each side of the (2) layer supp ort laminates that are bonded t o the rear spar
shearweb. Trim any excess cl oth while in the green cure state and then let
final cure.

STODDARD-HAMILTON
AIRCRAFT. INCORPORATED
REVISION DATE VOLUME PAGE
MODEL ASSEMBLY NAME
GLASAIR III AILERON & FLAP ASSEMBLIES II F-64
 C u t (2) p i ec e s of (1 11 x 1 11 x .1 25") 2 024-T3 a lum inum ang l e l" l on g. F il e any
saw c ut roughn ess sm ooth and deburr. Drill (4) #30 holes in on e leg of eac h
of the a lum inum angles f or m o unting th em to th e (6) layer web la mina te. Dri ll
a 1 /4" d iam eter h ole in the oth er leg of each of the angles f or the NAS428 -4-
20 bolt. (S ee FIGURE [F-56 ].) Prep th e angles f or pa inting and spray on a
c oat of zinc chromate prim er or ep oxy prim er f or protec tion aga in st c orrosion.

CAUTION: Do not breath e th e over spray of zinc ch romate or ep oxy primer a s

th is i s ha zardous t o your health.

Insta l l th e AN315-4R nut on th e NAS428-4-20 stop bolt. L oca te and drill th e

n utp la te attach holes around the 1 /4" hole on the alum inum ang le a s shown in
FIGURE (F -56) VI EWS A-A, B-B, and D-D. C oun ter sink th e f orward sides of th e
riv et h oles and in stall the n utp la tes on the a lum inum angles w ith AN426AD3-5
rivets.

M oun t th e aluminum angles to th e web lam ina tes with th e ABL 4-4 rivets a s
shown in FIGURE (F-56).

R ein sta l l th e f lap s and ad just the stop s so tha t th e f lap s rest sn ugly again st
th e NAS428 -4 -20 bolts when th e f laps a re in the f ully retrac ted position.

NOTE: Make sure th e plunger lock ing m echani sm on th e f lap handle lock s in to
the n otch on the ra tch et p la te when the f laps a re in the f ull up position and
resting sn ugly again st th e stop s.

Tigh ten th e AN315-4R jam n uts again st th e alum inum angle (wh i le hold ing th e
NAS428-4-20 b olt w ith a wrench) to lock the stop s in their proper p osition.

The f lap stop s are n ow c omp lete.

WARNING: Be sure to prov ide v en ting f or all interna l airspac e s of th e f lap s

and ailerons to prev ent structural damage due to pressure changes w ith
a ltitud e. If holes were drilled th rough th e f lap B ribs b ef ore closure, a s
shown in FIGURE (F-44), a single hole through the af tmost part of each f lap 's
A rib w ill v ent both f lap bays. This w ill also help prev ent wa ter ( resulting
f rom c onden sa tion) f rom acc um ula ting in side the f lap s.

NOTE: To in sta ll th e aileron s, rem ove th e coun terw e igh t and attach th e
a ileron pushrod to th e a ileron actuator f itting only. Def lec t the a ileron
d own to prov id e acc ess to install and saf ety th e aileron hing e p in s. Onc e
s ec ured, b olt the a ileron c ounterweigh ts on to the aileron s, using only one
AN960-10L wa sher und er th e head of each AN3-11A bolt. C onnec t the aileron
p ushrod to the aileron bellc rank, using th e outboa rd in spec tion pan el f or
acc ess. F ina lly, in sta l l th e wing tip s.

In sta l l th e f lap h inge p in s and pushrod s in a similia r mann er.

COMPLETED [ ]

___,,-
STODDARD-HAMILTON
AIRCRAFT, INCORPORATED
MODEL ASSEMBLY NAME REVISION DATE VOLUME PAGE

GLASAIR III AILERON & FLAP ASSEMBLIES F 1/ 15/89 II F -66