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Assembling parts of the glider flight control linkages in tight places.

1st photo - if only every job were this simple! Room to get both hands in, visibility, room to turn wrenches, etc. That's more the exception than the rule.

2nd photo - looking into the landing gear box through a hole that's large enough for one arm/hand. At the far end, where the bulkhead walls and fuselage converge into a tight corner...and where there are plenty of parts already installed...I need to connect another push-pull tube. I can only get one hand in there, there is barely enough room to insert the bolt, I'm working only by feel, and I also need to start the nut and tighten it.

What to do?

3rd - bolt the rod end outside the landing gear box, insert through a hole, then spin the rod end into its threaded socket.

4th - there is only room for a half wrench to tighten the jamb nut.

Whew!

#AvGeek #Aviation #ElectricAircraft #ExperimentalAviation #Homebuilt #Glider #DIY #Collision #Bolt #Clearance

An example of an easy connection job in the glider. Lots of room, visibility, even more room to turn wrenches. But this is not a typical situation because gliders are very space limited.
A more typical situation - cramped, tight corner that is already populated with other installed parts. Only room for one hand to manipulate parts. This calls for a different approach.
As a workaround, bolt the rod end into place with the push-pull tube outside the landing gear box. Insert this assembly into the box through a hole, insert the threaded end into its threaded socket and rotate it a dozen times. But that golden jamb nut needs to be tightened so that the parts don't unscrew over time....
It's so crowded in the landing gear box that there is not enough room for a wrench to be turned. I cut this one in half, and I ground the jaws of the box end wrench thin because of other obstructions near the jamb nut. It took a couple hours to install one part and tighten one nut.
#DIY #Aviation #avgeek #bolt #Collision #glider #electricaircraft #clearance #experimentalaviation #homebuilt
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TomKrajci 🇺🇦 🏳️‍🌈 🏳️‍⚧️
mastodon - Link to source
TomKrajci 🇺🇦 🏳️‍🌈 🏳️‍⚧️
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@davepolaschek

Thanks!

There often is more than one way to skin the cat, and I'm learning a new way every week.

@Dave Polaschek (he/him)
in reply to Guanaco

TomKrajci 🇺🇦 🏳️‍🌈 🏳️‍⚧️
mastodon - Link to source
TomKrajci 🇺🇦 🏳️‍🌈 🏳️‍⚧️
• •

@Guanaco

Good question.

See first attached photo.

Nut circled in green is a nylon insert locknut...called a nylock. Extra friction of the nylon insert helps retain the nut over time.

The nut circled in purple is a jamb nut. It will be jammed/tightened against another part, creating force and friction to ensure the other part will not come loose over time.

2nd photo shows a castellated (castle) nut. 3rd photo shows a drilled bolt. Together, they will use a cotter/retaining pin, or safety wire.

4th photo shows a rod end. This part, plus a jamb nut, will be held tight over time...if I did a correct job of tightening the jamb nut.

I use nylocks in most cases, jamb nuts to hold rod ends, and castellated nuts/cotter pins on landing gear parts that can be subjected to significant, repeated shock loads.

Nut circled in green is a nylon insert locknut...called a nylock. Extra friction of the nylon insert helps retain the nut over time. The nut circled in purple is a jamb nut. It will be jammed/tightened against another part, creating force and friction to ensure the other part will not come loose over time.
https://www.aircraftspruce.com/catalog/pnpages/AN310-4.php
A bolt with a hole drilled in the threaded portion. This part will be combined with a castellated nut, then held in place with a cotter/retaining pin.
A rod end, male threaded. This part is screwed into a female threaded part, and a jamb nut is tightened against the female part to hold it tight over time.
@Guanaco
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