Sender: <marv@lancaironline.net> (Marvin Kaye)
To: lml
Date: Tue, 26 Aug 2003 20:25:23 -0400
Message-ID: <redirect-2547946@logan.com>
From: RWolf99@aol.com
Subject: Attaching Mk2 Tail to Mk1 Lancair 360
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I sent the following to the 360 Tech Reps at Lancair for their comments.  I 
would appreciate the collected wisdom of "all y'all" for added comments.  And 
perhaps when all is said and done we can record the final result for posterity 
so that others don't have to ask the same question...

When I talked to Mark Mahnke and Orin a couple of years ago at Oshkosh, this 
is what I was able to remember about attaching the Mk2 tail to a Lancair 320 
fuselage with the Mk1 flanges.  Oh, and by the way, the 320 tailcone is twisted 
so that the flanges aren't level with each other (not just mine -- they're 
all this way).

1)  Cut off the old flanges.

2)  Level the fuselage (left-right, fore-aft)

3)  Set up the stabilizer on the fuselage sidewalls and the mid bulkhead so 
that the stabilizer pushes up against the (tilted aft) forward bulkhead and is 
plumb and square and level and all those good things, but with a -1/2 degree 
incidence (leading edge down).  Mark suggested building up a flox pad between 
the stab and the fuselage sidewalls so that there's no air gap.  (And have 
release tape on the stabilizer).

4)  Make a new flange with a 3-BID layup from the fuselage exterior onto the 
bottom of the stabilizer.  Extend the 3-BID at least 1-1/2 inches onto the 
fuse and the stabilizer.  Use flox to make a smooth fillet between the fuselage 
sidewalls and the bottom of the stabilizer.

5)  Pop the stabilizer off and smooth down the inner edges of the flox pad.

6)  Put 3-BID on top of the newly-created flange but run it down to the 
inside of the fuselage, over the flox pad and onto the inner fuselage sidewall.  
This traps the fuselage sidewall between a Y-shaped 6-BID flange.

(Note:  This is different from the manual, which suggests using the old 
flange and making a dry micro pad.  I don't think I'd get a decent fit that way.)

7)  Epoxy/flox the stabilizer to the new 6-BID flange.

8)  Complete the joint by running 3-BIDs from the inner fuselage sidewalls 
onto the bottom of the stabilizer.

9)  Do the 6-BID flange between the (tilted aft) forward bulkhead and the top 
of the stabilizer.

Well, that's it.  Comments, anyone?  I have a gullible friend coming down for 
a week in September to help me do this.  Sure would be nice to know what to 
do....

- Rob Wolf
Lancair 360 Mk2