By ART BIANCONIEAA 92330

P. O. Box 607Plainfield, NJ 07061

The three drawings shown withthis article are for the purpose ofcreating a lightweight alumi-num/Fiberfrax sandwich that formseasily. The prototype was con-ceived so as to protect compositelanding gear and related compo-nents by deflecting heat from thebrake rotors. Initial tests suggestthat the sandwich is an equally ef-fective device for protecting criticalparts elsewhere in the aircraft. Vari-ations on this concept are beingtested for use in forming enginebaffles and heat shields for gasco-lators, fuel pumps and exhaustguards.

The advantages of this methodthus far are:

1. It protects both sides of thedelicate Fiberfrax from abrasion andgrease whereas the original idealeaves one side of the fiber exposed.

2. The finished cross section issignificantly stiffer. The Fiberfraxacts the same as a core material inany composite sandwich thus pre-venting bend buckling.

3. It has a lower natural fre-quency and is self dampening sothere is a significantly reduced ten-dency to vibrate and generatestress cracks, a common problemwith 2024 Alcad, particularly in ap-plications that have large un-supported sections such as heatbaffles around engine cylinders.

4. It's much less expensive thanany aircraft grade aluminum.

Aluminum flashing typically comes

SHIELDCO.DWG

88 MAY 1993

MAIN GEAR BOW

CONTOUR ONC SIDE OF PHENOLICBLOCKS TO MATCH CONTOUR OFFIBERGLASS GEAR BOW. THEN

FLOX TO GEAR AS SHOWN.AFTER CURING. SAND FRONT OFBOTH BLOCKS LEVEL DRILL *TAP BLOCKS BEFORE FLOXINC

TO LEG. THE HEAT SHIELD "HANGS"FROM THE PHENOLIC BLOCKS

CLEVELAND BRAKE ROTOR AND CALIPERARE NOT SHOWN FOR CLARITY

O

rolled in coils. Unroll the flashing andcut off enough material to support theproject. Next, loosely roll the flashingin the opposite direction so as to re-move the curve "set" from coiling.Try not to wrinkle the material in theprocess. Once you've succeeded ingetting the material to lay flat on thebench, prepare the cutting guidedrawing as follows.

Enlarge to full scale and makefour photocopies of the drawing,"SHIELDCO.DWG." Using a can ofspray adhesive, lightly dust theback of each photocopy and posi-tion it on a clean section of flashing.If you do not have enough flashingmaterial to use the template "as is,"trim away most of the hatched lines.This will allow better optimization ofthe flashing material.

Cutting the Material - Both flash-ing and Fiberfrax can be cut easilywith household scissors. Largesections can be cut on cuttingboards. Another method for cuttingflashing is to score the cut line witha carpet or Plexiglas™ scoring knifeand then bend the aluminum onceor twice. A set of sharp dividerscan be used for scoring circles and

arcs. The aluminum will crackcleanly at the score line. For cut-ting larger straight sections with thescore method, grip the material be-tween two straight edges (2 rulers).The larger surface area provided bythe ruler ensures a distortion freebreak and prevents unsightlybends. Both the aluminum andFiberfrax should be cut "full" anddressed to the proper dimensionsafter riveting and bending has beencompleted.

Treat this stuff with some re-spect: it can produce razor sharpedges when cut. It's not a bad ideato wear protective gloves and dressthe edges with emery. Lastly, I sug-gest you consider substituting athin disk of aluminum for the Fiber-frax at any place where a threadedfastener is likely to concentratestress. Flashing aluminum is softand the stiffer core at the hole willreduce the likelihood of damagingstress risers that could tear the alu-minum.

Drilling and Riveting - Using thehole guides on the paper template,lightly punch mark two of the fouraluminum panels. All rivet holes will

be drilled out with a 1/8" bit. Placeone of these pre-punched aluminumshields on top of a piece of Fiber-frax and another aluminum shieldon the bottom. Make sure that thesandwich lays reasonably flat. Alignthe pieces and carefully drill onerivet hole through all three. Main-taining part alignment, position andcrimp one rivet. Insert rivets fromthe rotor side of the sandwich. Thisprovides more clearance during in-stallation and minimizes thepossibility of the rivet heads rub-bing against the brake surface.Some pop rivets do not retain themandrels after forming. Anotherreason for encouraging this methodis that it places the rivet mandrel onthe far side of the heat shield, awayfrom moving parts. Continue to drilland pop rivet around the rotor sec-tion of the shield making sure thatthe sheets are flat before drillingeach hole. Make certain that youare not deforming the part as youdrill. Once the pop rivet is installedand crimped, it's almost impossibleto correct the deformity. Note: theuppermost rivet is the last one to beinstalled and only after the edges

SPORT AVIATION 89

DRILL AND PLACE THIS RIVET AFTERCRIMPING EDGES TO OBTAIN CURVATURE

——— 4.SEE FOO'PINOT

FOOTNOTE "A":ANY DIMENSION MTU A FOOTNOTE "A" VARIES AS A FUNCTION Of THE SPECIFIC A/C WHERE WIS SHIELD MIGHT BE USED-FABRICATORS SHOULD BE MINDFUL OF THE NEED TO ADJUST THESE DIMENSIONS TO SUIT EACH INSTALLATION. FOR ADDITIONALINFORMATION ON THIS, SEE DOCUMENTATION SHEET "HEATSHLD.DOC"

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have been crimped. Otherwisebuckling of the sandwich will occur.

Forming and Bending - Becauseit's so soft, flashing can be formedeasily without need of a bendingbrake. The same method used forsnapping off straight, scored sec-tions can be used to bend. Except,of course, you don't score it. Evenafter the sandwich has been riv-eted, it is not difficult to clamp thesandwich in a vise first, then grabthe sandwich with two thin piecesof wood and bend as needed. Noneed for C-clamps. When formingthe flanges on each side of thecurved upper section, remember tobend one set of flanges away fromyou on one sandwich and towardsyou on the other part. Otherwiseyou'll wind up with two shields forone side of the plane and none forthe other!

Crimping - Curved sections canbe formed by crimping the bentflange with a pair of fluting pliers.The idea here is to induce sufficientcurvature in the upper portion ofthe shield to conform to the bendradius of the gear leg being pro-tected. Space the flutes evenly onboth flanges. Make the first pass alight one. Make a second deeperpass with the fluting pliers to in-

90 MAY 1993

crease curvature. When you haveobtained the desired bend radius,drill the final rivet hole at the top ofthe shield and install the last poprivet.

Finishing - Most of the edgescan be easily sanded to their finalcontours with a disk sander. Theinside is best finished with a drumsander. A half round file will alsowork. Be careful to support thesandwich.

Fitting - There are four .050 drillholes at the "mouth" of the shield.These holes permit safety wire tobe used to secure the shield to thebleed screw (on the bottom of thecaliper) and the brake line fitting (onthe top). Position the shield andmark the locations of these holesso that the safety wire lines up withthe two fittings. The top of the pro-totype shield was successfullysecured to the gear bow by floxinga small piece of phenolic to thegear. The phenolic was predrilledand tapped for a pair of 6 x 32round head screws dipped in Lock-tite. Make certain there is nointerference between the shield andthe caliper and that the calipers fullrange of travel can be obtained.

About Footnote "A" - The geom-etry for parts on homebuilt aircraftmay be the same from one aircraftto the next but dimensions rarelyare. Footnoted dimensions reflectwhat we used on the prototype andshould be altered as necessary tosuit each application.

Bill of MaterialsPop-Rivets - Aluminum rivet/alu-

minum mandrel, 1/8" diameter, 1/8"grip range. Quantity: 20 pieces.

Fiberfrax - Enough for 2 pieces:7-1/2" wide x 12" long (see Foot-note "A"). Total: 12" x 15". Note:Fiberfrax comes in different thick-nesses. The prototype used .060"and was effective. It is availablefrom Aircraft Spruce & SpecialtyCo. and Wicks Aircraft Supply.

Flashing - Soft aluminum, 0.010"thick. Hardware store soft alu-minum as used for roofing leakstoppage. Enough for 4 pieces: 7-1/2" wide x 12" long (see Footnote"A"). Total: 12" x 30".

Phenolic - Enough to form two1/2" cubes per side. Total of fourcubes per installation.

Fasteners - 6 x 32 round headscrews and flat washers to match.Total of four per installation.

Safety Wire - 1 2" is more thanadequate, gauge is not critical. *

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