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Date:  9-2-2006
Number of Hours:  6.00
Manual Reference:  
Brief Description:  Elevator Balance Weight

Balance weight needs to be placed on both elevator horns; according to Mark Goldberg, they should be balanced to 90% - 110% of neutral. I decided against using epoxy and shot because I wanted to use the minimal amount of weight; the most effective weight is that at the very front of the elevator. Using a less dense shot-epoxy mix requires distributing the mix over a broader area, requiring overall more weight, as the most aft weight is not as effective at balancing the elevator. I trialed the amount of weight needed to balance neutrally as slightly over 4 lbs on each elevator; I used Russ Erb's estimate of the weight of fabric and paint as 1 lb located 7.5 inches aft of the hinge centerline. My 7/8 inch wrench turned out to weigh exactly one lb. One way to mount the weight is to make a mold, and pour molten lead into it, then mount the weight using screws. Avipro provides a tab on the tubing to assist in this process. I decided to use the elevator as the mold, and fabricated a .032 4130N channel rib to help sandwich the lead, and removed the tab. I also welded a wood screw on the tubing to assist in stabilizing the lead on all 3 edges. I obtained 20 lbs of used tire balance weights from a local metal recycling plant for $10, and melted the lead on my trusty backpacking stove. Scrap aluminum was used to seal one side of the elevator. On the first elevator, I used high-temp RTV to help seal the aluminum to the elevator, but it's not necessary, and I didn't use it on the second. To make sure the lead flowed into every nook and cranny, I used my welding torch to flow the lead as needed. After trimming with a Vixen file, I checked the balance, which turns out to be slightly heavier than needed, which is just what I wanted. I plan on putting a small cellulose acetate window on the lead under the fabric, for access to the lead in case I can remove some when the final paint is done. I can cover that with a small access panel, if needed.
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Retaining rib and screw

Retaining rib and screw

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Ready to pour

Ready to pour

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Balanced slightly nose heavy

Balanced slightly nose heavy

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