Page 1 QUICKIE AIRCRAFT CORPORATION has no control and assumes no control over the Buyer's ability to successfully construct and test the QUICKIE Q2 AIRCRAFT. Buyer expressly waives any and all claims arising from structural integrity, performance, flight characteristics, mechanical failures, and safety against QUICKIE AIRCRAFT CORPORATION.
Page 2: Table Of Contents
Q2 Plans – Appendix Page i TABLE OF CONTENTS CHAPTER TITLE NO. OF PAGES NO. OF SHEETS SECTION I DESCRIPTION AND INTRODUCTION BILL OF MATERIALS COMPOSITE MATERIALS EDUCATION INDIVIDUAL PART CONSTRUCTION HOT-WIRING AILERONS, RUDDER, AND ELEVATORS CONSTRUCTION VERTICAL FIN CONSTRUCTION...
Page 3 1981 techniques, and a poster. Quickie & 'Q2 Provides an education in the techniques 8 April, Composite Materials required in the building of a Q2. 1981 Introductory Includes a booklet, and sufficient Package materials for several suggested projects. Somewhat redundant with Chapter 3 of the Q2 Construction Plans.
Page 4 Q2 Plans Change Notices (Q2PC9 & Q2PC10) are mandatory revisions to the Q2 plans. Each Q2PC has a number and a publication date along with a description of the change. All Q2PC notices should be incorporated into the builder's set of Q2 Construction Plans immediately upon receipt by the builder.
Page 5 16-2 does not indicate the required spacer. The material is 4130 steel, or mild steel of 1/2" 0.0. x 3/8" 1.0. The sketch indicates the location of this QEM5 spacer (4 required). Q2 Plans - Appendix Page iii NUMBER DATE DESCRIPTION...
Page 6 Revmasters and possible A-65 thru C-85 installations, we have further explored the very high speed area of the Q2 operating envelope. We have found that mass balancing the elevators improves the ride qualities at high speed. Therefore, we are supplying to all builders...
Page 7 ..Once the amount of lead weight on each elevator has been adjusted, bolt the entire pitch control system together and check for friction, excess play, and interferences. Q2 Plans - Appendix Page iv NUMBER DATE DESCRIPTION...
Page 8 Q2BT12 21 August, 1981 IMPROVED BRAKING EFFECTIVNESS. We have determined that a single pull brake handle modulating both main gear brakes simultaneously is superior in nearly all situations to the standard toe brakes. Materials and drawings are available for retrofit for all builders returning their unused Q2BSW1's &...
Page 9 ..BS4 is mounted in position with flox and 2 BID tapes to the top of the fuel tank near the left side console. Position the BS4 so that the handle will be an easy and comfortable reach for the pilot and so it will not interfere unnecessarily with pilot comfort.
Page 10 Q2 Plans - Appendix Page v Q2 Plans - Chapter 1 - Page 1-1...
Page 11: Description And Introduction
..The origin of the Q2 dates back to 1977. Although the Q2 has much in common with the QUICKIE, considerable progress has been made since that earlier effort. As a result, the Q2 has lower drag than any other two place aircraft available to the public.
Page 12 Corporation is not the manufacturer of your aircraft, we do, through these plans and services, provide you with information about how our Q2 was built and what we feel is the best way for you to build a safe, reliable airplane. We do encourage you. to build the airplane...
Page 13 Identified the difficult to build items, and included them (prefabricated and ready to install) with the basic Q2 Kit. 7. Set up our newsletter, "The Quickie Newsletter" as a continuing plans updating/correcting system.** *..Over 80% of homebuilt airplane construction projects started, are never finished and flown.
Page 14 Building Sequence ..The nature of the Q2 structure requires that a part be left alone to cure for a longer period of time than that required to build it. Thus, you will find that when following the step-by-step order, you will often find yourself out of work, waiting for a cure.
Page 15 Quickie builders can benefit. If it is not a good idea, we'll tell you why, if you include a self-addressed stamped envelope..Do keep us up to date on the progress of your project. Send us a black and white snap shot of your airplane for publication in "The Quickie Newsletter".
Page 16 (FAA form #AC8050-1), a notarized affidavit that you built the airplane from parts that you bought yourself, and include $5 registration fee, along with copies of your sales agreement and invoice signed by Quickie Aircraft Corporation. Send those things FAA Registry Box 25082...
Page 17 Q2 Plans - Chapter 1 - Page 1-3...
Page 19: Bill Of Materials
PAGE 1-3 Q2 Plans - Chapter 2 - Page 2-1 BILL OF MATERIALS TOOLS ..There are certain tools which are necessary to complete the aircraft. Three lists of tools are provided here. The first is the absolute bare minimum required, sacrificing efficiency; the second is a recommended list for the best compromise of cost and work efficiency;...
Page 20 #30, #32, #10, 1/4" and #12 bits • Taps; 1/4-28, 10-32, 1/8 NPT (Pipe Tap) • Roll of grey duct tape • Saber saw • Cheap hole saw set or flycutter • Pop rivet puller • Homemade balance for rationing epoxy •...
Page 21 If you insist on making non-approved substitutions for replacement and spoilage, we insist that you do not call your aircraft a Q2. Quickie Aircraft Corporation will not provide assistance in the application of substitute materials or components.
Page 22: Composite Materials Education
Q2 Plans - Chapter 3 - Page 3-01 COMPOSITE MATERIALS EDUCATION ..DON'T SKIP THIS SECTION. Every hour you spend in this preparation section will save you five when you really start building your aircraft. INTRODUCTION ..In this section you won't build any part of your airplane. What you will do is learn how to build your airplane the right way.
Page 23 Much elbow grease is saved if you replace the sandpaper often. Long Straightedge ..This is not absolutely required, but is quite handy when jigging or checking the straightness of flying surfaces. It is merely a 6-ft or 8-ft lx3 or lx4 piece of lumber that is hand-selected to be "eyeball straight".
Page 24 Pivots - metal tube bushings in wood. Loose fit on nails. The 1/8" dia. brass tube available at hobby shops is excellent for the bushings. MUST BE FRICTION FREE. These ratios result in a 43-part hardener to 100-part resin mix. RATIO BALANCE FOR RESIN/HARDENER 1.
Page 25 CONTINUED ON NEXT PAGE PAGE 3-1 Q2 Plans - Chapter 3 - Page 3-02...
Page 26 ..The variable voltage control can be obtained from Aircraft Spruce and Specialty or Wicks Aircraft Supply, or you can substitute any controllable power supply to include the 14 to 20 volt range with at least 4 amp capability. An alternative is to borrow two 12-V battery chargers or auto batteries and lash up the following device.
Page 27 ..The materials, processes, and terminology used in the construction of your Q2 are recent to homebuilding. This section is devoted to familiarizing you with the language, materials, and techniques used in these plans. This information is basic to the construction of your airplane.
Page 28 Even fewer are suitable for the hand layup techniques used in the Q2. The glass cloth used in the Q2 has been specifically selected for the optimum combination of workability, strength, and weight..The glass cloth in your Q2 carries primary loads, and its correct application is of vital importance.
Page 29 CONTINUED ON NEXT PAGE...
Page 30 ..Marking and cutting the plies of glass cloth is a job that you will repeat often in the construction of your Q2. Glass cloth should be marked, cut, and stored in a clean area with clean hands and clean tools.
Page 31 "aluminum" is a general term for a whole family of specialized metal alloys. Just as the "aluminum" pots and pans in your kitchen, the "epoxy" in your Q2 is vastly different from the hardware store variety.
Page 32 The epoxies are not similar to the common types normally marketed for fiberglass laminating. Two different systems are used in the Q2: a normal curing system, and a 5-minute system. The very fast curing (5-min.) system is used much like clecos are used in sheet metal construction (or clamps in woodwork);...
Page 33 ..The working and strength characteristics of an epoxy system are dependent on the resin, the hardener, and on the amount of each in a given mixture. Epoxy systems are engineered for a specific ratio of resin and hardener. It is quite important that the proper mixture be obtained.
Page 34 Do not mix with a brush. The bristles can soak up the hardener, changing the ratio. Use a tongue depressor or wood stick..The working temperature has a substantial effect on the pot life and cure time. Very hot conditions will cause the cure to speed up. In cold working conditions the cure will be delayed and if it is cold enough, epoxy may not cure at all.
Page 35 obtained. Use micro only as specifically shown - never use micro between glass layers..Always use the following method to join foam blocks. This is extremely important. Check that the foam blocks fit closely together. If there are voids over 1/16 inch, sand to fit, or fill the void with a sliver of foam.
Page 36 Q2 Plans - Chapter 3 - Page 3-05 FLOX ..Flox is a mixture of cotton fiber (flocked cotton) and epoxy. The mixture is used in structural joints and in areas where a very hard, durable buildup is required. Flox is mixed much the same as dry micro, but only about two parts flock to one part epoxy is required.
Page 37 works up to a point where so much hardener is added that the mixture never hardens. Follow the general directions on the Bondo can for fast setting Bondo. Mixing is done on a scrap piece of cardboard or plywood (or almost anything), using a hard squeegee or putty knife. A blob of Bondo is scooped out of the can and dropped on the mixing board.
Page 38 2 lb urethane, but found its physical properties, fatigue life, and fuel compatibility to be much lower than the urethane supplied to Q2 builders. Do not confuse styrofoam with white expanded polystyrene. Expanded polystyrene is a molded, white, low...
Page 39 CONSTRUCTION TECHNIQUES HOT WIRE CUTTING ..The airfoil-shaped surfaces of your Q2 are formed by hot wire cutting the orange or blue-white styrofoam of 2 lb/ft3 density. The hot wire process given airfoils that are true to contour, tapered, properly twisted, and swept with a minimum of effort and the simplest of tools.
Page 40 Templates are made from thin plywood, sheet metal, masonite or Formica. A variable voltage control is used to supply the electrical current that heats the wire..The blue-white or orange foam used in your flying surfaces was selected for a combination of reasons and its hot wire cutting ability was one of them.
Page 41 pausing on the tab, wire's out." As the cut is made, the person on the small rib follows the numbers, passing over them as he hears them called out. Pause marks are indicated in places where it is necessary to pause for a couple of seconds and let the hot wire's center lag catch up with the ends.
Page 42 templates should be a close fit for the nails. Be careful not to angle the nails so that the hot wire can catch on them! Some rib templates are used several times, for both inboard and outboard, requiring you to transfer the talking numbers, pause marks, trim line, and waterline to the opposite side of the template.
Page 43 Q2 Plans - Chapter 3 - Page 3-07 ..The use of the hot wire saw is a simple thing if your equipment is set up properly. Proper wire tension and wire temperature should be maintained for good cutting. The wire tension should be tightened after the wire is hot by twisting one tube with a pair of pliers.
Page 44 ..The hot wire should be guided around the templates with light pressures. Pushing too hard against the template may move them or flex the foam block which results in an under cut foam core..The correct set-up is just as important as using the correct tools and materials.
Page 45 Use a dust respirator mask while carving urethane. Try not to aggravate the better half by leaving a green foam dust trail into the house. PAGE 3-7 Q2 Plans - Chapter 3 - Page 3-08...
Page 46 GLASS LAYUP ..The glass layup techniques used in your Q2 have been specifically developed to minimize the difficulty that glass workers have traditionally endured. The layups that you will do will be on a flat horizontal surface without the molds, vacuum bags, and other special equipment that are common in glass work.
Page 47 part - be sure your core looks exactly like that on the section view. Lay a 12 inch straightedge spanwise on all critical areas of the flying surfaces and be sure you don't have any high or low places or joggles.
Page 48 wet and the excess resin brought up by squeegeeing to help wet out the middle plies. To do this, pour epoxy onto the part and move it around the surface with a squeegee. Your work will go much faster if you make the layup too wet, then remove excess epoxy with many light passes with the squeegee.
Page 49 epoxy is much better on the floor than on the airplane. It is possible to squeegee too hard and make the layup too dry. If this occurs, the surface will appear white, indicating the presence of air. If this occurs, wet the cloth by painting on a little epoxy and stippling it down into the layup.
Page 50 around a sharp corner. STEP 9: PRELIMINARY CONTOUR FILL ..Certain areas, like along the trailing edge (see cross section views) require a dry micro fill. It is preferred to apply this fill within 2-3 hours of finishing the fiberglass layup. However, where the micro filler obscures the structure underneath, FAA inspection should be completed before dry micro filling.
Page 51 Wood requires no special preparation for bonding but should be free of grease, oil, paints, and varnish. Sand wood surfaces with 36-grit sandpaper before layup. Metal bonding is not relied upon for strength but PAGE 3-9 Q2 Plans - Chapter 3 - Page 3-10...
Page 52 metal surfaces should be free of oil and grease and, except for bolts, nuts, and other fasteners, metal surfaces should be dulled by sanding with 220-grit sandpaper, and coated with epoxy before setting in place. Cured micro surfaces should be sanded dull but be careful not to obliterate surrounding foam surfaces while doing it.
Page 53 ..The Dremel (Moto Tool) or Home Shop (Weller) is a very versatile tool with many uses in the construction of your Q2. The kits usually have a nice selection of bits, cutters, grinders, stones, and mandrels for every conceivable use.
Page 54 A pneumatic riveter is not required. The few hard rivets used can be set with a hammer, using your vise as backup. The 'pop-type' rivets are pulled with a low-cost hand puller available at any hardware store. Q2 Plans - Chapter 3 - Page 3-11...
Page 55 CUTTING THE UNI SPAR CAPS ..The spar caps used in the main wing, vertical tail, and canard, are strips of UNI cloth that you will cut from the roll provided in the kit. Begin by unrolling the roll on a long, flat surface. The example to be used here will be a spar cap A that is 8"...
Page 56 TAPES ..Quite often during the construction of your Q2, you will be asked to use glass tapes to join two pieces together..A glass tape is a strip of BID cut at 45 degrees which is used to lap up onto both surfaces that are being joined.
Page 57 construction technique is your ability to visually inspect the structure from the outside. The transparency of the glass/epoxy material enables you to see all the way through the skins and even through the spar caps. Defects in the layup take four basic forms: resin lean areas, delaminations, wrinkles or bumps in the fibers, and damage due to sanding structure away in finishing.
Page 58 Q2 Plans - Chapter 3 - Page 3-12 ..The following is a listing of the "critical areas"; the portions of the Q2 that must meet all the inspection criteria: 1. Entire canard. 2. All portions of the fuselage within 10" of the engine mounts, canard, and wing.
Page 59 4. All flying surfaces in the shaded areas shown, plus all overlaps at L.E. & T.E..Major wrinkles or bumps along more than 2" of chord are cause for rejection in the wings, canard and vertical fin, particularly on the top (compression side).
Page 60 CORNER TREATMENTS ..A variety of structural corners are employed in the construction..There are two basic types of corners: one where the glass fibers are continuous around the corner, and the other where a structural filler is used and glass is bonded to the filler. The corner with the glass fibers running completely around it is used where maximum strength is required.
Page 61 ..Outside corners require a radiused edge. Where the glass fibers run directly around the corner a minimum radius of 3/16 inch is required. Where the fibers run at an angle to the radius, only a 1/8 inch radius is needed. CONTINUED ON NEXT PAGE PAGE 3-12...
Page 62 Q2 Plans - Chapter 3 - Page 3-13 ..In some areas a sharp corner is desirable and maximum strength isn't required. In these areas a flox corner is used. A simple unsupported glass corner has very poor strength. To strengthen this corner, a triangle of flox is used to bond the glass plies together.
Page 63 SKIN PROTECTION ..If you work with epoxy on your bare skin, you can develop an allergy to it. This "sensitization" to epoxy is an unpleasant experience and is to be avoided. You generally have to get epoxy on your unprotected skin to become sensitized. If you use a protective barrier skin cream like Ply No.9, or disposable plastic medical examination gloves, the allergy can be avoided.
Page 64 ..Using these three references, any point in an airplane can be described with a fuselage station, butt line, and waterline. Fortunately, your Q2 is so simple that we don't need to locate very many things this way. When you start on your 4/5 scale replica of a B-1 Bomber, this reference system will be real handy.
Page 65 Proper techniques must be adhered to for safety as well as to obtain an attractive airplane..The Q2 is sensitive to weight growth. You may easily add 50 pounds during the finishing process if you try to finish the entire aircraft to sailplane standards (smooth, wave-free surfaces).
Page 66 White has been chosen as the standard color for fiberglass sailplanes to preclude any possibility of excess temperature due to solar heating. The same criteria apply to the Q2, and white is recommended. Trim colors in less-critical areas such as the fuselage, vertical tail, and the underside of wings and canard, can be other than white.
Page 67 TOOLS AND MATERIALS ..The tools and materials used in finishing the composite airplane are simple and straight forward. A low density microsphere/epoxy mixture (dry micro) is used for coarse filling requirements. Automotive type polyester body fillers (Bondo) are very heavy and not recommended as a primary aircraft finishing material.
Page 68 Q2 Plans - Chapter 3 - Page 3-15 ..The sanding spline is a finishing tool common to the sailplane industry. It is an easy tool to make and does an excellent job of contouring. You may find it handy to make two, one for coarse grit sandpaper and one for medium or fine sanding.
Page 69 THE FINISHING PROCESS ..Finishing the composite airplane is a five-step operation. Repairs or rework of structure must be completed first, before the obscuring finish is applied, and final structural inspections must be complete. Second, coarse contour filling is done with microspheres/mixed with epoxy (dry micro) as required in areas requiring .03 inch to .20 inch of fill.
Page 70 CONTINUED ON NEXT PAGE PAGE 3-15 Q2 Plans - Chapter 3 - Page 3-16...
Page 73 STEP TWO: COARSE FILLING ..You must be extra cautious in this step or you may destroy your structure. When you take a piece of sandpaper and start grinding on your composite structure it's like using acid to clean a metal wing spar.
Page 74 CONTINUED ON NEXT PAGE PAGE 3-16 Q2 Plans - Chapter 3 - Page 3-17...
Page 75 ..Paint a thin coat of epoxy over the area to be filled. Dry micro is then lumped over the area. The fill must be high, such that material is sanded away to bring the area into contour. The micro should be mixed very dry (lots of microspheres) to save weight. Let the micro cure at least 24 hours.
Page 76 block in preparation for feather fill. A spray or brush coat of feather fill will build up .02" to .03" thick, fill the glass weave and any medium sized out-of-contour spots. Feather fill will require several hours curing time before it can be sanded. The cured feather fill is sanded to contour using a spline or soft block and 100-grit sandpaper.
Page 77 Automotive trunk paint may also be used. Its “speckled" appearance will hide the weave of the glass cloth. PAGE 3-17 Q2 Plans - Chapter 3 - Page 3-18...
Page 78 If you have a gap of more than .005 inch, your surface is too wavy. Check this in several places from the leading edge back to 50% chord. The bad Quickie wing had gaps of about .012 inch. After refinishing with gaps of less than .005 inch, its stall angle of attack increased from 8 deg.
Page 79 ..The materials, methods, and practices employed by the amateur builder in the construction of the Q2 type are new to light aircraft construction and may be unfamiliar to the inspection personnel involved with the licensing of amateur built aircraft. Structural design criteria for the Q2 exceed F.A.R.
Page 80 5% of the laminate surface area. Voids greater than 2 inches in diameter should be repaired as shown in paragraph 4. CONTINUED ON NEXT PAGE PAGE 3-20 Q2 Plans - Chapter 3 - Page 3-19...
Page 81 3.2 LEAN AREAS ..Areas where the epoxy/glass matrix is incomplete because of inadequate wetting of the cloth with epoxy (lean areas) are speckled whitish in appearance. The fully wetted laminate will have a consistent transparent greenish appearance. Epoxy lean areas are acceptable, as long as the white speckled area is less than 10% of the surface area.
Page 82 4.0 REPAIRS ..There are seldom single defects so massive that a major component must be scrapped. The repair procedures described here may be applied throughout the QUICKIE and Q2 composite sandwich structures. 4.1 SMALL VOID REPAIRS ..Voids up to 2 inches in diameter may be repaired by drilling a small hole into the void and injecting the void full of epoxy.
Page 83 QUICKIE and Q2 structures. Design safety factors in excess of three enable somewhat relaxed acceptability criteria compared to other similar structures. PAGE 3-20 Q2 Plans - Chapter 3 - Page 3-20...
Page 84 1/2 ounce layup has too much resin, and if you make all of the 1ayups in the airplane this wet, your Q2 may be as much as 50 pounds over weight. An 11 ounce layup is just about perfect. Save this piece; it will be useful to check future 1ayups against.
Page 85 This layup is a sample of composite sandwich structure and is typical of the load carrying structures in your Q2. When this layup is finished, and completely cured, you will subject it to a simple load test, and thus demonstrate the strength of your workmanship.
Page 86 ..Now for the test: lay a broom handle or piece of tubing on the work bench and try to break the sample by putting all of your weight on the ends. A 200 pounder will stress the sample more than any part of your airplane is stressed at 10 g's.
Page 87 Q2 Plans - Chapter 3 - Page 3-21 BOOK END ..The last practice part that you will make before starting on your airplane is a book end. It takes three layups to make the book end and involves most of the operations that you will need to learn, to build your airplane.
Page 88 ..Mix 4 oz. of Safe-T-Pox epoxy; using about 1 oz, make a small batch of micro slurry and coat the foam as shown. Make dry micro from the leftover slurry and a small radius with it as shown..Lay up the first ply of BID as shown..Using plain epoxy (no micro), lay up the other two plies and allow to cure.
Page 89 Radius the corners of the depression. Blow or brush all of the foam dust off the surfaces..Cut three plies of BID as shown. CONTINUED ON NEXT PAGE PAGE 3-21 Q2 Plans - Chapter 3 - Page 3-22...
Page 90 ..Mix Safe-T-Pox, make a small batch of slurry, and save the remaining epoxy. Slurry the foam surface and apply two plies of BID to the contoured surface. Start the layup in the center and work out toward the edges. If you have trouble getting the glass into the depression corners without bubbles, lift the plies and wipe in a little dry micro.
Page 91 ..Wait until the second layup is fully cured. Remove the 1 inch foam block with a butcher knife and sanding block. Remove foam for a 1/4" flox corner and sand the glass surface dull.
Page 92 ..Mix Safe-T-Pox, a small batch of flox, and a small batch of micro slurry. Fill the corner with flox and slurry the foam. Lay up the four UNI plies with the orientation shown.
Page 93 BID and UNI weave cloth PAGE 3-22 Q2 Plans - Chapter 3 - Page 3-23 EDUCATION SUPPLEMENT Rip this page out of your plans and staple it to the wall of your shop.
Page 94 CLOTH CUTTING : You-can get by with just a standard pair of good fabric scissors, but the job is much easier with the large pair of industrial scissors (Weiss model 20W). They're $25 (gulp!) but worth it in the long run. SURFACE PREPARATION: FOAM - Hot-wire-cut surface needs no preparation.
Page 95 Wet Micro - Enough microspheres for a "thick honey" mix. Dry Micro - Enough Micro so it won't run. Wet Flox - Thick, but pourable mixture of epoxy and flocked cotton. APPLY TO SURFACE: Layup Over Foam - Brush or squeegee on a thin micro slurry layer (thick over urethane).
Page 96 PRELIMINARY CONTOUR FILL : Save sanding by troweling dry micro over low areas while the glass layup is still tacky. This is done at trailing edges, spar caps, or 'over any low areas. The low places are overfilled with micro then sanded smooth after full cure.
Page 97 URETHANE FOAM SHAPING ..BASIC TOOLS: Sharp butcher knife, sanding block, surfoam file, wire brush and blocks/scraps of urethane. Use a dust mask. Hack away, have fun. HOT WIRE CUTTING STYROFOAM ..Hot wire tool has a length of 56"..Wire must be tight. The adjustable voltage control is best, but the job can be done with 212-volt, 6-amp battery chargers or 12-volt car batteries.
Page 98 HARDWARE SKETCHES AN3 3/16" AN509 AN525 dia. bolt flush head washer head AN4 1/4" screw screw dia. bolt all metal plain lock nut wide washer washer AN363-1032 AN970 AN960 AN363-428 QUALITY CONTROL CRITERIA/REPAIRS See the Education section END OF CHAPTER Page 3-23...
Page 99: Individual Part Construction
INDIVIDUAL PART CONSTRUCTION INTRODUCTION ..The first task in the construction of your Q2 is to make many of the small, individual parts required for assembly later. Quickie Aircraft Corporation has found that making these parts at one time is...
Page 100 template drawings in case you destroy one accidentally. Don't be bashful about spending a few bucks for a replacement rather than to soldier on incorrectly trying to piece together a drawing that looks like your dog ate it. MAIN FUEL TANK CONSTRUCTION ..
Page 101 Fuel Tank Profile Templates may be used; if the hot forming operation does not go well, you may cut-and-join several straight line segments. Of course, the easiest way to build the Q2 main fuel tank is to buy it prefabricated from Quickie Aircraft Corporation or one of its dealers.
Page 102 on Appendix Sheets 1,2,& 5 for the center and side console vertical pieces, as will as for the top side console pieces. Make 2 of each from the'3/8" thick white foam and number them left, right, and center, to identify where they are assembled in the aircraft. (In airplane talk, left is the pilot's left as he sets in the cockpit.) Fiberglass 1 BID on the inside face of each piece.
Page 103 Q2 Plans - Chapter 4 - Page 4-02 ..It is important to note that if you modify either your Seatback Bulkhead angle (see Chapter B) or Instrument panel location, or if you are wider and bigger than normal in the hips, you may wish to change the geometry of the pieces somewhat.
Page 104 is 6.7 inches each. The 4 LG21s are made from the /" thick white foam. The 3 carving templates are made from hardboard, plywood, masonite, etc. FUSELAGE BULKHEADS ..In this section, you will construct the following bulkheads: FS120, FS94, Seatback Bulkhead, and aft canopy bulkhead. All bulkheads are made from the 3/B"...
Page 105 ..Each full size template outline has a forward face marked on it. Also, the words describing the template are always written so that they can be read when the template is right side up and facing forward. Be sure to mark each bulkhead upon completion with the proper information so that you don't forget which way it is jigged.
Page 106: Hot-Wiring
Q2 Plans - Chapter 5 - Page 5-01 HOT-WIRING INTRODUCTION ..In this section, you will hot-wire the foam cores for the wing, canard, rudder, vertical fin, ailerons, and elevators..Begin by reviewing the COMPOSITE MATERIALS EDUCATION chapter. That means more than just glancing through the chapter; study it thoroughly until you can recite it in your sleep.
Page 107 48" length. Both the Trailing Edge Foam Cores and the Aileron Slot Foam Cores (outboard) are cut considerably oversized, and will be trimmed to the proper length during installation. PAGE 5-1 Q2 Plans - Chapter 5 - Page 5-02 CANARD CORES ..The outboard and inboard canard cores are cut from skewed,...
Page 108 section. The reason for this is to obtain the proper sweep of the canard when the cores are jigged together later..Begin by squaring up the 10" x 20" X 96" nominal dimension block of polystyrene foam to obtain a length of 51.2", with the skew as indicated. Next, using the sketch provided, hot-wire the outboard canard foam cores.
Page 109 CONTINUED ON NEXT PAGE PAGE 5-2 Q2 Plans - Chapter 5 - Page 5-03 ..Finally, locate the remaining part of the 10" x 20" block and size it as shown, in order to make the canard center section. Keep the unused portion for cutting the vertical fin, so don1t make the height over 6.0".
Page 110 OUTBOARD ELEVATOR CORES ..Find the two pieces of foam that you saved after hot-wiring the inboard canard cores. (The areas are marked 'save' on the sketches). Add some additional scrap pieces, being careful to obtain proper skew throughout the setup, and make the inboard elevator cores. The template offsets are necessary to obtain the proper geometry.
Page 111 PAGE 5-3 Q2 Plans - Chapter 5 - Page 5-04 VERTICAL FIN ..The vertical fin is cut out of the remains of the piece that you used to make the canard center section core. (Remember, the one we told you to keep and not throwaway).
Page 112 the front view is necessary because the rudder core is 27" long, while the remaining trailing edge length is only about 13". It is suggested that you cut the rudder core first, and then reduce the block length to 13" for the trailing edge core. As a note of explanation, the rudder extends up the vertical fin only part way.
Page 113: Ailerons, Rudder, And Elevators Construction
Q2 Plans - Chapter 6 - Page 6-01 AILERONS, RUDDER, AND ELEVATORS CONSTRUCTION AILERON CONSTRUCTION ..Both ailerons may be constructed at the same time. These instructions will only cover the construction of the left aileron, but the right aileron is a mirror image.
Page 114 joggles. Layup 2 UNI at 45 deg. to the trailing edge. At the leading edge, overlap a minimum of 0.5" onto the previous bottom layup. At the trailing edge, layup glass to glass. Leave the aileron alone until it has cured to avoid changing the alignment, and then feather the top surface UNI plies to remove the leading edge (L.E.) joggle.
Page 115 Q2 Plans - Chapter 6 - Page 6-02...
Page 116 RUDDER CONSTRUCTION ..The rudder construction is very similar to the aileron construction that you have already completed. Re-read the AILERON CONSTRUCTION section before proceeding further..Unlike the aileron, the rudder is a tapered chord, symmetrical surface..Begin by finding CS21, which is a 27" length of 1" O.D. x 0.035" wall 2024T3 aluminum tubing.
Page 117 PAGE 6-2 Q2 Plans - Chapter 6 - Page 6-03 ELEVATOR CONSTRUCTION ..The elevator construction is very similar to the aileron construction that you have already completed. Reread the AILERON CONSTRUCTION section before proceeding further..These instructions cover only the construction of the left elevator, but the right elevator is a mirror image.
Page 118 cores are joined they should total 6 ft. in length..Basically, you will join the inboard and outboard core together, insert CSI6, replace the front foam pieces, sand the combination after it has cured to remove bumps and joggles, layup the bottom skin, layup the top skin, and final trim the trailing edge after installation.
Page 119: Vertical Fin Construction
END OF CHAPTER PAGE 6-3 Q2 Plans - Chapter 7 - Page 7-1 VERTICAL FIN CONSTRUCTION INTRODUCTION ..The vertical fin is a symmetrical sandwich composite structure with solid foam core. two layers of UNI at 45 degrees to the trailing edge of the vertical fin for torsional stiffness and surface durability, and spanwise tapes of UNI for bending strength.
Page 120 rudder extends only partway up the vertical fin. Trial fit the vertical fin trailing edge core against the vertical fin core where the surgery had been performed. Note that the vertical fin trailing edge core was hot-wired longer than necessary, and will have to be trimmed to fit properly.
Page 121 sure that all level lines are level. Sand the ‘tail’ of the vertical fin core so that when you laminate the skin, you will obtain a glass- to-glass bond at the vertical fin slot..The lamination of the skin and spar caps is very similar to what you have previously accomplished in making the ailerons, elevators, and rudder.
Page 122 Q2 Plans - Chapter 7 - Page 7-2 ..Cut all of the UNI cloth for the skin and spar caps..Laminate 2 UNI at 45 degrees to the trailing edge of the vertical fin. Don't forget the peel ply tape on the trailing edge of...
Page 123 END OF CHAPTER PAGE 7-2 Q2 Plans - Chapter 8 - Page 8-01...
Page 124: Basic Fuselage Assembly
BASIC FUSELAGE ASSEMBLY INTRODUCTION ..Jigging the fuselage is your first major assembly task on the Q2. Because the Q2 fuselage shells are provided you in a prefabricated form, jigging is simplified, and there is no messy carving of urethane foam, as is the case with other homebuilts.
Page 125 All you are trying to do here is to gain access to the inside fuselage and to establish a rough fit on the canopy. PAGE 8-1 Q2 Plans - Chapter 8 - Page 8-02...
Page 126 ..The location and angle of the seatback bulkhead is the prime consideration for comfortably accommodating different pilot sizes. If the primary pilot is over 616" tall or less than 5'5" tall, then Quickie Aircraft Corporation should be contacted for assistance in creating a comfortable fit.
Page 127 CONTINUED ON NEXT PAGE PAGE 8-2 Q2 Plans - Chapter 8 - Page 8-03...
Page 128 canted portion to be moved aft, which increases cockpit room. Moving the break point up moves the canted portion of the Seatback Bulkhead forward_ making the cockpit more comfortable for shorter people. The nominal FS64 shown on the sketch as the intersection of the forward edge of the seatback bulkhead and the fuselage bottom is optimum for people up to 616".
Page 129 ..Next, the canopy mounted to the fuselage is turned over and the aft canopy bulkhead fitted into position. The aft face should be located a maximum of 1/8" forward of the forward face of the Seatback Bulkhead with a few dabs of 5-MIN. It is permanently mounted with flox and 2 BID tapes on either side, lapping onto the bulk head and fuselage a minimum of 1.5 inches, and lapping onto the canopy a minimum of 0.7 inches.
Page 130 0.7 inch minimum lapping onto the canopy and a minimum of 1.5 inches lapping on the existing fuselage inside skin..Permit the laminations to cure for 24 hours. PAGE 8-3 Q2 Plans - Chapter 8 - Page 8-04...
Page 131 JOINING THE FUSELAGE SHELLS ..This step is very exiting; you are going to actually complete your first major structure - the fuselage..In this section, you will join the top forward fuselage shell to the lower forward fuselage shell and the top aft fuselage shell to the lower aft fuselage shell.
Page 132 CUTTING THE CANOPY FRAME ..In this section, you regain access to the cockpit area and obtain your canopy frame at the same time. The sketches show the suggested cut line for the canopy frame. This line is somewhat arbitrary on our part, but the rest of the cockpit area is designed around it so be careful of deviations.
Page 133 Q2 Plans - Chapter 8 - Page 8-05 INSTALLING THE LONGERONS ..A longeron runs on each side of the cockpit forward from the Seatback Bulkhead to the instrument panel. These longerons are made of 5/8" square wood and must first be bowed to shape in order to fit the curvature of the fuselage side.
Page 134 END OF CHAPTER PAGE 8-5...
Page 135: Main Wing Construction
Q2 Plans - Chapter 9 - Page 9-01 MAIN WING CONSTRUCTION INTRODUCTION ..The main wing is a sandwich composite structure with solid foam core, two layers of UNI at 45 degrees to the trailing edge of the wing for torsional stiffness and surface durability, and spanwise tapes of UNI for bending strength.
Page 136 NOTE: See Bottom and Top Main Wing Lamination Drawing for exact sizing of sparcaps A thru M.
Page 137 CONTINUED ON NEXT PAGE PAGE 9-1 Q2 Plans - Chapter 9 - Page 9-02...
Page 138 CONTINUED ON NEXT PAGE PAGE 9-2 Q2 Plans - Chapter 9 - Page 9-03...
Page 139 ..Now begin to trial fit the four main wing cores into position. Be careful not to put too much pressure on the foam cores and damage them. The two 4nboard cores will have to be beveled at BLOO by sanding because of the main wing dihedral and the other core joints may have to be sanded to make the cores fit within the maximum tolerance of 1/16".
Page 140 16.3". Also measure the width between the two points that you took the measurements at..You are now ready to transfer the information onto the main wing foam cores with a felt tipped marker pen. Using the main wing shear web and the BL00 foam core joint as the reference mark the two points on the foam cores, and connect them with a line.
Page 141 CONTINUED ON NEXT PAGE PAGE 9-3 Q2 Plans - Chapter 9 - Page 9-04 ..The first UNI ply is put on at 45 degrees to the main wing T.E.. The fibers must be straight, so take your time getting the...
Page 142 wrinkles and kinks out. Don't get ahead of yourself on pouring microfoam slurry on the foam; otherwise, by the time you are ready to place the UNI over a particular area, you will have a messy, hard lump of slurry. Work with one piece of cloth at a time, and with small batches of slurry and epoxy.
Page 143 But, if your like everyone else, you won't be able to resist making that jigging table into a main wing for your Q2 as quickly as possible. LAMINATING THE TOP SKIN AND TOP SPAR CAPS ..
Page 144 ..Next, when you are sure of your framework, break loose the main wing core female jigging templates with a hammer, (they won't be needed again), and turn the main wing over so that the unglassed cores are upward. Set the main wing on the jigging table once again..Check the main wing tip level lines.
Page 145 Q2 Plans - Chapter 9 - Page 9-05 GLASSING THE AILERON SLOT FOAM CORE SLOTS ..The aileron slot foam core inside slots are glass ed with 2 BID at 45 degrees to the spanwise direction. (i.e. T.E.). Knife trim to the edge of the foam core, as shown on the sketch.
Page 146 INSTALLING THE AILERON SLOT FOAM CORES ..This step is critical to having a nice looking main wing and aileron union, so follow the directions carefully..To start out with, the aileron slot foam cores that you hot- wired way back when were purposely made longer than necessary. Your first task is to size them for the correct length.
Page 147 (don't forget to remove the Peel Ply!), plus a few dabs of 5-MlN to keep the two attached during cure. PAGE 9-5 Q2 Plans - Chapter 9 - Page 9-06...
Page 148 OUTBOARD AILERON PIVOT ASSEMBLY ..These instructions cover only the assembly of the left outboard aileron pivot, but the right outboard aileron pivot is a mirror image, and may be accomplished at the same time..First, find a QCSM7 pivot and position it about 0.25" inboard of the outboard end of the aileron using 3 MSP43 cherry rivets spaced radically at least 0.4"...
Page 149 AILERON INSTALLATION ..In this section, you will mount the ailerons to the main wing. After the main wing is attached to the fuselage, it will only be necessary to connect the CS5 and CS12 push-pull tubes in order to have a functioning aileron control system.
Page 150 ..Take a piece of QCSM1 and make two 1.8" length. pieces to use as aileron reducers. A saw cut and perhaps some light sanding will be necessary to make them fit snugly and flush with the inboard ends of the two ailerons.
Page 151 Q2 Plans - Chapter 9 - Page 9-07 ..The following procedure was developed to help you get the ailerons mounted without binding, with the proper clearances, and with the ability to get them off again:...
Page 152 C57 held in place and check for binding. Work slowly, correct any binding or clearance problem by modifying C510, C56, and C57. Please, do one thing at a time. CONTINUED ON NEXT PAGE PAGE 9-7 Q2 Plans - Chapter 9 - Page 9-08...
Page 153 5. When the complete aileron assembly fits well, and rotates freely, mix up some 5-MIN with flox and temporarily mount CSIO, CS6, and CS7 in place against the main wing shear web, again checking for alignment, clearances, and binding. 6. If you haven't already done so, repeat for the other aileron.
Page 154 CONTINUED ON NEXT PAGE PAGE 9-8 Q2 Plans - Chapter 9 - Page 9-09...
Page 156 Finally, make the aileron spacer, which has a nominal 1.0" length. This spacer should be sized lengthwise to allow the aileron to have a lateral freeplay (i.e. inboard to outboard) of about 0.05". Assemble each aileron, and again check for binding, misalignment, or excessive freeplay.
Page 157 An alternative method would be to do each surface on the flat, instead. END OF CHAPTER PAGE 9-9 Q2 Plans - Chapter 10 - Page 10-01...
Page 158: Canard Construction
However, the basic procedures are identical, and the experience you have gained in completing the main wing for your Q2 should allow you to construct the canard in the same amount of time. You may wish to reread the chapter on the MAIN WING to review the procedures.
Page 159 Q2 Plans - Chapter 10 - Page 10-02 JIGGING THE CANARD ..Next, you will need to jig the canard cores on the jig table. It would probably be a good idea to clean off the jig table of any bondo chips, wood, epoxy, etc., so that you start with a clean surface.
Page 160 after verifying that the core fit is within 1716". Check, recheck, and re-recheck each core level line and alignment as the cores are joined. Note that the canard center section foam core gets a glass rib of 2 BID and flox corners at each end of the canard center section foam core. The flox corner should be added after the entire series of canard cores have been joined and cured.
Page 161 PAGE 10-2 Q2 Plans - Chapter 10 - Page 10-03 PAGE 10-3...
Page 162 Q2 Plans - Chapter 10 - Page 10-04 LAMINATING THE BOTTOM SKIN AND BOTTOM SPAR CAPS ..Study the two sketches labeled "Bottom Canard Lamination", and "Top Canard Lamination" very carefully..In this section, you will only be doing the "Bottom Canard Lamination", but that one should keep you and two others busy for...
Page 163 any excess epoxy. By this time, if your floor does not contain enough hardened epoxy to build the Q3, you are either very accurate at mixing epoxy, or else you are not working hard enough at squeegeeing off excess epoxy..Spar caps A thru F are laminated in that order, with the widest caps going on first.
Page 164 Also, install the flox corners on either end-of the canard center section core. CONTINUED ON NEXT PAGE PAGE 10-4 Q2 Plans - Chapter 10 - Page 10-05...
Page 165 PREPARING THE TOP CANARD FOAM CORES FOR GLASSING ..At the leading edge, feather the bottom skin to a feather edge at the tangent point just 1ike you did on the main wing. Prepare the canard top surface just like you did the canard bottom surface. (See "Preparing The Canard Cores For Glassing").
Page 166 ..The top canard skins are laminated similarly to the bottom skin lamination. The skin is the same two UNI at 45 degrees to the T.E., draping over the T.E. down to the bottom of the shear web, and the spar caps are G thru Q this time.
Page 167 PAGE 10-5...
Page 168 Q2 Plans - Chapter 10 - Page 10-06 INSTALLING THE ELEVATOR SLOT FOAM CORES ..This step is critical to having a nice looking canard and elevator union, so follow the directions carefully..To start out with, the elevator slot foam cores that you hot- wired way back when were purposely made longer than necessary.
Page 169 ..Your canard should now be looking more like a canard, and less like a lump of foam and glass. CONTINUED ON NEXT PAGE PAGE 10-6 Q2 Plans - Chapter 10 - Page 10-07...
Page 170 OUTBOARD ELEVATOR PIVOT ASSEMBLY ..These instructions cover only the assembly of the left outboard elevator pivot, but the right outboard elevator pivot is a mirror image, and may be accomplished at the same time..First, review the MAIN WING chapter section on "Outboard aileron Pivot Assembly".
Page 171 CONTINUED ON NEXT PAGE PAGE 10-7 Q2 Plans - Chapter 10 - Page 10-08...
Page 172 ..With the C517 hinge mounted on the elevator up against the end of the QC5M2 pivot, and with the elevator in position in the elevator slot foam core, you can mark on the elevator slot foam core where the 2 C518 inserts must go.
Page 173 ..The following procedure was developed to help you get the elevators mounted without binding, with the proper clearances, and with the ability to get them off again: CONTINUED ON NEXT PAGE PAGE 10-8 Q2 Plans - Chapter 10 - Page 10-09...
Page 175 1. Trim the inboard edges of the elevator slot foam cores flush with the sides of the fuselage. 2. Slip CS15 over the outboard end of Q2C5A8. the universal joint into the inboard end ofQ2C5A8. and then the outboard end of the Q2C5A8 assembly into the elevator reducer mounted in the inboard end of the left elevator.
Page 176 CONTINUED ON NEXT PAGE PAGE 10-9 Q2 Plans - Chapter 10 - Page 10-10...
Page 177 not interfere with the elevator movement, or bond the elevator to the shear web. If you previously removed the top and bottom canard skin where the slot was ground out, be sure to laminate 2 BID top and bottom once the laminations have cured. . The above procedures are used with both elevators.
Page 178 POST-CURING THE CANARD STRUCTURE ..In order to minimize creep in the canard, the canard should be post-cured prior to installing it on the aircraft..Creep is the tendency for the epoxy to deform due to heat and load. In the case of your aircraft, the heat could be obtained on a hot day with the aircraft setting in the sun, and the load is always there when the aircraft is resting on its 'landing gear'.
Page 179: Wheel Pant/Tire/Wheel/Brake Assembly
..It is not necessary to post-cure any other structure on your aircraft. END OF CHAPTER PAGE 10-10 Q2 Plans - Chapter 11 - Page 11-01 WHEEL PANT/TIRE/WHEEL/BRAKE ASSEMBLY INTRODUCTION ..In this chapter, you will make one left wheel pant and one right wheel pant, complete with wheel, tire, and brake assemblies.
Page 180 BASIC ASSEMBLY ..Begin by making two Wheel Pant cores (LGl) and four Wheel Pant Covers (LG2). The procedures that follow cover assembling the left wheel pant. Since the right wheel pant is a mirror image of the left wheel pant, you will probably find it easy to assemble both wheel pants simultaneously.
Page 181 ..While the layup is curing, take a second LG2 and layup two BID on the inside face (i.e.) the face that will be inside the LGI cutout when it is attached. Roughly trim the glass so that it doesn't extend beyond the edges of LG2, but don't be concerned if you trim somewhat inside the edges.
Page 182 lumber bracing. When everything is jigged properly, 5-MIN blobs are used to attach the pant to the canard and a piece of lumber is attached between the LG4 insert and the canard so that the assembly will not move. Begin by rigging the wheel pant in the approximate position. The wheel pant slips into place against the canard shear web and canard bottom skin.
Page 183 Q2 Plans - Chapter 11 - Page 11-02 ..The objective is to be able to sight through each wheel pant and see the other wheel pant axle hole lined up in the "sight". The process is iterative until you can confirm that a bullet fired along the sightline through each wheel pant will go right thru the opposite wheel pant axle holes.
Page 184 1. LG4 should remain .250" thick at the axle hole. 2. A smaller pant will be lighter and cleaner looking, so don't leave excess foam on the pant. 3. The top canard skin will be sanded back for 5"-8" to provide a pleasing, curvaceous contour..
Page 185 PAGE 11-2...
Page 186 Q2 Plans - Chapter 11 - Page 11-03 MOUNTING THE RUDDER PEDALS ..The rudder pedals must be mounted to the canard prior to mounting the canard to the fuselage..The rudder pedals are not easily adjustable for different pilot...
Page 187 CONTINUED ON NEXT PAGE PAGE 11-3...
Page 188 Q2 Plans - Chapter 11 - Page 11-04 ..Next, study the sketches carefully to understand the routing and function of the brake cable. Depressing the toe brake (Q2BSWl) pulls the cable, which travels around the pulley attached to BS2 and through a short piece of Nylaflow tubing to a second pulley cantilevered off the shear web of the canard.
Page 189 ..On the canard shear web at each wheel pant, there is another AN210-1A pulley to change the direction of the brake cable so that the cable will have a straight pull on the brake arm..Use a piece of 0.063" thick aluminum one inch square and drill a hole in the center for an AN3 bolt, and then rivet a nut plate to the aluminum so that the bolt can pass through the aluminum into the nutplate.
Page 190 A sample sketch of a pulley guard is included for your reference; they should fit as closely as possible to the outside diameter of the pulley. PAGE 11-4 Q2 Plans - Chapter 11 - Page 11-05...
Page 191 INSTALLING THE WHEELS/TIRES/BRAKES ..The Q2 uses 5" diameter wheels, internal expanding drum brakes, and 400 x 5 tires standard. The wheel pant is large enough to accommodate a 500 x 5 aircraft tire..Begin by assembling the wheel halves and the brake drum using the bolts and nuts provided.
Page 192 CONTINUED ON NEXT PAGE PAGE 11-5...
Page 193 Q2 Plans - Chapter 11 - Page 11-06 some trial fitting to make things come out right. In the future, whenever you want to remove the wheel, USE the LG6 piece, just reversing the above procedure..The AN310-4 castle nuts must be safetied, so where everything fits properly, drill a hole in each end of QBSMI and run a cotter pin through to prevent the nut_ from backing off.
Page 194: Main Wing And Canard Mounting
MAIN WING AND CANARD MOUNTING MOUNTING THE MAIN WING ..The main wing is permanently attached to the fuselage with flox and a series of BID tapes..Begin by leveling the fuselage both longitudinally and laterally. Use several pieces of scrap lumber and Bondo to firmly hold the fuselage in position.
Page 195 ..Before mixing up the flox, recheck the fuselage and main wing level lines and blocks. It is very critical to your Q2's excellent flying qualities to have the proper incidences angles..Check the skew of the main wing by measuring the distance from each wing tip to the base of the vertical fin.
Page 196 PAGE 12-1...
Page 197 ..Later, you will construct fairings for the inboard elevators, ailerons, and for the lower part of the canard, in order to make your Q2 aerodynamically cleaner. For now, stand back and admire your Q2 setting on the landing gear; your over 50% completed at this point.
Page 200 PAGE 12-2...
Page 201 ..If, on the other hand, you intend for your Q2 to be trailerable, you should skip ahead in these plans to Chapter 15 and complete that work prior to mounting the vertical fin in Chapter 14.
Page 202 BID tapes have the following widths: 5",4",3", and 2" with a 45 degree orientation to the joint. The extra BID is to make up for the glass strength lost when the foam was beveled. END OF CHAPTER Q2 Plans - Chapter 13 - Page 13-01...
Page 203: Canopy Assembly And Mounting
CANOPY ASSEMBLY AND MOUNTING INTRODUCTION ..In this chapter, you will install the canopy that you previously mounted and cut out in Chapter 8. It is important to the passengers' safety to have a canopy that is strong, rigid, and securely fastened while in flight.
Page 204 ..Once the laminations have cured, it is time to mount the stiffeners to the canopy frame. Begin by setting the canopy on the fuselage and checking the general fit of the canopy on the airframe. There should not be any trimming required for a good fit..The two stiffeners, one on each side, fit out board to the outside skin line as shown.
Page 205 ..To join each stiffener to the canopy frame, use a 2 BID wrap- around lamination from the inside skin of the frame to the outside skin of the frame, with an overlap onto the frame of a minimum of 0.7".
Page 206 PAGE 13-1 Q2 Plans - Chapter 13 - Page 13-02...
Page 207 CANOPY HINGE INSTALLATION ..The canopy is hinged on the right side of the aircraft with one 12" length of MS20257P4 hinge. (Or alternative MS20001P4 hinge)..The accompanying drawings give the details of the attachment. Note that recessing of the hinge into the longeron is necessary to provide clearance.
Page 208 FORWARD CANOPY LIP ..In order to provide a secure seal at the forward edge of the canopy frame, a fiberglass lip is fabricated from 4 BID and bonded to the inside of the upper forward fuselage shell as shown..Since the forward edge of the canopy frame is curved, when viewed from above, the lip will also be curved.
Page 209 PAGE 13-2 Q2 Plans – Chapter 13 – Page 13-03...
Page 210 CANOPY LATCH ..The canopy latch is installed on the left side of the cockpit midway along the left stiffener..Find C1 and C2. Make C3..Install C1 on the longeron. Next, take C3, a batch of Bondo, and climb into the cockpit. Close the canopy, and position C3 on the left canopy stiffener to match the position of C1, as shown.
Page 213 PAGE 13-3...
Page 214 Q2 Plans - Chapter 13 - Page 13-04 CANOPY GUIDE PINS ..To maintain the canopy in position, and to increase the fuselage stiffness in flight, canopy guide pins are installed at both the front of the canopy and the rear of the canopy.
Page 215 Failure to properly secure the canopy latch prior to takeoff will allow the canopy to open in flight. The flight characteristics of the Q2 with a partially open canopy have not been explored. A safety latch is assembled to prevent this potentially lethal situation from developing.
Page 216 END OF CHAPTER PAGE 13-4...
Page 217: Fuselage Detail Assembly
Q2 Plans - Chapter 14 - Page 14-01 FUSELAGE DETAIL ASSEMBLY WRAPPING THE TAILSPRING ..The tailspring provided is a molded S-Glass roving tailspring with extremely good bending strength along the length. Because of the production method, however, the tailspring does not yet have sufficient strength torsionally, to prevent torquing up in a tight taxi turn.
Page 218 PAGE 14-1 Q2 Plans - Chapter 14 - Page 14-02...
Page 219 TAILWHEEL INSTALLATION ..Once the tailspring has been installed in the fuselage permanently, then you are ready to install the tailwheel..Locate the following parts: QTW3, QTW4, QTW5, QTWMl, and the tailwheel. Insert the QTW4 spacer into the QTW3 weldment as shown. Trial fit QTW5 to the QTW3 assembly with a AN3-2LA bolt.
Page 220 RUDDER INSTALLATION ..The rudder hinge assemblies are very similar to those of the ailerons, so review the section on mounting the ailerons before proceeding further..The upper rudder hinge consists of the CS22 plywood mount, which is bonded to the vertical fin core, and the same hardware and fittings called out in the Main Wing chapter section on 'Outboard Aileron Pivot Assembly', so follow those directions.
Page 221 PAGE 14-2 Q2 Plans - Chapter 14 - Page 14-03...
Page 222 RIGGING THE RUDDER/TAILWHEEL CABLE ..The sketch on page 14-1 shows the cable layout to actuate the tailwheel and rudder. Note that from the rudder pedals, the 3/32" cable travels aft through 3/16" Nylaflow tubing fairleads at each bulkhead, exits the fuselage about 10" forward of the tail of the aircraft, and then goes directly to the tailwheel weldment, QTW5, where it is attached to the outboard hole using a thimble and NICO press sleeve attachment.
Page 223 MAIN FUEL TANK INSTALLATION ..Once installed, the main fuel tank also serves as a support for the legs of the pilot and passenger. The geometry of the tank was, therefore, laid out to provide not only fuel volume, but also adequate support.
Page 224 1" lapping onto each surface. ,Upon installation of the fuel tank permanently to the fuselage, these baffles will be coated liberally with flox so that they bond to the fuselage bottom. PAGE 14-3 CONTINUED ON NEXT PAGE Q2 Plans - Chapter 14 - Page 14-04...
Page 226 ..The fuel gauge consists of a direct reading float type mounted near the centerline of the aircraft. Before installing the gauge permanently, you should make sure that it will not interfere with the elevator control rod CS13 which runs from the control stick to elevators.
Page 227 CONTINUED ON NEXT PAGE PAGE 14-4 Q2 Plans - Chapter 14 - Page 14-05...
Page 228 Liberally apply flox around the exit of the fuel line to prevent leaks. SEATBELT ATTACHMENTS ..A very important safety feature of your Q2 is the individual seatbelt/shoulder harness assembly provided for each occupant.
Page 229 Previously, you have mounted the attachments for the shoulder harness in the main wing. In this section, you will install the mounts for the seatbelts, and, finally, install the seatbelts in your aircraft. Do all of the procedures exactly like these plans state; this section is your first line of defense in the event of a mishap.
Page 230 CONTINUED ON NEXT PAGE PAGE 14-5 Q2 Plans - Chapter 14 - Page 14-06...
Page 231 ..At BL00, a common attachment is used. The plywood should be about 2.4" x 1.5" and is beveled to form an A-frame arrangement, so that the aluminum extrusion can again pull off at about 45 degrees. The 7 BID is again laminated in place with the 0.75"...
Page 232 The 'kink' is achieved with a saw cut into the foam (not glass) and beveling the foam so that the piece can angle upward. CONTINUED ON NEXT PAGE PAGE 14-6 Q2 Plans - Chapter 14 - Page 14-07...
Page 233 ..The side consoles can be completely assembled permanently at this time. Again, remember that the previously glassed faces go on the outboard and lower sides, so that they are not visible upon assembly. Laminate 1 BID tape at the joints wherever you can reach, and use flox at the joints also.
Page 234 side consoles are installed with 2 BID over the outside faces of each console, and 1" minimum lapping onto the rest of the fuselage structure. The consoles are now strong enough to put weight on. INSTRUMENT PANEL INSTALLATION ..It is suggested that the Instrument Panel not be mounted in the fuselage permanently until all cutouts for instruments, radios, and equipment have been made.
Page 235 Side view of baffle installation Lower Bottom view, of baffle installation CONTINUED ON NEXT PAGE PAGE 14-7 Q2 Plans - Chapter 14 - Page 14-08...
Page 236 ..In order to make your Q2 have that "custom fitted" appearance, sit in the cockpit in a comfortable posit¬ ion that allows you to both see out of the cockpit and reach the rudder pedals.
Page 238 CONTINUED ON NEXT PAGE PAGE 14-8...
Page 239 ..The stick grip is carved out of Balsa wood and attached to QCSA1 with epoxy., Once your aileron and elevator control systems are functioning, climb into the cockpit and spend 5 minutes playing fighter pilot. Then get back to work, or you'll never finish your Q2.
Page 240 PAGE 14-9...
Page 241 ..The rope should be replaced every 1 year/100 hours. See the "Initial Flight Testing of Your Q2" guide for information on altering trim rates and forces.
Page 243 PAGE 14-10...
Page 244: Making Your Q2 Trailerable
MAKING YOUR Q2 TRAILERABLE INTRODUCTION ..In this chapter, you will make your Q2 trailerable and at the same time join the forward and aft fuselage shells together. As stated in Chapter 12, this task should be accomplished prior to mounting the vertical fin in Chapter 14.
Page 245 INSIDE LAMINATION ..Then mark the 10 locations for the fasteners. Remove the inside shell skin and core foam as shown at the 10 locations. The taper shown is to allow the next laminations to flow smoothly around the corners. Each location will have an area 1”...
Page 246 PAGE 15-1 Q2 Plans - Chapter 15 - Page 15-02...
Page 247 FASTENER INSTALLATION ..Make 10 of FC1 and 2 of FC2 using the full size patterns provided. Attach the 10 FC11s to the forward fuselage at the 10 locations using AN525-10R10 screws. (2 per fastener)..Jig the rear fuselage shell into position flush against the forward fuselage shell using a few dabs of Bondo.
Page 248 AN3-5A bolts indicated above..As a final note, if your Q2 has any antennas located in the aft fuselage, they too will need to have quick disconnect fittings.
Page 249: Engine Installation
END OF CHAPTER PAGE 15-2 Q2 Plans - Chapter 16 - Page 16-01 ENGINE INSTALLATION...
Page 250 ENGINE MOUNT INSTALLATION ..Make 4 EM2 backup plates. A full size drawing is included..Find the 4 Q2EM1 engine mount weldments. Use a AN6 bolt to stack each Q2EM1 to one EM2. Next, drill in 4 0.190” diameter holes in each Q2EM1/EM2 combination in the corners.
Page 251 MAGNETO/STARTER BOX ..On the Q2, the starter and magneto section of the engine projects aft of the firewall into a plywood box. This box is 9 sided and constructed from 1/8” thick plywood. It has the inside dimensions shown. These dimensions are rather critical, so follow them closely.
Page 252 To attach the aluminum to the firewall, use a few BSP46 rivets located not closer than 2" to the outboard edge of the firewall. (The cowling flanges will be mounted there later.) PAGE 16-1 Q2 Plans - Chapter 16 - Page 16-02...
Page 253 MOUNTING THE ENGINE ..A typical engine mount assembly is shown in the sketches. Mount the engine permanently. MOUNTING THE PROPELLER ..The propeller is delivered to the builder with the mounting holes pre9rilled..Make EM3 from a piece of 0.25" thick 606IT6 Aluminum. A full size pattern is provided..
Page 254 PAGE 16-2 Q2 Plans - Chapter 16 - Page 16-03...
Page 255 COWLING FLANGE CONSTRUCTION ..In this section, you will make the flange that attaches the cowling to the firewall. This flange will fit around the entire circumference of the firewall..First, use masonite, scrap plywood, or particle board to make an accurate template of the firewall.
Page 256 on the airframe and the propeller spinner available for fitting. Do not proceed further until that has been accomplished..Previously, you fabricated two cowling mounting flanges, one for the top cowling half and one for the bottom cowling half. Locate these two flanges.
Page 258 PAGE 16-3 Q2 Plans - Chapter 16 - Page 16-04...
Page 259 The cowling air inlets can now be cut into the cowling. They are nominally each 3.5" x 6.5" in size, with a 3/8" radius (using Bondo) around the lip. A sketch is included for reference. COWL FLAP CONSTRUCTION ..In order to improve the efficiency of your Q2, we have utilized...
Page 260 a simple cowl flap..Using a felt tipped marker, mark on the inside bottom cowling the 12" x 8.25" outline of the cowl flap. Trim 1.5" forward of the aft edge to remove the crosshatched area on the illustration..When the cowl flap is opened, it is necessary to have both sides closed off, like a dustpan.
Page 261 AN507 1032-RI0 screws using an approximately 4" spacing. The nutplates are secured using AN426-3-5 rivets. Take time to accurately mount the cowling halves and you will be rewarded with an excellent fit. PAGE 16-4 Q2 Plans - Chapter 16 - Page 16-05...
Page 262 CABLE GUIDES ..Every push-pull cable except the carb heat control uses a cable guide to provide positive control of cable movement. Make up three cable guides as shown. The mounting bolt hole should be drilled upon assembly later..These cable guides function by sizing the hole that the cable housing passes through such that when the AN3-14A bolts are tightened, pressure will be exerted upon the cable housing, preventing slippage.
Page 264 PAGE 16-5 Q2 Plans - Chapter 16 - Page 16-06...
Page 265 ENGINE BAFFLING ..The purpose of the engine baffling is to provide adequate airflow for cooling to all critical areas of the engine and accessories. Air enters through the cowling air inlets located on either side of the spinner. A vertical baffle located in front of the forward engine cylinders forces the incoming air to travel upward across the cylinders and then down through the fins, exiting the bottom of the cowling through the variable opening cowl flap.
Page 267: Fuel System Installation
FUEL SYSTEM INSTALLATION INTRODUCTION ..The Q2 fuel system consists of a main fuel tank that forms part of the seat, and a fuel header tank positioned above the passengers' legs. The carburetor receives fuel by gravity feed from the header tank.
Page 268 FUEL FILLER SYSTEM ..Provided with your Q2 kit is a small storage bottle. By cutting the ,neck from this bottle, the upper part can be used as the fuel cap. The storage bottle top is compatible with fiberglass/epoxy laminates.
Page 269 HEADER TANK CONSTRUCTION ..Previously, in Chapter 14, you have installed the main fuel tank permanently in the fuselage, along with the main fuel tank fuel gauge..The important fuel header tank dimensions are shown in the accompanying drawings. This fuel header tank is installed against the upper fuselage inside skin approximately 5 inches aft of the firewall.
Page 270 One BID on either side of the foam is used when assembling the header tank. The laminations that will 'see' gasoline, should be made slightly wet to minimize leakage. PAGE 17-1 Q2 Plans – Chapter 17 – Page 17-02...
Page 271 HEADER TANK PLUMBING ..Prior to permanent installation inside the fuselage, the plumbing for the header tank should be installed. The accompanying drawing shows the location for all header tank plumbing. The fuel feed to the engine should be patterned after the main fuel tank feed shown on Page 14-3, including the screen and flox, but omitting the drain valve.
Page 273 PAGE 17-2...
Page 274 Q2 Plans - Chapter 17 - Page 17-03 HEADER TANK INSTALLATION ..It is much easier to install the header tank prior to mounting the canard to the fuselage..Install the header tank using 2 BID and flox where it meets the inside fuselage skin.
Page 275 ..Included with this section is a schematic of the fuel system for your Q2. It is really quite simple..Both the squeeze bulb (backup fuel pump) and the fuel shutoff valve must be capable of being actuated by the pilot while seated in the cockpit.
Page 276 END OF CHAPTER PAGE 17-3...
Page 277: Instrument And Pitot-Static System Installation
Q2 Plans - Chapter 18 - Page 18-01 INSTRUMENT AND PITOT-STATIC INSTALLATION INSTRUMENT PANEL INSTALLATION ..An infinite variety of instrument panel configurations are possible. Since this area of the aircraft is such a popular focus for that 'custom' look, we have refrained from presenting any specific configurations beyond the pictures of our panel and a few suggestions.
Page 278 PITOT-STATIC SYSTEM INSTALLATION ..Begin by mounting the two Q2PS1 static ports on either side of the fuselage as shown. Use flox, being careful not to clog up the static hole. Two static ports are used in order to assure accurate readings during sideslip maneuvers.
Page 279 END OF CHAPTER PAGE 18-1...
Page 280: Electrical System
INTRODUCTION ..The schematic accompanying this chapter details the necessary wiring for the standard Q2 kit. Additional information is provided for wiring the more popular optional equipment items. A separate schematic details hooking up the magneto switches and tachometer..The panel ground bolt is simply a AN3-7A bolt located on the instrument panel that is used to connect all items that must be grounded.
Page 281 12 v, 18 AH battery..It is advisable to wait until a weight and balance has been performed (see the Q2 Pilot's Manual) prior to locating the battery, in order to use it as ballast to achieve the desired center of gravity range.
Page 282: Completing Your Q2
COMPLETING YOUR Q2 STREAMLINING YOUR Q2 ..A significant improvement in your Q2's aerodynamic cleanliness can be achieved by fabricating fillets and fairings for the major component intersections. A bit of artistic ability is necessary to develop a pleasing and efficient shape, but at this stage of the construction, you will be up to it.
Page 283 ..A fillet is also necessary between the inboard face of the wheel pant and the outboard end of the elevator. Set the elevator with the trailing edge approximately 4 degrees up. Use scrap foam and 1 BID to create a fillet similar to the one shown in the picture. ELEVATOR INBOARD FILLETS ..
Page 285 PAGE 20-1 Q2 Plans - Chapter 20 - Page 20-02 CANARD/FUSELAGE FAIRING ..At this point, their should be a noticeable and ugly gap under the fuselage where the canard and fuselage meet. A fairing should be made out of scrap foam and 1 BID similar to the picture.
Page 287 MAIN WING TIPS ..Now would also be a good time to carve wing tips on the main wing. If you wish, you may add up to 3 inches of foam to the wing span to facilitate a smooth looking wingtip. Keep it simple, however. VERTICAL FIN TIP ..
Page 289 PAGE 20-2 Q2 Plans - Chapter 20 - Page 20-03 CARBURETOR AIR INLET ..Cut a round hole in the lower cowling for the carburetor air inlet. Fabricate a round tube by laminating 4 BID around a bottle such that the tube will slip over the end of the alternate air source.
Page 290 CANOPY RETENTION ..It is advisable to have some form of restraint for an open canopy besides permitting it to rest on the main wing. Otherwise, in case of a strong wind, the canopy may be blown off of the aircraft..The illustration shows a simple shock cord arrangement.
Page 291 COCKPIT AIR VENTS ..A cockpit air vent on either side of the fuselage must be installed prior to first flight. A simple shape, and recommended location, is shown in the sketches..To exhaust the cockpit air, a hole could be cut in the tailcone, or else an exhaust vent could be cut in the aft top fuselage.
Page 292 PITCH TRIM SYSTEM TENSION ..While writing Section II of these plans, and building N81QA, we built a simple system to vary the tension, or drag, on the pitch trim wheel..Make a third TS-1 bearing from phenolic. Drill a 3/8" diameter hole as shown.
Page 293 Q2 Plans - Chapter 20 - Page 20-04 EXHAUST SYSTEM MOUNTING ..The exhaust pipe exits the cowling next to the cowl flap. In traveling from the cylinders to the exit, the exhaust system will enter and exit the baffling. These holes must be closed up to prevent air leaks, and consequent reduction in cooling.
Page 294 Q2 GEOMETRY ..On the following sheet is a three view of the Q2. On it has been indicated the important aerodynamic and geometric references. These have been expressed in terms of your old friends WL, BL, and FS.
Page 295 Congratulations on completing your very own Q2. PAGE 20-4...
Page 296 Q2 Plans - Chapter 20 - Page 20-05...
Page 298 PAGE 20-5 Document originally scan copied by Dan Yager. Formatted into MS Word and Adobe .pdf by QDF_Files To see embedded drawings and photos at higher resolutions view at 200% or more.

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