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As well as fitting winglets, Al has a number of other modifications and simple improvements that can be done to the 'Mini' to help improve its performance. Details of these are given extensively below.
1. FLAP TORQUE TUBES...seal any way you like but try an
automobile CV boot with a hole roughly the size of the torque tube.
We're talking abut sealing that whole wing fuselage juncture.
2. Replace or fix up the CONTROL ROD SEALS on the wing
root. If factory sealing material is not available, consider large beach
balls, cutting off a foot or so below the neck and cut and paste it to your
satisfaction.
3. CANOPY FIT; When doing the fuselage, check the canopy
for exact fit. I used a filler in some places and a pneumatic sander in
others. Many older Minis have had the wind catch the canopy and the
hinges have been broken. This is a good time to really make it flush and
get the fit right. Once the canopy sill is gelcoated, the fit is
completely different as you might know.
4. CG TOST HOOK SEALING; When you have the seat and seat
back stuff out, check or replace all seals around the CG hook. That
includes the SS cable going forward . While you are there, check the
records to see if it has ever been replaced as required by the TOST folks.
At the minimum, blow out all the dirt and dust that accumulates. I had a
200 ft inadvertant release after takeoff just over the lake water at Jimmy
Stoia's field near Manning SC. It was dirt and dust in the mechanism
after I had refinished the fuselage. Yup I made a 180 and had to pull on
airbrakes to land downwind.
5. Install a PEE TUBE for long flights. If you're
up tight, you can't make right decisions X-C. One hole is drilled in the
seat pan behind the stick and one hole is drilled in the right rear of the
wheel well. Use hard somewhat hard,flexible tubing under the seat with
fittings for hospital/surgical tubing on both ends. Buy a soaring season
supply of Male External Catheters from any Medical Supply Store. Secure
the tubing with nylon ties once it goes on the starboard side (rear) of the
wheel well cover. The 90 degree fitting from the semi hard tubing is for
the actual drain tube which you secure to the right wheel door.
From the 90 degree fitting, it should go straight down as close to the bottom
edge of the door as possible. You too can sit in the cockpit on the grid
with the rest of them with a small towel over your crotch. Keeps the sun
off don't you know. You gotta figure out for yourself where you are
going to put the catheter on prior to take off. While in the general
gear well area, put a piece of mylar on one gear door for seal. Check
for fit.
6. I put on WINGLETS. I bought a reasonably priced
kit from M&H up in El Mira, Corning, NY area from Heinz. He
might still sell a kit which consists of two carbon fiber shells (with the
attach angle accurately cut at the factory), aircraft grade plywood rough cut
ribs, various hard to get fiberglass tubing and rods etc. He does not
sell the guts it takes to take a hand saw and cut your tips off just outboard
of the ailerons. Heinz walked me though the steps and it was basically
painless. Lots of filler and resin glue are needed. Mine had
ASW-20 airfoil shapes to the 'root' of the winglets so lots of filling and
sanding was required to get everything just right. Result: Aileron
response greatly improved plus an unknown LD increase but I think you have
read of the winglet reports by masak and johnson, etc. Reducing that
humongus low speed wing tip vortex swirl over the top of the wing tip (with
winglets) gets the air flowing the right way on the outer aileron and improves
lift. This translates to better L/D in the 40 to 55kt area based on all
winglet testing I have read. Most wings with winglets have benefit
crossover at about 80Kts. All my performance testing in my Mini has been
without winglets.
7. REAR VENT: The rear vent I installed relieves
the air pressure buildup from the nose vent that wants to go out into the wing
and exit over the control surfaces. With side vent closed,
ventilation could be better. The same wing root offending air comes in for
ventilation but most of it goes out the rear vent when modified. The
vent is a NACA vent or NASA Vent which is normally seen on commercial and
military aircraft. With the point going forward, it sucks air in.
With the point going aft, it has a reciprocal function and vents the air out
just ahead of the tail wheel you will want to put on. T. Knauff sells
the tail wheels. Do a careful CG measurement iaw the handbook
formulas. Required after major repair. I recommend 2/3 aft from
datum and not way aft as some like. I mention this as now is the time to
put 1/8 inch sheet lead around and above the tail wheel to get the CG in the
right place. I know, tail wheels are double stick glued on (to come off
under side loads) to prevent damage in a ground loop!!! Fill and smooth
around the lead when you have the CG in the 'ideal' location for you. (with
chute if you wear one). Again this requires a cut into the underfuselage,
which requires internal strengthening which requires hardware cloth chicken
wire type stuff to be fitted into place to keep the vermin etc, out.
Use the same surface refinishing that Applebay does. I would avoid
mixing different kinds of resurfacing materials. He can advise you on
how he actually does it I'm sure. Follow his advice.
After transition/checkout and depending on your experience, try
test flights with measured weight 1/8 in lead taped on with duct tape above
the tailwheel /skid. (IAW CG calculations). With CG too far aft, a quick
check is that the 1G stalls will fall off on either wing rather consistently.
With 2/3 aft CG, the nose will fall through slightly forward without the
drastic wing drops associated with the too far aft CG stalls. It also
means that with too far AFT cg, that spin entry is easier on those
cross-controlled final overshoots that none of us pilots ever do. BTW,
don't be jocking the airbrakes all around base and final with the Mini. +8deg
flaps on downwind along with gear opposite touchdown point, and then full
airbrakes as required on final to make a minimum energy landing. Don't
jocky the airbrakes. On calm wind takeoffs, follow the handbook
exactly.....aerotow or auto/winch.
I space my downwinds 45 degrees down toward touchdown while I
am on downwind. That's close in. Fly 55 kts in calm air around base
and final. As I said, I recommend full airbrakes to a min energy stick
in the gut touchdown. If you have been used to wheelin'' in your
landings, this will take some getting used to. Get an IP to help you out
if necessary. Some folks fight a bounced wheel landing and get
into PIOs. Learning to min energy land reduces that PIO stuff. Off
field landings are safest when you touchdown at min energy and stop in
the least amount of rollout.
8. CG ADJUSTMENT on TOP of the vertical stabilizer:
When you carry water, (I like about 4 or 5 gallons each side to get rid of
that cork in the ocean feeling on a strong day), the CG moves forward.
The area just below where the horizontal stab sits and on top of the vertical
stab, there is a small place for a small amount of sheet lead. Do your
comps on paper and figure out how much weight in addition to the tail wheel
weight, is needed up top to stay in a safe/ideal CG area. Trim and
secure the sheet lead with vertical bolts into the top 'rib'. When
dry, take the weight out. Schempp Hirth makes a very strong tail plus
that tail cone is filled with strong braces. The bird flys well at 2/3
or so aft of datum (LE at wing root). That's both running and climbing.
9. STATIC VENTS: Always use the under wing static
vents for the airspeed. Otherwise the factory CAL airspeed tables will
be off. The Altimeter statics are on either side of the instrument
panel. When the big TE boxes and fuselage venturies were in vogue, the
fuselage boom vents were also used. When finishing the fuselage,
protect these vents with 'headed' pins and/or tape to keep the dirt out.
The TE tube needs protection too of course. Just before putting in the
instrument panel, check all lines for leaks (pressure or suction) WITHOUT
instruments attached and vents taped over. When you are in the cockpit,
I suggest sprucing things up a bit and painting most everything Schempp Hirth
gray. I painted mine two tone gray and the seat covers a black and
white stripe which looks OK. On the inside sides of the fuselage, I
glued in a gray padded material that adds a bit to the cockpit. That
original factory interior was gaudy. I was always used to a shorter
control stick in the fighters I flew so I cut an inch off the top of the
Mini's stick and put the formfitting handgrip back on no problem. You
will probably have to fit a press to talk switch in the stick anyhow to talk
on the radio.
10. The wings will have full mylar and internal seals
replaced/installed. I like both internal cloth and external mylar seals.
The original factory wing gap cloth tape was terrible. I put the
large zig zag turbulator tape on the bottom of each wing full length at about
.70 chord. Others suggest .66 and some .75 chord. I have even heard
that none is required. I like .70 chord placement. Gluing metal vortex
generators at the top wing/ fuselage juncture cuts a big separation
bubble down to something manageable. Rubber cement some yarn tufts in
that area and have someone watch them stand up on end at low thermal
speeds.....that means a big separation bubble on top, near the fuselage.
Vortex generators at max chord height out to a foot and a half from
the fuselage help lay those yarn tufts straight aft. Fine tuning a 78
bird requires us to pay attention to every small air leak, every little bump
on the airfoil and wing root seals. When you have all the basic stuff
done, and you are comfortable with all the handbook instructions on the
critical take off and landing part of the operation, you will want to make a
700 foot (safe) high speed pass over the airfield with a couple of pilots on
the ground listening for whistles, rumbles, any noise whatsoever. Check
to see on a pull up if your gear doors open. If so, increase the spring
tension on each door. Any noise that the ground pilots hear is fixable. NOISE
translates to DRAG. No reason why a great bird like the Mini should not out climb
and outrun a good many other 15M newer birds when we pay attention to the
details. Many new birds are not sealed properly. Listen to them go
by on a contest finish. Some are really noisy.
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