Course Work Assessment – Lab Report 1

Semester 202420 Division ETS

Assessment title in
Lab Report 1 Program AVT
Syllabus

Course Code AVT 4503

Course Title AIRCRAFT FLIGHT CONTROL AND STRUCTURES

Dr Warnakulasooriya
Course Instructor CRN 18413
Rodrigo
Submission
Assessment Weight 12.5% 26.02.2025
Date
Grades for the students in one group will vary based on the individual
performance in the additional assessment.

Student Declaration:
Academic Integrity Statement
In accordance with the HCT Academic Integrity Policy
• Students are required to refrain from all forms of academic integrity breaches as
defined and explained by HCT.
• A student found guilty of having committed acts of academic integrity breach(es) will
be subject to the relevant sanctions as outlined by HCT.
‫إفادة النزاهة األكاديمية‬
‫وفًقا لسياسة كليات التقنية العليا للنزاهة األكاديمية‬
‫ كما هو مبّين وموضح في السياسات واإلجراءات‬،‫• على الطلبة اإللتزام بلوائح وقواعد النزاهة األكاديمية‬
.‫الخاصة بكليات التقنية العليا‬
‫ سيتعرض الى العقوبات الموضحة‬،‫• في حالة ارتكاب الطالب أي شكل من أشكال اإلخالل بالنزاهة األكاديمية‬
.‫في السياسات ذات الصلة‬
This assignment is entirely my own work except where I have duly acknowledged other
sources in the text and listed those sources at the end of the assignment. I have not
previously submitted this work to the HCT, or any other entity. I understand that I may
be orally examined on my submission.
Student (s) Signature: NH

Student Name: Nouf hazza

Student HCT ID: H00472245

For Examiner’s Use Only

Section No. Task 1 Total %
Marks
50%
Allocated
Marks
Obtained

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Read the instructions carefully.
1. Pls upload the completed Lab report on or before 1200 midnight on
26.02.2025.

Task 1
Practical Test: Aircraft Control Cable Rigging with Flight
Control Rigging Practice Trainer
Objective:
To assess the students’ ability to rig aircraft control cables accurately and
ensure proper tension and alignment.
Materials Needed:

 Aircraft control cable rigging kit

 Tensiometer
 Cable cutters
 Swaging tool
 Turnbuckles
 Safety wire and pliers
 Rigging manual for the specific aircraft model
 Personal protective equipment (PPE)

Instructions:
1. Preparation:
o Review the trainer’s rigging manual and safety procedures.
o Ensure all tools and materials are available and in good
condition.
o Wear appropriate PPE.

2. Tensioning:
o Use the tensiometer to measure the initial tension of the
cables.
o Adjust the turnbuckles to achieve the specified tension.
o Recheck the tension after adjustments.

3. Alignment:
o Verify the alignment of the control surfaces.
o Ensure there is no slack or excessive tension in the cables.
o Check for smooth operation of the control surfaces.

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 4. Safety Wiring:
o Secure the turnbuckles with safety wire to prevent loosening.
o Ensure all connections are properly safety-wired.

5. Final Inspection:
o Conduct a thorough inspection of the rigged cables.
o Verify that all steps have been completed correctly.
o Document the rigging process and any observations.

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Instructions:
Write down the procedure in detail and attach photographs of the
process in all the following steps.

1. Preparation:

First, I got ready for this task by going reviewing the AS-70-3 Training Manual to follow
the correct procedure. I also made sure that all the required tools and materials were available
and in good condition. These included:

- Aircraft control cable rigging kit

- Tensiometer
- Cable cutters
- Swaging tool
- Turnbuckles
- Safety wire and pliers
- Rigging manual for the specific aircraft model
- Personal protective equipment (PPE)

I made sure to put on all required personal protective ( PPE) equipment before starting the
task.

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 WEAR PPE ALL TOOLS AVAILABLE FOLLOWING THE MANUAL

2. Tensioning:

I located an appropriate spot to place the tensiometer to measure the cable's initial tension.
Then, I adjusted the turnbuckles to reach the specified tension.

After adjusting the turnbuckles, I rechecked and measured the cable tension until it reached
the required 15 lbs.

ADJUSTING THE TURNBUCKLES REACHED THE RQUIRED 15 LBS

3. Alignment:

I checked the alignment of the control surfaces and made sure the cables had neither slack nor
excessive tension.

After verifying the alignment and tension, I checked the control surface to ensure it operated
smoothly for proper functionality.

4. Safety Wiring:

I secured the turnbuckle with a safety wire to prevent loosening , movement and vibration,
ensuring that all connections were properly safety wired.

I used a 0.040-inch wire with the single safety wire locking method, utilizing twisting pliers,
a cutter, and pliers.

SINGLE METHOD

5. Final Inspection:

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After completing the procedure, I conducted a final inspection of the rigged cables, verified
that all steps were performed correctly, and documented the rigging process along with any
observations.

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Task 2
Task Description: Removal & Installation of Ailerons and Flaps
Objective: To safely and efficiently remove and install the ailerons and
flaps on a Piper Cherokee aircraft, ensuring all components are properly
aligned and functional.
Scope: This task involves the preparation, removal, and installation of the
ailerons and flaps, followed by final checks to confirm proper operation.
The process includes disconnecting and reconnecting control linkages,
removing and securing hinge pins, and performing functional tests.
Safety Precautions:
 Ensure the aircraft is properly secured and powered down.
 Use appropriate personal protective equipment (PPE).
 Follow all safety guidelines as per the aircraft maintenance manual.
Required Tools and Equipment:
 List of necessary tools and equipment (e.g., screwdrivers, wrenches,
safety gear).
Documentation:
 Gather all necessary documents, including the aircraft maintenance
manual and any relevant service bulletins.
Steps:
1. Preparation: Assemble tools, equipment, and documentation.
2. Removal of Ailerons: Follow the step-by-step procedure to safely
remove the ailerons.
3. Installation of Ailerons: Follow the step-by-step procedure to
install the ailerons.
4. Removal of Flaps: Follow the step-by-step procedure to safely
remove the flaps.
5. Installation of Flaps: Follow the step-by-step procedure to install
the flaps.
6. Final Checks: Conduct thorough checks to ensure all components
are secure and functioning correctly.
Expected Outcome: The ailerons and flaps are correctly installed and
fully operational, with all safety and performance standards met.

Task Sheet: Removal & Installation of Ailerons and Flaps

1. Preparation
 Tools and Equipment:
 Protective gloves and goggles
1- Box ended wrenches
2- Combination wrenches

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 3- Pliers
4- Torque wrench
5- Socket wrench
6- Screwdrivers
7- Hammar 12 3 4 5 6
8- Screws 8 9
9- Screwdriver
10- Flathead screwdriver

 Documentation:
o Aircraft maintenance manual
o AMM reference manual – piper PA 28 AMM
o Page 1g17, 1g18 – ailerons 4-7 , flaps 4-10
o Figure 4-1

2. Removal of Ailerons

 Step 1: Detached the Control Rod

 Step 2: Removed the nut, washers, and bolt from the rod end
bearing at the aileron attachment point.
 Step 3: Removed the Aileron Hinges
 Step 4: Took out the screws and nuts securing the hinges at the aileron’s leading
edge.
 Step 5: Lowered the inboard end of the aileron and swing it forward to clear the
balance arm from the outboard rib

3. Installation of Ailerons

 Step 1: Moved the inboard end of the aileron forward to insert

the balance arm into the outboard rib opening
 Step 2: (If installing a new balance weight assembly, follow
modification instructions in Paragraph 4-75.)

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  Step 3: Positioned the aileron and secured it with screws and
nuts. Ensured it moves freely without interference.
 Step 4: Attached the control rod using a bolt, washers, and
nut.
 Step 5: Distributed the washers to ensure the aileron can
rotate freely without binding or rubbing on the aft spar
opening.
 Step 6: Ensured the rod end bearing has no side play and does
not touch the bracket sides when tightened
 Step 7: Operated the aileron controls to confirm smooth and
unrestricted movement.

4. Removal of Flaps
 Step 1: Fully extended the wing flaps.
 Step 2: Using an angle or offset screwdriver, we removed the bolt and bushing
from the rod end bearing.
 Step 3: Removed the nuts, washers, bushings, and hinge bolts that secure the flap
to the wing assembly.
 Step 4: Carefully pulled the flap straight back to detach it from the wing.

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5. Installation of Flaps
 Step 1: Placed the wing flap in its proper position on the wing.
 Step 2: Inserted the hinge bolts, bushings, washers, and nuts
to attach the flap to the wing.
 Step 3: With the flap control in the full-flap position, placed the
bushing on the outboard side of the rod end bearing.
 Step 4: Inserted and tightened the bolt to secure the control
rod.
 Step 5: Operated the flap several times to ensure it moves
freely and functions correctly.

6. Final Checks
Ailerons
- Check that all screws are in their place
- Check if the ailerons are moving smoothly
- Check then connectors

Flaps
- Check that its movable not fixed

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 - Check the connectors
- Check if it has corrosion

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