Front Foil Assembly

The Front Horizontal Foil Assembly (WZFFH84X) requires a few different processes when assembling it for the first time.

PRE-ASSEMBLY CHECK

CHECK THE LENGTH OF YOUR PUSHROD TO ENSURE IT IS NOT LOADING UP THE SYSTEM

• Make sure the pushrod is within +- 1mm of 17.5mm when the bell crank is pushed all the way back.
• NOTE: Unlike the older foils, the pushrod is not threaded into the horizontal.
• When the bellcrank is fully back against the plastic casing, the flap must be at maximum range. E.G. THERE MUST BE NO PRESSURE ON THE FLAP.
• This is CRITICAL: if the rod is too long, it will bend and break just below the top terminal, or push the rod through the foil flap.
• The bottom of the rod may be trimmed with a hacksaw if it is too long.



Note: With the Bell Crank pushed fully back, the push rod must extend 17.5mm from the bottom of the foil.

RE-ASSEMBLE THE PUSH ROD IF REQUIRED

APPLY LOCTITE 243 TO PUSHROD WHERE IT ENTERS THE TOP TERMINAL

• Use Loctite 243 when screwing the push rod into the top terminal before attaching the bell crank.
• This is critical because it can easily unscrew itself, making the rod longer and causing damage.

APPLY LOCTITE 263 TO TOP TERMINAL & BELLCRANK

• NOTE: The Bell crank is outside the foil only for photographic purposes.
• Use Loctite 263 High Strength (Red) if available. Otherwise, use 243 (Blue).
• Screw in the grub screw, leaving a few threads showing before applying the Loctite.
• DO NOT force the grub screw or you may damage the terminal. Sometimes it works to rotate the terminal 180deg (i.e. reverse the thread direction) if it is binding.
• Check the bell crank has a full range of movement.

ASSEMBLING THE FOILS

The foil bolt alone is not enough to hold the foils together. If there is any wobble in the foil joint, the bolt will eventually fail. Also, the socket will slowly get damaged. Hence the foils must be glued.

1 - CLEAN SOCKET

2 – CLEAN THE PLUG

3 - JOIN FOIL TOGETHER (USE A MALLET IF REQUIRED)

• This is to check that it fits together properly. Once satisfied with the fit you can detach them, ready to add epoxy.

4 – MIX TOGETHER EPOXY

• Use full-strength epoxy glue. (Don't worry, you will still be able to dismantle the foils)
• If using a thin epoxy (i.e. a laminating resin) you need to mix it with a glue powder such as fumed silica.
• Make sure the consistency is a little thicker than toothpaste (as below).

5 - APPLY EPOXY TO VERTICAL PLUG

• Paddle pop sticks work well to apply the epoxy. (cut the end square)
• Make sure epoxy is on all sides of the socket.
• When applying epoxy be careful NOT to add any on the flap cutaway of the vertical foil, as this can stick to the flap. (best to leave a 5-10 mm gap from the cutaway to ensure no epoxy gets in the hinge).
• Keep the epoxy away from the bolt hole.

6 – APPLY EPOXY TO THE CONNECTOR SOCKET

7 – JOIN FOILS TOGETHER

8 – REMOVE EXCESS EPOXY FROM BOLT HOLE

9 - LOCTITE FOIL JOINER BOLT & SCREW INTO THE FOILS

• Use Loctite 243 Medium Strength (Blue)
• Make sure you fully cover the thread to stop the epoxy adhering.

10 – REMOVE EXCESS EPOXY FROM THE FOIL JOIN

• Work from the back to the front to ensure no epoxy gets into the flap.
• Use Acetone and paper towel to remove excess again working from back to front

Allow to dry, and you are good to go!