FUSELAGE CONSTRUCTION REAM THE WELDING SCALE AND SHRINKAGE FROM. gear attach fittings (.250 x 6) xear aileron bellcrank mount (.1250 x 15/16 .3125) front aileron bellcrank mount (.1250) flap handle mount (.250) wing attach fittings (.313) flap bellcrank mount (1250) horizontal stabilizer mounting brackets (.188) starter rope pulley mouht (.250) door hinge holes (.188) strut attach fittings (.313) Cut, fit, trim, drill, cleco, bolt and temporarily install all parts that go into, and attach to the fuselage, in their proper position. Some parts will have to be installed, removed and re-installed several times before all parts are fitted in place. The fuselage construction procedures explain how to fit and Permanently install each part. After every part is temporarily fitted and installed and all systems are checked for proper function, disassemble the airplane. See drawings for all locations and tab identification. Deburr and clean all steel parts, i.e., fuselage, strut fittings, struts, landing gear, stabilizer, rudder, elevators, controls, etc. An ideal method of cleaning would be to sandblast or wipe with thinner such as acetone, lacquer or M.E.K. of pant degreaser. Round all tabs with a file or grinder. Remove all traces of . welding wire and scale. See drawings for tab identification. Cheek to ehowe all welds exe aompletely welded, After cleaning, apply two coats of epoxy primer to all steel parts in the kit, or use zinc chromate primer before spraying on epoxy. Builders located near salt water, or living in hot, humid climates can use this opportunity to improve the life of their aircraft by the application af zinc chromate. Some fuselages are open inside the landing gear fittings on the bottom longerons. Spray the interiors of the openings created by the weld with epoxy primer. Allow to dry. Fill-the«opening with structural adhesive. Allow to dry. Sand any roljjf’ areas. This process will close off the area and prevent moisture buildup and corrosion within the opening. NOTE: USE A LIGHT COLOR PRIMER FOR THE FIRST COAT AND A DARK COLOR PRIMER FOR THE SECOND COAT. BY USING TWO DIFFERENT COLORS, YOU WILL EASILY SEE ANY AREAS THAT HAVE BEEN MISSED IN EACH APPLICATION. Roll the fuselage several times in the course of spraying to be sure all surfaces are covered. Allow the primer to dry on the areas that the fabric will be glued to for at least a week. After the primer dries, and before assembly, ream any paint in the holes. The reason for priming first is to prevent rust and prevent the steel from bearing on aluminum parts, which can cause dissimilarmetal corrosion. After the airplane has been covered with fabric and all painting is done, the airplane-is ready-for FINAL ASSEMBLY. Refer to 4 the following fuselage construction procedures to be sure all parts are re-installed correctly and securely. LANDING GEAR NOTE: nose wheel fork trails to the rear when The main gear axles (LG-. threads on both ends. installed. Nose Main Gear Attach (Taildragger) Wheel a Fork ie 7 ‘Brake Mount, axle Gear Bole Mount: Holes at al Front Left Left Front View ©) View Side main Main Gear . : View Gear (Taildragger) Ream the main gear fuselage fittings (.250) Ream the main axle gear mounting holes (.750) 1) are provided in one piece with Cut the axle in half. If-axles are to be used only for the standard wheels, cut the axles to 7.75- 8.00 inghes. axle wij 4 a when it Th used f If you might later use tundra wheels, leave the axles long enough to use for either type of wheel. yes jhrough the axle ho’ the standard wheels. The long der a little further Sand the wheel end of the axles with emery paper. Bend the brake mounting bracket to fit parallel to the mounting bolt on the landing gear. See drawing on next page. Install the wheel on the axle with the spacer (LG-27) between the brake backing plate and the inner wheel bearing. (Place the wheel bushing (LG-6) in the tailwheel. Use the tailwheel axle bolt (ANG-21) to secure the tailwheel to the bracket. Attach the tailwheel steering springs (LG-18) to each side of the bracket and horn. See drawing INSTALL THE FLOORBOARDS, RUDDER PEDALS, AND CONTROL COLUMN Cut, fit, and trim the floorboards (F-24) to £it snugly into position in the bottom of the cockpit. Tape the boards together with masking tape and clamp them down with spring clamps. See drawing below. Floorboara Mount Tab Mount ‘Tab, BOTTOM VIEW OF FUSELAGE Back drill up through the tabs on the fuselage and through the floorboards. Bolt the control column housing (F-15) and the rudder pedals (F-32, F-52), into position. See RUDDER CONTROLS drawing and MOUNT THE CONTROL COLUMN drawing. The bolts will secure the floorboards into position. Install the starter pulley. See drawing below. Puselage = ands © priol Starter Rope Guide ”SG The brake backing plate m drum and shoes with 80 gr. ‘pBerone Note: bend ears on Brake anconniy before installation. wanda sre ade to'nateh Landing Sear when ingeal a shown. hole eheoust aa fe Pront view of Lett ‘Gearon Tal lareaiee Insert the axles tight in end of the axle outboard. When the axle is in its! drill the axle locking bo: about 3/8" from the inboa: axles in place with AN3-1. NOSE GEAR Center punch two places, gear tube on the fuselage the grooves on the outsid oe patie TMLIRO Ise gue lay need to be reamed. Scuff the brake it sandpaper. eer Builder artis nto fit, cot to the axle holders with the threaded Proper position in the axle holder, it hole horizontally through the tubing rd end of the axle holder. Lock the 2A, bolts. 5/16" up from the bottom of the nose + On Opposite sides to correspond with le Of the nose gear bushings (LG-5). This will lock the bushings in place. See drawing next page. Install. the upper bungee fork (LG-13). Ensure the bolt together. support (LG-19) on the nose gear bungee mount points forward and thenReam the nose wheel axle holes (.500). Polish the upper tube portion of the nose gear with 400-600 grit sandpaper until it is very smooth and shiny. The nose gear should slide up and down in the bushings freely. Mount the main tires on the wheels. Mount the nose wheel on the nose fork. Inflate the main tires to 15 lbs. and the nose wheel tire to 10 lbs. or full footprint with gross load. Bolt the assembled landing gear to the fuselage. See drawing below. Use the center arid forward gear attach brackets for the taildragger, and center and rear gear attach brackets for the tri-gear. Fuselage Bungees wrapped. Bungees. Twraps ea. sve; Left Main. (Taildragger Srey , Cable (eqsure cable will not aut bungee Gear Attachnent Rear View of y to" fuselage Main Gear s7* Loop one end of the bungee cord on the upper bungee support on “ the fuselage and wrap the bungee cord around the supports seven times - (you will have 7 wraps on the gear, 6 wraps on the support) Hook the remaining end of the cord around the upper bungee support. ¢ 2 13/165—aJe—1 5 on Jo$—LG-4 is 1/8" thick Neop: 218 Wich cones ina single sheet a3 shown. Bullder must cut Len4-1 6-4-2 as shown. Optignal: tubing of the right dimension also works well for this function. te-tel 164-2 Before final installation of the main landing gear, use some fine sandpaper or scotch-brite to remove the gloss from the fuselage and main landing gear in areas shown in drawing. Cut OF ahet on eet (uG-4) into four strips. Ensure pieces are free of dirt or grease before gluing. Use 3M super weather strip adhesive or equivalent. «Follow the instructions on the adhesive fouglue the neoprene stops in place. Wrap filament tape tightly around the neoprene to hold it in place until the adhesive cures. Make certain the seam is butted together and glued as tightly as possible. Fuselage’ Section B-B Fuselage tube with stop ine = : stalled. Note seam ontop. Right Main eft Main Landing Gear Landing Gear ee ‘tube with stop installed. Note bottom, opersticic. Cot seme 4h.Note: on the tri-gear, the neoprene piece (LG 4-2) is not long enough to cover the full circumference of the tube on the fuselage. With the gap on the top of the tube, use the same procedure as above. ‘rim the edges with a sharp knife after the adhesive cures, so that the bungees do not catch on the neoprene. At FINAL ASSEMBLY (before flying), install the gear limit safety cables. See drawing below. Make up two cables 19.5" long with a loop nicopressed in each end to loop over the bungee supports. Measure and allow for full bungee deflection before nicopressing the cable ends in a lodp. Bungee deflection should be 3 inches. eq }+-—-19.s»—+]rusotage tubes! Section B-B: Safety Cable Bungee Aeech Note: large rubber bands safety cabies in shes foaltlost TAIL WHEEL ASSEMBLY Fit the tube of the tailwheel spring horn (LG-29) into the bottom of the main spar tube of the rudder. Drill a hole just above the rudder hinge all the way through the rudder spar and spring horn tubes. Bolt the spring horn to the rudder. See drawing below. — x, f Sapulded ove later models. Beets ape been ANS*ITA —raxiwnool~- Steering Springs builder @riiie hole through vA ‘allvheet Spring Polyethelene searing Bolt the tailwheel spring (LG-17) to the fuselage. Bolt the tailwheel bracket (LG-28) to the tailwheel spring with a piece of polyethelene bearing material (supplied in kit) between the 3-9 two parts.3/0 INSTALL THE FIREWALL ANSTALL THE FIREWALL See INSTALL THE FIREWALL in the “engine installation" section for firewall and cowling instructions. FIT AND INSTALL COwLING EET AND INSTALL COWLING NOTE: THE GAS TANK, COWLING AND WINDSHIELD SHOULD BE FITTED AT THE SAME TIME. See WINDSHIELD INSTALLATION and FUEL TANK INSTALLATION instructions and drawings. The Cowling (E-12) is fitted with engine and spinner installed. it is split down the center and can be removed without removing the propeller. ‘The two cowling halves are joined together by two aluminum channels (E-9, E-10). along the top and bottom of the center of the cowling. Butt the cowling halves together 2nd center them along the two aluminum channels, top (E-10) ana bottom (E-9). The left side of the cowling is rivered to the channels. Camlocks are used to secure the right side of the cowling to the channels. See drawing below. ~ Puol Flier Hole cantock — Aluminum Rivet Channel (e=10) canto enon ~ (9) Camtock iver, ‘NOSE VIEW OF INTAKE HOLE IN PROWT OF cowLING {he Catburetors are on the right side of the engine. ‘This is the side that will be first accessible when one half of the cowling is removed. Position and clamp the top (E-10) and bottom (R-9) cowling channels onto the LEFT side cowling. The edge of the cowling runs down the center line of the channels. Drill #30 holes and use 1/8" clecos to secure the cowling to the channels,” see drawing for rivet and camlock hole spacing. oNPosition the left cowling on the fuselage using a cleco in the lower rear mounting tab. Drill through the fuselage mounting tabs from within, up through the cowling. Establish a 1/8" ~ 3/16" gap between the cowling and the fuel tank, for the windshield to slip into. Any gaps remaining can be sealed with weatherstripping on either side of the windshield after FINAL ASSEMBLY. Butt the right cowling edge up to the left cowling edge, at the center of the aluminum channels. ‘ape the center cowling joints together with masking tape. Lay out the camlock hole spacing on the right half of the cowling. See drawing below for spacing and camlock receptacle installation. top View of Cowling W Botton View of coving Nalves Fitted at Sean ‘Halves Fitted at Sean Drill and cleco the right .cowling into position. NOTE: POSITION THE TOP FRONT OF THE COWLING SLIGHTLY HIGHER THAN THE SPINNER (APPROX. 39 INCH), CENTERED DIRECTLY ABOVE THE CRANKSHAFT AND THE SPINNER. Rivet the left side cowling to the aluminum channel with 1/8" monell or aluminum pop rivets. Install camlock receptacles on the channels, both top and bottom. Install camlock studs to the right side cowling along top and bottom of the split line at FINAL ASSEMBLY. ‘The same procedure is used on the cowling and the turtledeck. attach camlocks to the cowling halves at the fuselage mount locations. Attach camlock receptacles to the fuselage mount tabs. Cut out the fuel filler neck hole in the cowling at the location already scribed on the cowling for you. + CAMLOCK INSTALLATION A camlock consists of three parts. A camlock receptacle which is attached to the mounting tabs, and a camlock stud and a retaining washer to be attached to the top connecting part. The camlock stud is secured to the part with the retaining washer. The camlock receptacle is secured to the mount tab 3-// *Eshbl numerous reforance posits accurately.H2 using two 3/32" driven rivets. A spring in the camlock stud releases the camlock stud as it is compressed and turned out of the lock in the receptacle. See drawing below. = C 3/32" Countersunk @—Spring \briven Rivets }+—cowling rab on Retaining camlock Fuselage Washer : J»_camlock Receptacle Note: ,camlocks come in various sizes (lengths) and the correct Size (4, 5: etc.) is determined by the ‘thickness of the sertects peing fastened together. The canlock screw should be snug thon fastened in place. ATTACH CAMLOCK RECEPTACLES FOR THE TURTLEDECK AND COWLING Position the camlock receptacles to the inside of the fuselage tabs. Drill 3/32" holes through the receptacle mount holes and the fuselage mount tabs. This is done to center and position ¢ the receptacles on the fuselage tabs. Do Not attach the receptacles (. to the tabs at this time. See drawing below for tab locations. TURTLEDECK "TABS _ TURTLEDECK TABS (Side View of Fuselage) (Top View of Fuselage) Ream the locking holes in the fuselage tabs with a letter F bit and enlarge to .257". Reposition the receptacles on the fuselage tabs, Rivet the camlock receptacles to the fuselage tabs with 3/32" aluminum countersink driven rivets. Using the tip of a larger drill bit, ream the sheet metal lip I that protrudes into the receptacle openings. The camlock stud should be able to pass freely in and out of the receptacle with= out catching on the edge of the sheet metal.ATTACH CAMLOCK STUDS TO THE TURTLEDECK AND COWLING MOCK STUDS TO THE TURTLEDECK AND COWLING After locating and drilling the holes for the camlock studs, Fenove the part from the fuselage and drill through the 1/8" _ holes with a letter F bit and enlarge the holes to 1257", NOTE: THE COLLAR ON THE STUD IS FINISHED, AND SHOULD Not BE PERMANENTLY ATTACHED UNTIL THE PART IT IS BEING ATTACHED TO IS PAINTED. DO NOT ATTACH THE RETAINING WASHER TO THE STUD DURING PRELIMINARY FITTINGS. ONCE THE RETAINING WASHER IS PLACED ON THE STUD, THE STUD WILL BE PERMANENTLY SECURED TO THE PART. PERMANENTLY SECURED CUT AND FIT THE WINDSHIELD COT AND FIT THE WINDSHIELD Attach the sheet metal windshield support angles (FC-2, PC~3) to the front and rear carry through spar. See drawing below. Seaton Sie Note: place a straight edge ey cee uerenl of butt ribs. Bottom surface of straight y edge represents inside sur- face of windshield. Move the windshield attach flange up against straight edge and sues rae install, See Windshield In- cir mn Stallation drawings. Measure and cut the windshield from the Lexan sheeting using tin snips. It should be large enough to fit between the cowling and the instrument panel, up over the front carry through spar and FC-2 angle and continue back over the butt ribs (F-36) and cen- ter rib (r-35) to the rear carry through spar and FC-3 angle. Leave approximately 3/4" spare material all around the perimeter. Leave the protective paper on the lexan during the above fabri- cation. See drawing below. Rivet f—Windshtexa jpindeniera Windshieta piasecomene ao Rivet net Spacer: : ae ‘ountersum a fea Attach__” Turtiedeck Countersunk front carry Flange in _— covtingt / thin ‘Theough Tube Rear Carry Foam Strip ‘Through Tube aqLine up the edge of the Lexan sheeting with the edge of the sheet metal angle (FC-3) on the rear carry through spar. Clamp to hold in position. Bring the Lexan sheeting over the top of the fuselage to the sheet metal angle (FC-2) on the front carry through spar. Clamp to hold in position. Peel back the protective paper just enough to expose the areas to be riveted, and to expose the butt ribs and center rib. Drill and cleco the Lexan sheeting to the two butt ribs. Space the holes evenly on 2” centers, in a straight line along the top of the rib capstrips. Drill and cleco the Lexan sheeting to the capstrip of the center’ rib. Stagger the holes evenly down each side of the center rib capstrip. See drawing below. ‘Top curve of Windshteté: center: nib Jing Ena ‘of Center Rib Windchieta actac Flange. on Front carey through Tube cows tetton sige of > visited PE oe comen ae anna ‘OF RINDSHTELD Rivets (2" ap) ~ Insert the aluminum spacer (FC-28) between the Lexan and the ear windshield support angle (FC-3). This leaves a space for the turtledeck to slip into. Drill and cleco'the Lexan to the sheet metal angles on the front and rear carry through spars using 2" centers. Bring the lexan windshield down the face of the fuselage, providing a gentle bend, and position the base of the Lexan between the instrument panel and the cowling. An optional relief of the out- side edge of the Lexan where it will be covered by the wing-to- windshield fairing will help preciu on. See windshield drawing. Clamp the Lexan to the face of the fuselage. Drill through the fuselage mount tabs, out through the Lexan. Position the aluminum’. fairing brackets (FC-4) against the door posts and over the Lexan. ‘Trim the Lexan around the wing mounting post and 1/8" beyond the center curve of the door post. Drill through the tabs, the Lexan, and through the aluminum fairing brackets and cleco. . ssFe'* Trim the excess Lexan along the outside edge of the butt ribs. NOTE: REMOVE THE WINDSHIELD BEFORE COVERING THE AIRPLANE WITH FABRIC. REPLACE THE WINDSHIELD AFTER PAINTING, AND RIVET INTO POSITION AT THAT TIME. (eb Blank The center rib rivets to the front sheét metal angle and carry through spar, ‘and the rear sheet metal angle. FIT, INSTALL, AND ADJUST RUDDER AND ELEVATOR CONTROLS See RUDDER and ELEVATOR instructions. ELEVATOR CONTROLS Cut the elevator, stabilizer, vertical fin, rudder and rudder cable guide bearings from the nylon stock (T-1, F-13) provided in your kit. Install the bearings.-See drawings. rmcut to length from nylon tube, by builder. Note: bolts hold bearings 7 | —. in place after Ya \ 7 assembly. ‘uopen enue curpes Zz hehe Te Cut begfing material long 54 about 1/4" ks out each side “ef bushing. SuEVaTOR_s_srapnureER Bolt the elevators (1-3) to the stabilizer (1-5). Bolt the stabilizer and stabilizer struts (1-2) to the fuselage. See drawing below. Stabilizer —, : Elevator —t . j oe Stabilizer Struts Bolts oriented to Inboard Fuselage Strut: Attach Bushings (2) ‘ear attachment is same) Temporarily install the control column. see control column installation in CONTROL SYSTEM AND LINKAGE sectigas Pull the control sticks (F-16) completely back to the front 2 9 edge of the seat tube and temporarily tie in place.w Thread rod end (F-40) on the forward end of the elevator push/pull tube and-.- clevis rod end (F-43) on the sft ong of fhe elevator push/pyll tube. Bolt the elevator Push/pull tube fo the elevator control horn and the control column hone Block ghe elevator up 30° before connecting the push/pull tube. See drawing below. 3/4" to 1" hole ev by builder to acce End (F-40) Elevator Push/Pull. ‘Tube AN3Ne-Hh ANS ‘levis Rod End (P=43) : <— Forward Tube of Elevator Check the operation of the elevator and adjust the rod ends, if rete ectY: for proper elevator travel, 30° up and 17° down.’ See pote on witness holes under AILERON LINKAGE section of manual> tren the adjustment is set, run the check nuts up snug against the rod ends. Tighten the clevis forked end first. Line up on the aft end, then torque the check nut on the forward ond of the push tube. . _ SPECIAL NOTE: WITH THE STABILIZER, ELEVATOR AND PUSH, BULL TUBE IN THEIR PROPER POSITION BULL THE-CORTHOE STICK ALL THE WAY BACK. MARK THE EDGE OF THE sige WHERE HE TUBE STOPS AGRINST THE GUIDES. PUSH THE STICK FOR™ HARD. MARK THE EDGE OF THE TUBE WHERE THE TUBE STOPS AGAINST THE GUIDES. “MASK OFF THE AREA OF THE TUDE WHERE 22 SLIDES THROUGH THE GUIDES. WHEN YOU ARE READY TO DISASSEMBLE TO PRIME ALL STEEL PARTS, PRIME SiS pUSe— LAGE WITH THE PUSH/PULL TUBE IN THE FUSELAGE. THE MASKED OFF AREA IS NOT TO BE PAINTED. OEE AREA IS NOT TO BE PAINTED.For push/pull tube guide bushings, use a 1.125" hole saw to cut four (4) bushings from the polyethelene stock (F-34A). Press into guides with a C-clamp, excess material will shave off. Using care not to distort the guides, peen the ends of the guides to secure the bushings. Drill .5469" dia. holes thru the bushings and insert push/pull tube from the front. escated shoves ‘nlovetse™ PiMn/pUld tbe precinetal ied, RUDDER CONTROLS Bolt the rudder on using AN3 bolts. See drawing below for rudder installation. rose AN +22 Bolt, 4 bearing should lager alruady be Installed tn’ bushinges Construct the rudder pedal bearing mounts f: Soaeeee relies is 8 from aluminum angle (F+3), Hon conven: i - i Yj 105 —-| MATLE Wet Yet y Oe . ALUM, ANGLE t | Hetwoue bs Fae "requires RUDDER PEDAL BEARING HoUNT 319Bolt the rudder pedal bearing mounts to the bearings (F-50) in the rudder pedal torque tubes. Position the rudder~pedals ( gn the floorboards and bolt into position with AN screws. 7 See drawing below. Rudder Pedai ANSI0-103287 Rudder peda, TT ans ‘Topae bet = ‘orgque Tube ae aa yP—nuader Pedat pearing (P50) fodder Pedat '+—nadder Pedal Bearing Hount Torque Tube tt tt ‘Attach Fleeing Construct the rudder cables using the 3/32" aircraft: cable (e712), cable bushings (F-9), and nicopress sleeves (P-45) Provided in the kit. See drawing below. Bolt the rudder cable bushings (F-9) to the rudder Pedals. Thread the cable through the cable guides, determine tne correct length for the cables and install the cable bushings and nico- eee se reeves to the end of the cables. Bolt these ends te the rudder horns. Ensure the nylon bearings (F-13) are in the cable guides. See drawings below. Rudder spring Oe ‘Agjustnent Links Sleeve (45) / oat eh Coie cate G\ uader 2 Canis 3-2 bushingAttach the rudder cables to the rudder horns with the two rudder cable adjustment links (F-44) between the rudder cable and the rudder horn. ‘Tie the cable ends in with safety wire at the bolts to ensure the cable does not come loose. See drawing below. ou 8E WHY MATL: ov 4130 ‘STeGL SuEeT au Note: builder may make mero modifications to these links to meet necessary Yorn Gorn Enos) RUOOER CAwLe ADSUSTMENT Link (4 REQ) dength requirements. NOTE: RUDDER CABLE EXIT - CAREFULLY MEASURE AND NOTE EXIT LOCA- TION WHERE CABLE WILL COME OUT THROUGH FABRIC. EXTT AREA SHOULD BE REINFORCED WITH REINFORCING FABRIC TAPE DURING COVERING. Install the rudder return springs (F-46) in the cockpit so the rudder pedals do not fall back against the floor. Adjust the links (F-44) to change the position of the rudder pedals. Check the operation of the rudder. Adjust the cable controls to provide 25° rudder travel, left and right. See drawing below. CONTROL SYSTEM AND LINKAGE Note: before beginning, study the parts list and the assembly diagrams thoroughly. THE PLAP AND AILERON CONTROLS ARE ASSEMBLED TO WORK IN CONJUNCTION OFF THE MAIN FLAPERON BELLCRANK-SYS- TEM. "See the diagram on next page. 3-2/BRR Ream the following: (see parts list for identification) rear aileron bellcrank pivot-bushing ~(.250) ——— forward aileron bellcrank pushrod attach holes (.188) xear aileron bellcrank/flaperon bellcrank attach holes (.250) rear aileron bellcrank pivot bushings (.313) flap handle pushrod attach holes (.188) flap bellcrank pushrod holes (.188) flaperon bellcrank mounting holes (.1250) flap handle pivot mounting holes (.250) flaperon bellicrank ends (.188) MOUNT THE CONTROL COLUMN Construct the right control column bearing support using 1/8" x 1" aluminum angle (FC-3). See drawing below. HA" DIA ALL comers: Wow determined bi ey Is— | fy" ——+| MATL: VI" He" ee ee ALUM. ANGLE (1 required) Ream the control stick lower pivot socket bushings (F-17) to .250 and cut the stick pivot socket in half. Push the control stick tubes (F-16) into the control stick pivot sockets until they seat against the stop. Drill through the stick pivot socket into the control stick tube after the control, stick is positioned comfortably. Bolt the stick pivot socket and control stick together. See drawings below. control ‘Stlok (P-16) cut Here: ean Bushings to. -250 ans-2A Sontzol Stick Lover Pivot socket (#-17) aeitie and bolte’ ew tegetnorsConnect the lower control stick pivot socket bushings, the connecting link rod (F-18) and the rod ends (F-38, P-39) together inside the control column housing (F-15). See drawing below. P16 (BuLder bends to aust) Pie 1 oman —s ra . ANS 1a i-ida ic=ofloo / r AU3-7A Pele MB OO) a ry Sree | " ‘ 8-2 C=-Ofr iz. fe Bolt the stick pivot sockets to the control column housing. Position the two wooden half bearings (F-11) for the control column housing together. Back drill through the fuselage bearing mount tabs, through the floorboards and up 1/4" into the bottom of the lower half bearing. CAUTION: center the block on the drill holes before drilling 1/4" into the bearing block. Use a 3/16" drill bit. Start the holes in the bottom of the lower bearing, put both bearings together with the control column housing between them, clamp into a vise in the drill press and finish drilling the two holes into the two bearing halves. This will ensure a straight drill line through the bearings. Round off the upper edges of the bearing and bolt the control column to the floorboards using the wooden bearing and the aluminum angle support (F-3). ‘Ang-27 Note: bolts through thé bearings, floorboards . poste i032? Tp etd oxi) Floorboara wooden tare A2/as-1.00" wore, created by seeinen te-11) teat crac PS both sides at each — cowmot. coxa Hosta ft S23FRY ASSEMBLE THE AILERON LINKAGE Bolt the main aileron pivot arm (F-1)-to the main bellcrank pivot bushing on the fuselage. See drawing below. Main Bellcrank. Pivot Bushing Level and block the main aileron pivot arm. Keep it blocked as you finish assembling the connecting linkage for the aileron and flap controls. a Bolt the front aileron bellcrank (F-5) and the aft aileron bellerank (F-6) to the fuselage mounts. See drawing below. . ae Fer tor ees Xho dee maak / J ‘Being cat > “ ‘Ges yjpen sm alle Front Aileron Bellcrank ‘Attach Fitting SBOTION: BB. * - SECTION A-A Roar Aileron Af pelicrank attach Attach the universal joint (F-47) to the forward end of the front aileron bellcrank. Connect the universal joint to the rod end coming out of the left end of the control column housing. Attach the rod end (P-40) on the forward end of the aileron push/pull tube (F-19) to the front aileron bellcrank (F-5) and the aft end of the aileron push/pull tube to the aft aileron bellerank (F-6). See drawings next page.Finish the connection between the aft aileron bellcrank and the main aileron pivot arm by connecting male (F-39) and female (F-38) xod ends together and connecting the rod ends to the aft aileron bellcrank and the main aileron pivot arm, (F-1 to F-38, F-6 to F-39). This will create a small push rod. ADJUST THE AILERON LINKAGE Clamp the control sticks (F-16) in vertical postion, left and xight, fore and aft. Left Blank Adjust the rod ends coming out the left end of the control column until the angle of the joint between the aileron push/pull tube and the front aileron bellerank is 90°, NOTE: some rod ends have a witness hole in the threading end. When adjusting the rod ends on any of the push/pull tubes, take care to note the thread position through the witness hole for each end of the rod. ‘By doing this you will ensure that the thread is equal on both ends. Adjust the connecting rod end of the aileron push/pull tube until the angle of the joint between the aft aileron bellcrank (F-6) and the small push rod between the aft bellcrank and the main aileron pivot arm is 90°. Adjust the small push rod between fhe ate aileron bellcrank and the main aileron pivot arm (P-1) is level. ASSEMBLE FLAP CONTROL LINKAGE insert a friction washer (P-54) between the washer on the fuselage and the washer on the flap handle. Use a piece of leather or a piece of 1/8" micarta or fiberboard. Bolt in the flap control handle (F-30). Tighten the bolt to the desired friction. See drawing next page. Bolt the flap bellcrank (F-8) to the mounting tabs on the fuselage. Attach a rod end (F-40) to the flap push/pull tube (F-10). Attach the rod end of the flap push/pull tube to the flap control handle 3-2 (P=30) . .S%o Bolt the aft end of the flap push/pull tube to the long end of the flap bellerank (F-8). Adjust the length of the flap push/pull tube at the rod end (F-40) \ next to the flap control handle. See drawing below. Aster FLAP_ASSEMALY Bolt the individual flaperon bellcranks (F-7) at their pivot point to the main aileron pivot arm (F-1). See drawing. Assemble the flap bellcrank pushrods-(P-38, F-37, P-38). ca can Apsetts antcsa : ec "aniy-33 [ore foteyatel”! Sescers d 7 Aloo! oO Oo puttaer @ Lnnsce, —S Pabricstes Gy a Attach the flap bellcrank pushrods to the short end of the flap bellcrank (P-8) and the inside ends of the individual flaperon bellcranks (F-7). Keep the main aileron pivot arm blocked level. ASSEMBLE FLAPERON CONTROL LINKAGE, ¢ Construct four flaperon vertical swiveling control tube universal joint blocks from 1/2" x 1/2" aluminum bar (F-2). See drawing.Connect the swivel ends (F-51) to the upper end of the flaperon vertical swiveling control tubes (F-21). Insert two washers between the swivel end and the control tube. See drawing below. f u-soints "fq Ans-10 (e-2) Plaperon ne Plaperon ey rc ae [torn Control Hora Peau. Pe21 Attach a universal joint to each of the flaperon swivel ends (F-51) on the vertical control tubes (P-21). ‘The lower part of the U-joint connects to the top of the swivel end. Bolt the upper Part of the u-joint to the flaperon control horn. See drawing. ¢ F-21— { Q. bsitser—| = er juve ® Po oo Fabricaces @. uinder (P-2) —— 2 I<—— r-21 Fabricates (2) Bolt a u-joint on each of the lower ends of the flaperon vertical control tubes. Bolt one end of the u-joints to the outside ends of the individual flaperon bellcranks. See drawing. above. SRIand ER.ADJUST THE FLAPERON CONTROLS Keep the main aileron pivot arm (F-1) blocked level. hevel tle aiweratt. With the flap control handle down (handle parallel to the floor), the flaps should be all the way in the up position. Adjust the main flap bellcrank pushrods between the flap bellcrank (F-8) and the individual flaperon bellcranks (F-7) until both flaps are level. Slowly swing the wings back toward the fuselage. As the wing swings toward the fuselage, the flaperon trailing edge should rotate up. Proceed slowly and adjust the linkage (see below note), if necessary, so the flaperon will rotate up into a vertical position, parallel against the vertical fin. NOTE: BEGIN ADJUSTMENTS WITH THE MAIN FLAP BELLCRANK PUSHRODS, (F-38, P-37, F-38). Refer to the note on witness holes under AILERON LINKAGE. If further adjustments are necessary, try the following options. 1. If the flaperon does not rotate enough, pull the flap handle up slightly until the flap is in postion. Remember to watch the wing for clearance as it swings. 2, If the flaperon does not rotate enough, increase the length of the vertical swiveling tube (F-21) by adding washers between the swivel end and the vertical tube (F-21). 3. If the flaperon rotates more than 90°, shorten the vertical control tubes by removing a washer, NOTE: ALWAYS BEGIN ADJUSTMENTS WITH THE MAIN FLAP BELLCRANK PUSHRODS. Minor adjustments can then be made to the flap push/pull tube. If these two adjust- ments are not enough, only then should you proceed with the three options listed above. THE MAIN AILERON PIVOT ARM MUST REMAIN LEVEL with THE Fuse LaGe. ADIUST THE FLAPERONS NOTE: THE RIGHT WING TWIST IS FIXED AND CANNOT BE ALTERED. THE LEFT WING HAS AN ADJUSTABLE ROD END ON THE STRUT SUPPORT WHICH CAN BE USED FOR MINOR ADJUST- MENTS. With the stick in the center and the flap setting at zero degrees, jevel the right wing‘by laying a level under the wing from the bottom of the front spar to the bottom of the trailing edge, just inboard of thé center rib. Lift the tail of the aircraft until the reading is level. Block the tail to keep the plane in position. NOTE: BECAUSE OF THE TWIST OF THE WINGS, ALL READINGS AND ADJUSTMENTS MUST BE MADE AT THE CENTER RIBS OF THE WINGS, When the reading is level, adjust the flaperon until the bottom 2°?3-30 of the flaperon is parallel with the straight edge of the level. Left Blank When the flaperons are set, adjust the travel 0° to 154°. SPECIAL NOTE: INSTALLING THE FLAPERON CONTROL HORN BEARINGS (FC-47) Because the procedure for installing the control horn bearing to the fuselage and turtle deck is of VITAL IMPORTANCE to the safe flight of your airplane, PLEASE REVIEW the following portions of your builders manua. Drawings showing camlock receptacle on fuselage and flaperon control horn. Drawing showing flaperon bearing mounting. Drawing showing flaperon control horn exit from fuselage. Manual sections: CAMLOCKS, ATTACH CAMLOCK RECEPTACLES, and ATTACH CAMLOCK STUDS. Manual sections: FIT and INSTALL TURTLE DECK COVER, and ATTACH ALUMINUM BEARINGS (FC-47) . READ THIS ENTIRE SPECIAL NOTE SECTION BEFORE PROCEEDING TO INSTALL BEARINGS!!! Parts Supplied: lea. 2" x 4", .090,°2024 T3 aluminum plate with 5/8" hole drilled in center. 2ea. 2" x 2", .090, aluminum plate. 16 ea. Ss42Fs 1/8" x 1/8", pop rivets. The large piece of aluminum plate with the hole drilled must be cut in half across the center of the hole. This will leave you of with (2) 2" x 2" notched plates to be used as top bearings. ¢ Do not INSTALL the top bearing until the bottom bearing has beén installed. See drawing next page for construction of the bottom bearing.3-3) FLAPERON CONTROL HORN BEARINGS (FC-47) Se turtte peck. a ae = sarin | | pstoppy rit — 7 . control x 2x1 5 Lx2x 12 T——— torn] ‘top Meage Bearing—o} O ° \*boara Rich Peariney | snug rit O° oO control control. iorn —>| Horn Tube Non Botton Bearing ‘Camlock position when under tension. Plange-| Longeron, Tube —y Note: bottom bearing is shaped by builder. Exact shape is determined by camlock location. Ensure maximum contact between bearing material and the Flaperon Control Horn Tube. NO SLOP? fo_install the bottom bearing, extend the wing and pin it in place. All control linkages should be in place. Put the bearing Plate between the flanges of the camlock receptacles and place the notch up against the control horn tube. Mark the tube where the bearing will touch the tube when in position and remove all paint and epoxy in that area. Again, place the bearing plate in position. The bottom bearing must put a small amount of preload on the flaperon control horn tube. To create the preload, simply force the bearing plate up against the tube, raising it approx. 1/64". Clamp the bearing in this position. From the bearing side, drill four (4) 1/8 holes as shown in the above drawing. These holes should be drilled no closer than 5/16" in from the edge of the bearing. it is best to drill one hole and Cleco, then the next hole is drilled directly across from it, and Clecoed. Then drill the remaining two holes. Deburr the holes and pop rivet the bearing in place. Zo make the top bearings, enlarge the notch in the bearing to fit the Control Horn Tube after the paint has been removed. fo install the top bearings, predrill.the 2" x 2" notched bearing Plates, as shown in the drawing above. Deburr the holes. With the wing and Control Linkage in place, put one of the turtle deck halves in place and lock down the camlocks.Place a board (1" x 2" x approx. 12") inside the turtle deck at the 90° bend above the longeron. Wedge another small board between the longeron and the-long board. (The-purpose is to place ¢ a small amount of upward loading on the turtledeck camlocks) . Put the top bearing in place, pushing it down against the control horn tube. Hold the bearing in this position and back drill one hole into the turtle deck. Cleco in place. Hold the bearing down again, and back drill another hole in the diagonal corner of the plate and Cleco in place. Complete the back drilling of the other two holes. Remove the boards and remove the turtle deck. Pop rivet the bearing in place. If you have done the installation of the bearings properly, it will require a_small amount of downward pressure on the turtle deck to lock the camlocks in place. You should not have any play at the bearing. NOTE: some builders have found it advantageous to make a tapered ramp of structural adhesive on the Control Horn Tube. Do not coat where it rides in the bearing. See drawing below. Top Bearing» ||¢—Turtle Deck roe Control Horn ( === U ' [} sss Bottom ————-p} iF Loam of, Structural Bearing Adhesive SPECIAL NOTE: FLAPERON CONTROL LINKAGE PLAY - INSTALLING THE 5 _ BELLCRANK, 1 Special care must be taken when assembling the control linkage to eliminate potential freeplay (slop). Please review the following portion of your construction manual. Drawing showing: INSTALL/CONTROL COLUMN Drawing showing: CONTROL SYSTEM and LINKAGE Special Emphasis on control linkage play: 1. Ream all bolt holes with a reamer - NO DRILLS!2. Make certain the control column housing bracket is bolted securely to the fuselage: 3. Make certain all parts (such as F-47) are bolted tightly to the eye of all rod ends. 4. Make certain the control linkage castle nuts are not tight. Not loose, either. Snug, while maintaining easy and smooth control movement. 5. Do not allow excessive slack to build up in the control linkage. “ADJUST CASTLE NUTS WIEN THEY NEED T Left Blank: ADJUST THE FLAPERONS (continued from page 3-27) ADIUST THE FLAPERONS (continued from page 3-27). Without moving the airplane, after adjusting flaperon travel at 0° to 15°, locate the level under the center rib of the left wing. Adjust the rod end (W-19) until the reading under the left wing is the same as under the right wing. Set the left flaperon parallel with the wing and adjust the travel. FIT AND INSTALL TURTLEDECK COVER EXT AND INSTALL TURTLEDECK COVER See CAMLOCKS. The two turtledeck parts (FC-35, FC-36) have 90° bends on the 3-333-34 outside edges. The right turtledeck half will have another 90° bend on the inside edge. The left turtledeck half will lap over this bend. With the wings and flaperons installed on the airplane, center the sides of the turtledeck fore and aft. Cut the openings in See the turtledeck halves for the flaperon control horns. drawing below. FC039A,B.C—y Note: weatherstripping may be glued to underside of turtledeck for soundproofing. Place a small strip between FC-39 and right turtledeck e half to create snug fit. ¢—totton seabing inside Attaching Flange <— cut out by bulider YIEW PROM REAR - LEFT stoE TURELE DECK With the wings and flaperons installed on the airplane, center the turtledeck halves fore and aft along the flap cutout. Clamp into position. Back drill 1/8" holes through the tabs on the fuselage. Start at the back corners and work forward. Cleco with 1/8" clecos. Lay the 43" aluminum stiffener (FC-39) along the edge of the left side against the inside bend of the right turtledeck half. Drill, cleco, glue and rivet the stiffener angle to the left turtledeck half. Add the 6 aluminum stiffener angles (FC-39A, B, C) at the ends and in the middle on the underside of the two turtledeck sides at 90° angles to center line with adhesive and rivets. See CAMLOCKS. Lay out the camlock hole spacing on the turtledeck where the two parts will overlap. Drill and cleco 1/8" holes... 1+ ATTACH BEARINGS (FC-47) 0 THE TURTLEDECK AND FUSELAGE FOR THE FLAPERON CONTROL HORN Locate the bearings (FC-47) above the openings for the flaperon control horns. Cut the bearings in two pieces. Trim out the half bearings so the horn fits snugly and drill and cleco thebearings into position. Remove. Deburr. Rivet into position on the turtledeck cover and the fuselage tabs. Refer back to previous instructions frequently during this installation. NOTE: THE FLAPERON CONTROL HORN IS TRAPPED BETWEEN THE BEARING HALVES. THE BEARING SUPPORTS SHOULD NOT ALLOW THE HORN TO MOVE UP OR DOWN. A SNUG BEARING FIT WILL BE A GOOD PRECAUTION AGAINST FLUTTER, EXT WILL BE A GOOD PRECAUTION AGAINST FLUTTER. APPACH PAIRINGS TO THE TURTLEDECK COVER APPACH FAIRINGS TO THE TURTLEDECK COVER After the airplane is fabric covered and just before the paint is applied, attach the wings to the fuselage. Position and align the top surface of the turtledeck fairing sides (FC-37, 38) and the turtledeck to create a cover for the gap between the root rib of the wing and the fuselage. Rivet the fairings to the turtledeck along the small flange on the fairings. A spring effect will be created because of the curve of the fuselage. Trim the outside corners of the fairings to flow smoothly back ina curve to the edge of the turtledeck and to fit smoothly just beyond the outboard edge of the rib capstrip on the root rib. Round off all corners of the sheetmetal. See drawing below, and finish and cover section of manual. Rivets on 2" Centers: Sate, Trailing Edge—* of Windshield Note: turtledeck-to-wing fairing may be attached with camlocks as shown wing in drawing, to facilitate easy change from speedwing to standard high lift wing. /*——Turtle Deck, EIT AND INSTALL DOOR, SHEET METAL COVERING AND WINDOWS 17H Dock INSTALLED ON FUSELAG: Ream the hinges on the door and the fuselage. Position the door frame up to the fuselage and conform the door frame to the opening. Pit the sheet metal sections (FC-10) against the door frame. Extend the edges of the sheet metal 1/8" beyond the curve of the fuselage tubing, to overlap adiectut Pusclane tubes. See drawings pg 3-36. Clamp the sheet metal to the door frame and lay out the rivet = hole spacing. Drill through the sheet metal into the tubing, 3°35 Cleco the sheet metal to the door frame as you go-Fit the Lexan (FC-25) against the door frame. Extend the Lexan on the upper part of the door frame the same as the sheet metal. Overlap the Lexan onto the sheet metal that covers the-center cross tube of the door. Extend the Lexan 3/8" below the center cross tube. Peel back the edges of the protective paper «and lay out the rivet hole spacing on the Lexan. Drill through the Lexan, sheet metal, and tubing of the center cross tube. Cleco as you go. See drawing below. aN wrFront Spar ~~ Note: builder must determine FC-6 locations on doorframe and underside of front spar and rivet in place. nN After the sheet metal is painted, rivet the sheet metal and Lexan to the door frame tubing using 1/8" aluminum pop rivets. Secure the sheet metal and Lexan to the center cross tube with single rivets going through all three layers. Some builders may prefer a one-piece Lexan door covering instead of sheet metal. This is an option. FIT AND INSTALL SHEET METAL COVERS BELLY SKIN Shape the belly skin (FC-8) to fit onto the fuselage belly in two pieces for the tri-gear. The one piece belly skin (FC-9) is for the taildragger version of, the aircraft. Postion the belly skin up to the fuselage BEFORE THE FLOOR- BOARDS ARE ON. Mark the belly skin on each side of the bottom Tongerons so you will know where the center of the tubes are. Lay out the rivet spacing pattern for the holes in the belly skin on 6" centers. Clamp the sheet metal belly skin up against the fuselage and drill 3/32" holes through the tubing. Cleco with 3/32" clecos. Final securing of the belly skin will be done with sheet metal screws after the fabric covering and painting are complete. See drawing next page.BELLY SKIN INSTALLATION Note: belly skin extends from just in front of landing gear to overlap bottom of firewall. Builder may cover belly with fabric, under the bellyskin, at his option: this requires extra fabric, or splicing of leftover pieces. 3-37Bolt the wing lock back braces (F-48) to the fuselage-brackets 5 at the front of the vertical fin. Bend up 2 small pieces of c steel 3" x 3h-4" for a holder for the other end of the wing lock back braces to lay in when the braces are folded back against the fuselage. Attach the holders tothe fuselage. Be sure the bend in the holder holds the wing lock back braces securely. See drawing below. $5 vivet or ‘Sheetnetal Screw into. be fi>tratiing of Vertical Stabilizer INSTALL SEAT SLING, SEAT CUSHION AND CURTAIN (After fabric and painting) Lace the seat sling in with nylon seat lacing cord using an overcast lacing. Put a SAE }" zinc washer on each end of the aluminum seat tie-back tube (FC-5) and flange the tube ends so the washer will stay on. Run the aluminum tube through the casing in the seat sling. Tie the aluminum tube to the fuselage with seat lacing cord from the middle of the aluminum tube and the two ends of the tube. Set the seat cushion in place. Glue Yelero strips to the fuselage tubing around the perimiter above the seat cushion. Use contact cement. The velcro on the curtain will attach to these velcro strips. - 4 Wrap front of #1 SECTION B-BINSTALL SEAT BELTS AND SHOULDER HARNESSES Bolt the seat belt and shoulder harness to the tabs on the four corners of the fuselage with 3/16" bolts, large area washers, and bushings. After disassembling the airplane prior to fabric covering, tape the bolts in place on the fuselage tabs. Otherwise, it will be difficult getting them through the attach tabs after the fabric is on the fuselage. See drawing below. Section : : SECTION A-A INSTALL SOUND INSULATION FOAM Cut and fit foam to the inside of the lower section of the doors and to the inside surface of the firewall and lower front cockpit. Glue in place with contact cement. Sound insulation foam is an option, but is very worthwhile. INSTALL SIDE/BELLY STRINGERS 7 Note: Stringers are dob model) Nokes to fuselage tubing and glued in place. Install 5/8" wooden block at the location shown in drawing, between the stringer and tubing, to provide even curve in stringer. _ Safety wire stringers together at tail post, and glue in place. Gusset at leading end of belly stringer is formed by builder. 5-39BUILD AND INSTALL THE PIReWALL vs AUILD AND INSTALL HE PrRéwaLD ‘tarter rope hole to be drilled during trial fitting of engine. Right side view © =} Front View Showin Riveting around fox The firewall is made of either 2 or 3‘ pieceg of ‘galvanized sheet metal, depending upon your fuselage, number.” The parts are labeled F°25 and P-25A. The main firewall is made up of either one or two pieces of precut, prebent sheetmetal, with a smaller piece provided for use by the builder in forming a sitall box in the center of the firewall to provide clearance for the rear of the engine. Study the firewall drawings thoroughly until comfortable with the size, shape, and location of all firewall parts. Construction is a step-by-step process, starting with the building of the box into. the middle. Aluminum rivets are used, approximately 14" centered. Determine the center of the bottom firewall piece, at the bend line near the top. Make two cuts from the top edge to the second bend line, as indicated in the drawings above. This will form a flap which will be 6" wide, 4 3/8" deep, and have a 3/4" angle at the back. Use the small piece of sheetmetal supplied as part of the firewall to form a piece with dimensions as shown below. ‘This piece will be used as the back and sides of the box you are building into the center of the firewall. 16 4__, + k—— 6" , F ‘$—4¢—1 * ming the above piece, bend at the dotted lines so that flaps can be used to rivet around the box. ‘The top two side flaps fold out, the bottom two fold in. study the drawing. If you received a one-piece firewall, you will have to make an additional 6" cut across the top location of the box area, in order to create a flap for the bottom part of the box construction.The firewall goes down the front face of the fuselage to the £o0x( boards and folds back at the bottom edge. With the two piece, ; the top overlaps the bottom as shown in the drawing below. Fuselage vPirewall Engine Mount aNd=25 (4) ‘aNa~33_(2) Washers (6) Castlenuts (6) Cotter Pins (6) _ Teetiyskin With either the one-piece or two-piece firewall, correct height is achieved by aligning the first bend from the top, with the bottom edge of the fuselage cross tube which supports the bottom four holes in the engine mounting configuration. After the firewall is assembled, place it in position (centered and aligned) against the fuselage and backdrill the mounting holes through the engine mount. Drill your starter rope hole after trial fitting the engine. Place the engine mount in position as shown above, and attach it in place using the AN hardware shown, sandwiching the firewall between the fuselage and engine mount. Note: when placing rivets in the two-piece firewall, and building the engine clearance box into the Firewall, make certain clearance is allowed for drilling your mountin: bolt-holes, and for drilling the starter fepe Hote te che firewall. When the cowling is installed, trim off any firewall that rubs or wears against the inside of the fiberglass. Reach up inside the cowling and scribe along the firewall with a pencil. This will show the highs and lows. Trim the firewall to provide a uniform C clearance to a tight tolerance. At final assembly, apply sound absorbing foam insulation to the cockpit side of the firewall using contact cement. Allow the foam to extend slightly beyond the edge of the firewall to seal the area between the firewall and the cowling.MOUNT THE ENGINE Bolt (Lonm x 70mm = '.053 to .062 drilled head) Washer (AN970-7) Rubber (Neoprene, 2 1/8 dia 5/8 thick, 1/24 dia hole) Assenblea Conponents Installed in ‘the Engine * Mount Rubber (Neoprene 1 3/8 dia Ld X°5/8 thick, 1/2" dia hole) fushing (4130 steel, 1136" x 1/2", ,058 wan) kubbur (Neoprene 21/8 dia 5/8 thick, 1/2" dia hole) 0 0 O= (0 0 Washer (ANY70=7) Cut neoprene washers for the engine mounts per the specifications shown in the above drawing. Prepare the engine for mounting per instructions contained in the Rotax engine manual. Ensure you turn the engine on its' side to remove air from the oil, the water pump, and rotary valve gear Sain - MoNITOR-ENGINE TEMPERATURE VERY CLOSELY DURING INITIAL RUN IN. AIR REMOVAL.FROM ALL SYSTEMS IS CRITICAL!!! SES TEMS 18 CRITICAL EE Bolt the engine to the engine mount, noting that the engine is mounted upside down. a The recoil starter housing must be rotated clockwise so that the Xope guide lines up directly above the starter pulley, which should be attached to the pulley mounting bushing on the fuselage. AT THIS POINT IN CONSTRUCTION, determine the precise location of the hole which will allow the starter rope to pass through the fire- wall, and drill the hole. Use a small length of hose to act as a bushing through the firewall, to protect the starter rope from abrasion. | Glue or silicone the bushing in place through the fire= wall. Remove the bolts that hold the starter in place and rotate the starter until the rope aligns correctly with the pulley. Redrill the housing and install it on the fan housing. Remove the knot in the handle end of the starter rope, then remove the handle and feed the rope through the firewall bushing and around the pulley and through the guide tubing. Replace the handle and check to ensure the rope makes a direct line from the rope guide around the pulley, Misalignment’may cause the rope to jump off the pulley during use. Thread safety wire through the en: gine mount bolt heads, twist the wire several times and secure. Tighten the bolts and then sealVent tube—, Rear Spar. Puet Outiet Neade: Tank Rudder cable Quierarain—/” the ‘safety wire around the bolt heads by applying a generous coat Of silicone sealer to reduce wire vibration. INSTALL THE FUEL sysTey and HEADER TANK C Piller cap Primer + ‘Tabs On : ef Fuselage Throttie Mount. Bushinga Fuel Line to shuts. Off on Instrument Panei 8 NOTE: ENSURE THE FUEL SYSTEM IS WELL REMOVED FROM THE EXHAUST. Mount the fuel system per the above drawings and the following item- by-item instructions: pestall a quickdrain in the rear outlet of the wing tank. This is best accomplished after the wing is fabric covered. Install the fuel line outiet (elbow) in the forward outlet, oriented to focate, drill tabs, and attach the header tank. it is attached to two large tabs which extend inboard immediately behind the cockpit on the passenger side of the fuselage. The header tank fabs should go on the forward side of the fuselage tabs with an Place 2 Of approximately 4" (just enough to be sturdily attached). seeee a otratgnt edge under the fuselage, below the header tanks decating the header tank bottom surface approximately 1/16" shove Where the fabric will be.when the kit is covered. This wi11 allow the quickdrain in the bottom of the header tank to be easily accessibie, : Rocate the fuel outiet on the side of the header tank and install an ,oibow oriented forward and slightly downward. Using 1/4" ID fuel line, measure and cut to follow along the bottom airframe tubing forward to the front edge of the floorboard, then up and across until reaching the tube upon which the throttle mount bushings are welded. The line should then follow the underside of this tube rearvard until it turns up to the location of the Fuel Shutoff. The Fuel Shutoff is mounted an tho Testens-~* Instrument ovterarain—t Fuel tank Fone ues y Shutore ater ¢va Panel at a location determined by the kit builder. Locate all fuel lines close to fuselage tubing wherever practical and attach to available tubing using plastic clips at regular intervals. Leaving the fuel shutoff, the fuel line runs to a "Tee" and separates with one line going to the fuel pump and the other going to the "In" side of the Primer. The primer is mounted on the instrument panel at a location determined by the builder. The Puel Pump should be mourited on the engine mount as shown in the drawings on previous page. Run a single 1/8" ID line from the "Out" side of the Primer to a "Tee". Single lines run from this tee to individual primer installations on each carburetor. See drawings. Two fuel lines run from the fuel pump to the carburetors, with a filter installed in each line as shown in drawings on previous page. Ensure filters are installed as shown, on "pressure" side of the fuel pump. The fuel pump is activated by a single line which runs from the side of the engine to the underside of the pump. Vent the Header Tank by running a 1/4" ID section of hose from the remaining outlet in the top of the header tank, to a section of aluminum vent tubing installed in the Butt Rib. Use the same basic installation and attaching procedures as used for the installation of the pitot tube. After final finish, bend the vent tube to the rear and downward. See drawings previous page. With the Header Tank mounted as far inside the fuselage as poss- ible, there will still be a tendency for the right rudder cable to rub on the tank. A section of plastic tubing should be installed on the rudder cable at this location to prevent wear. NOTE: if fuel tanks are installed in both wings, a "Tee" can be placed in the fuel line between the right wing tank and the header tank. NOTE: some early Header Tanks have the fuel outlet located app- roximately 180 degrees around the tank from the location shown in drawings on previous page. Fuel line routing remains the same. RELOCATE ROTARY VALVE RESERVOIR See page 4-12 drawing for relocating. INSTALL AND ADJUST THROTTLE CONTROL CABLES ANSTALL AND ADJUST THROTTLE CONTROL CABLES The throttle control is two cables that run from a push tube to the carburetors. See the drawing on next page.+6 When the throttle knob is when the knob is Lock Throeeie P/?. off and flight. To adjust the throttle, pull the throttle knob back. aa bushed forward, the throttle opens; pulled back, the throttle closes. it_is important that the throttle linkage be adjusted at the car- buretors so both will open and close in unison. need to be adjusted from time to time after flights. is rubber mounted to cut down vibration, The linkage will ‘The engine and it moves during take- Before it reaches stop, when it could still move back 1/8", adjust the link- age so the carburetors are at the idle stop. forward. reaches it's limit. Push the throttle Adjust the linkage to wide open, 1/8" before the throttle These adjustments allow engine movement without fluctuation in the throttle settings; however, during your first few hours of operation, you will want to check regularly, and readjust until a stable setting is found. INSTALL THE PRIMER ON THE CARBURETORS A primer is installed by attaching a push-pull valve on the instru- ment panel and running 1/8" ID clear primer line from a "T" in the fuel line to the valve. and split off to a 1/8" fittin: the builder. residue from drillin primer lines. Note: fitting Lecation is shown in drawing. A hole is drilled into the carb- urctor on tha shoulder area behind the air filter flange, with aictitter removed. Either a straight-in or 7 A 1/8" line is then run to another "T" angied hole may be drilled. Measurements shown are approximate to ald the builder in Locating the Fitting. g installed in each carburetor by Drill into carburetors as shown in the drawing below. The holes should be sized to provide a good press fit. jets inside the carburetors. install the fitting and seal with structural adhesive. Ensure no After drilling, Attach the 1/8" ID Primer Line 0 Fitting must be cut ie cut Here {4 Chokes are also available, and should be instailed for extremely cold weather operations, to aid smooth engine start-up. 5/32" Hole Into Carburetor by bullder, to allow fuel to pass through ¢ 1 C)GEAR REDUCTION MOUNTING Turn the gear reduction unit upside down and install it on the engine in accordance with the instructions in the Rotax engine manual. The plugs must be switched to place the vented plug in the top of the unit, and the drain plug in the bottom. Modify the vented plug as shown below. here 1/16" hole | Note: the builder modifies the vented ‘plug by cutting the vent tube off as indicated above, right. Drill a 1/4" hole down through the vent plug. Slide ‘the 1/4" x 2" aluminum tubing in placé’ and secure with structural adhesive. Crimp both ends, leaving a small gap for air flow. Drill a 1/16" hole at the crimp shoulder as shown. Install in gearbox. PROPELLER INSTALLATION Check the balance of the propeller before attaching it to the airplane. This is accomplished by inserting a l-inch shaft into the center of the propeller. and laying the shaft across two level yubes. Balance the blade horizontally, and perform this procedure indoors so that moving air does not disturb the balance. zf the blade is heavy on one side or the other, sand the heavy end to remove any imperfections. Revarnish. If the propeller is out of balance just a small amount, add a little paint to the tip of the propeller. add the paint to the tip one layer at a time until Propeller is balanced. Check to determine if the propeller balances vertically by rotating the propeller to a vertical position and then watching for a shift to either side. If the propeller shifts, you may either remove material from the outside of the hub, or may add material by inserting a small screw, etc., into the hub. 4-7 “NOTE: NEVER STORE THE PROPELLER ON END. THE MOISTURE WITHIN “THE WOOD WILL SETTLE TO ONE END. STORE IN THE HORIZONTAL POSITION AND TORN IT OVER OCCASIONALLY- RORTONTAL POSITION AND TURN IT OVER OCCASIONALLY4-9 Bolt the fiberglass spinner bulkhead, the propeller, and the large + aluminum washer to the propeller flange on the gear reduction ante. enstail AN washers on the propeller bolts. ‘Tighten the bolts untii they are snug, but not too tight. Spinner Bulkhead wea ‘Large Aluminum Washer aN Flange fhe down position. Position the stick so that the tip of the propelle: just clears the end of the stick. ‘Turn the propeller and check to Seoure the blade ends fall in the same position in relation to the ena of the stick each time. If the tip passes too far forward, tighten the two bolts which will move it back.. Make minor adjustments on thi bolts until the propeller is in track, within 1/8" ona uecden Propelle NOTE: DO NOT EXCEED THE RECOMMENDED TORQUE ON THE BOLTS. (4-6 ft. lbs., 50-70 in. lbs.) sr onaghtening the bolts does not provide proper tracking for the Propeller, medium weight paper shims may be used under theybolts as necessary. propeller When the propeller is in track and the bolts are torqued, safety wire the bolts... 5 NOTE: CHECK THE TRACK OF THE PROPELLER AGAIN AFTER YOU FIRST RUN THE ENGINE, AND CHECK IT AT REGULAR INTERVALS APTER THE AIRCRAFT IS OPERATIONAL. Sik out the propeller spinner and position the spinner on the fiber- glass spinner bulkhead with the rear edges flush. Clamp, and drill i/a" oles through the spinner and bulkhead and install’ ticses* ren ready, silicone between the spinner and propeller and trowel smooth using your finger. Let dry overnight. See drawing next page for spinner installation.SPINNER INSTALLATION ®, aa44uF (Large Flange Aluminum Rivets) ‘Spaced 1" apart all the way around Silicone Around Prop after installed, trowel smooth and clean with your finger. L Propeller cutout Carefully cut inside dotted line, a small amount at a time, and trim to fit individual propeller as you go. about 1/16" final clearance is desired. The propeller cutouts are to be made by the builder, and must be spaced 180° apart. This is a Sample Drawing and is no to_scale. Do some accurate measur a, before cuthrg, anything.4-10 INSTRUMENT PANEL AND WIRING INSTRUMENT PANEL AND WIRING We yeconmend removing the coil from the engine and placing dt on the firewall in a convenient location. The most common cause of coil failure is engine heat and vibration. Cut new sparkplug leads sufficiently long to fit between the coil and spark plugs, leaving sufficient slack to compensate for engine vibration. Tt is recommended that you protect the entire length of wire with heat shrink tubing. Locate all wiring so that insulation does not require addit- jonal holes and cutting, i.e. close to engine mount and fuselage tubing. Use plastic tie wraps or tape to hold the wiring bundles next to fuselage tubes. Prior to painting your instrument panel, locate your instru- Bones and drill a small pilot hole. The method of establishing a centerline and referencing to all locations from this centerline works best to ensure the panel will appear properly balanced when completed. hocate the holes for your lord mounts on the facing portion of the, instrument panel first, keeping in mind the need for a 1/8" standoff as shown in the drawing below. N= toca mounts O*™ Tirottie Ho1e NOTE: OUR EXPERIENCE HAS BEEN THAT IT TAKES AN AV- ERAGE OF TWO INSTRUMENT PANELS PER BUILDER. TAKE ae YOUR TIME!! THINK ABOUT Throttle Mount Bushing IT BEFORE YOU bo ites biker establishing the location of the rubber shock mounts on the face of the instrument panel, drill holes centered at the correct location, checking the 1/8" standoff one last time. Place the instrument panel in position and’ check the measure- ents of the relief area where it fits around the fuselage Gubes at the windshield and bottom of the instrument panel. Gradually remove the necessary material to get a good fit. _Back drill the instrument mounting screw holes (very carefully) and install the instruments in the panel. Wire according to the wiring diagrams provided with the instruments. See the Rotax Owners Manual for a schematic on how to run dual ground and ignition wires. Before you actually make any holes in your instrument panel: MAKE A PATTERN OF YOUR LAYOUT AND TRY IT OUT. SEE HOW IT LOOKS! LEFT BLANK “iELECTRICAL WIRING Yellow w/stripe Green w/stripe ey Bot Gauge Yellow Sender © y Brown ya). tac mater Temp. relly igne : wack a = aed (Black) 150 Bae eae a a ‘accetscries (Red) Gonition Gone Gioae hago aueee Ror nor “Aggelecor Sender Sender Note: two runs of 4 wires = @ wires. Ident. x runs. un 1 brown wire = 1 wire. e kee elle See exhaust syste drawing for locational instructions on EG? probes. NOTE: 12 18 RECOMMENDED THAT THE BUILDER RELOCATE THE COIL TO A ERRYENEENT LOCATION ON THE FIREWALL. THE PRIMARY CAUSE OF COTE FAILURE IS ENGINE HEAT AND -VIBRATIOI SASURE US ENGINE HEAT AND VIBRATION. RELOCATE ROTARY VALVE RESERVOIR to Lower Engine Outlet Builder fabricates a mounting bracket similar to drawing above, and rivets to firewall at a convenient location. Longer oil lines may need to be fabricated and attached as shown in drawing, with line from center of reservoir to Lower outle on the inverted engine, and line from outside edge of reservoir going to Upper outiet on inverted engine. See drawing. HRV-13 BUILD AND INSTALL RADIATOR MOUNT The radiator mount consists of parts listed below, with part B-43A being the basic mount and other parts forming a slot at top and ( bottom which the radiator slides into from the front. The width of slots should be 2", full length, to fit radiator snugly after the weatherstrip padding is applied. Firewall: Attaching Tab" Weatherstripping ‘o+-\camtock Holes . (pre-drillea) Rear View of : Assembly a wv Firewall Weatherstrip Part 6-430 The top mount slot is formed by riveting parts E-43B and E-43E together and then riveting to part B-43A using reference measure- ments of 3 3/4" and 3/8" at locations shown in the drawing above. All riveting during construction of this mount is aluminum rivets. The bottom mount slot is formed by riveting parts E-43C and E-43E (there are two E-43E parts, which are simply }"xs" angle) together and then riveting to part E-43A using reference measurement of 15/8" at lower left corner of assembly. Slip the radiator in place to get snug fit and to get exact location of bottom slot. Use a small piece of left-over metal to form the tab used to attach the lower right corner of the assembly to the firewall. Rivet in place after pressing assembly snuggly against the firewall. The upper right corner of the assembly is attached to the firewall by bending the tab around onto the front surface of the firewall and riveting.The rear edge and bottom of the radiator mount assembly is attache to the fuselage using camlock positions which already exist on the | / fuselage. The camlock holes are predrilled in part E-43A. When both the upper and lower mounting slots are attached to Part E-43A, attach part E-43D to the rear to prevent the radiator from sliding out the back. Part E-43D must be cut and shaped by the builder, to create tabs at the top and bottom which are used to rivet it in place. Slide the radiator in place and check the fit before making final rivet attachments. When placing rivets in the ¥ x } angle (E-43z), to form the top and bottom slots, rivet from the outside surface in, So that the rivet ends will not scratch the fiberglass air scoop when it is installed over the radiator. Attach weather stripping inside the radiator mount slots, to serve as padding around the radiator, and to seal around the rear of the Fadiator to prevent air loss between the radiator and the fiberglass Scoop. Place a strip on each side surface of the slot, and a strip down the bottom for the radiator to rest on. An additional piece of weatherstripping is placed at the inside trailing end of the fiberglass air scoop to seal between it and the radiator. See the drawings for the air scoop for location. Use structural adhesive to hold weather stripping in place. Complete final assembly of radiator mount by riveting as shown in drawings. INSTALL THE COOLING SYSTEM Note: builder must paint the radiator. Use ONLY radiator quality paint. firewall and shielded with ‘silicone. Note: after radiator is mounted, the remainder of the cooling C system is installed as per above drawings. Just like you were putting new hoses in your car.INSTALL THE RADIATOR SCOOP Make a rough cutout in the right side cowling using the above drawing for dimensions. The starting reference point for all measurements is the center of the camlock shown on the drawing. Rivet part E-43F to front edge of rough cutout to deflect air past front of radiator. Determine location and fit by placing in position after radiator is installed, and cowling is placed in normal position. See location in above drawing. 13/8 x 3/4 weatherstrip| {|} at inside 1 Trial fit the air scoop over the radiator (cowling installed on aircraft), and mark location of edges of scoop and visually align for best appearance. Attach scoop to cowling by locating camlocks approximately 5/8" out from bend radius at approximate locations shown, in above drawing. Above dimensions:ido. not need- to be exactly as shown, and precise location of camlocks is not critical. Drawings are not to scale. Note; make certain your locating of camlocks does not hit YAS tubing or other portions of the structuriEXHAUST SYSTEM AN3-4 Boll Theeuat Right Side View Builder cuts block INSTALL EXHAUST SYSTEM inte equal SNSTALL EXHAUST SYSTEM . : _- pieces. ( The exhaust system is installed in a simple, straight-forward manner. Attach the 4130 welded steel ‘ube mount to the éngine utilizing existing bolt locations as shown in the above drawings. ° pest y2/26" holes at locations shown above for inserting EGT probes into exhaust system. Attach by using metal bands around exhaust, The three sections of the exhaust (muffler, coupler, manifold) all Elontegether in an obvious manner and are held in the proper rela~ tionship by springs. The pre-formed and welded bands which encircle the muffler are attached to the exhaust mount using rubber blocks at locations shown in above drawings. Sandwich each end of the rubber block between the mount and the tab provided,¥after drilling holes in the rubber blocks, and insert AN3-6 bolts with castle nuts and cotter keys. ‘The builder can use a vise to grip the rubber block fo thé metal tab while drilling, and a hot welding rod to ream the hole in the rubber after drilling. This will aid in the Passing of the bolt through the hole during installation. Note: the exhaust system and mounts are highly stressed during Qperation due to high temperatures and will occasionally crack. Zhey should be subjected to routine pre-flight check on a very Fegular basi *Absolutely precise location of EGT probes is not critical. The © attaching bands will effect exact location. lg “18 Very hot He vod works best for'deitiig” holes,Optional ELECTRIC STARTER Installation - Avid Flyer 0? ‘ut a round hole in the fire- wall, providing approx. 1" clearance around starter. A rubber grommet should be in- stalled to provide firewall seal ‘New piece of bent 1/2" tubing provided from factory, is welded vin place as shown. Cut old tube ovt and discard. Ensure the clearance is sufficient to pre- clude the starter motor from chaffing on the tubing, Fuel Selector Mounting Bracket must be moved down sufficientiy that starter motor will clear. It may be heated using an acety- lene torch to dull red, and bent down, or the tubes may be cut and rewelded at a lower point. A notch must be cut in the rear of the engine casing at center, bottom, rear, exactly 180 degrees from the presently existing notch. Cut to the same dimensions as the existing notch, making absolutely certain no metal shavings get inside the mag. neto housing. See sketch belo Fatima oan: “Tor VIEW OF rue Mux Hew == ENGINE, FKOM Ci oectniet — LEET RE, —— a ELA ‘The battery should be mounted immed- behind the seat on the fuselage tub- ing, secur astened. Rotax recom- mends a minimum 16 amp battery (of the small motorcycle type). The builder should adhere to wiring instructions pro- vided with the Rotax elec- tric starter. Recommended battery mount would be constructed of light sheet metal, by tailder. EN HEIGHT AND BALANCE CALCULATIONS should be performed by the perme’, builder prior to final locating of battery mount and battery. einei VY . Rotax Service Bulletin ., Updated Bing Jet Chart and Main Jet Conversion Chart (nvormation Courtesy Leading Edge Alols, Inc.) eras Roto, has recon pub lished an updated Bing Jet Chart Main Jet conversion char. Allultalighis, ____ BINGCCARGURETOR MAIN JET CONVERSION CHART and lights planes using Rotax engines : ‘may want to verify what is in theit car- bburetors versus the current recammen- dations. These new recommendations are a result of continued research and {esting which allow the Rotax engine to eriorm more efficiently and reliably {throughout its power band, ‘The “Bing Jet Chart Common Appii- cation” chart shows each engine and the stock carburetion setting at sea level. i you live other than sea lovel or ina hotier climate, then you must refer {o the Main Jet Conversion ‘Chart to Calibrate for alitude and temperature. Air density decreases with decreas- ing pressure and increasing tempera- ture. fan engine is operated at higher vation, the weight of the aspirated decreases, whereas the aspirated fuel quantity ‘remains practically the ‘Samo. This results in richer fuel/air mix lure than at lower sea level. It the engine is operated in high al- titude for a longer period, itis necessary to adjust the carburetor calibration tore establish the original composition of the fuel/air mixture. With increasing altitude (lower air pressure), the oxygen quan- The concer eine engine decreases. Example: I! a Rotax 509 engine set sion chart, going to the approximate seaee(s as se Sense 8 2 a eis cannaresesuent loss in performance up for sea favl is shipped to Colorado. ona 6,500 feet and using tha Carouctorsempenssted for by diferent Springs, Colorado, approximate exove, (ula of 8,500 dogrees, you can see we carburetor settings, tere800 eet tho main jt would have have a muliparof 8, Wo mulipiy ie fraediust ne carburetor in generala to be changed. Our Bing Jet Char Ne jt of 180 by our factor of 96 and ‘erent main jot size is eufficient.Only shows the Hotax 503 used wih are, Tail ‘up with our recommended jet of in very particular cases a diferent nee- NA Cleaner and without the nicke 171. This main jet will produce the same le jet andlor ditferent ile jet also has alter muffler would have a main Jet of composition of air/luel mixture that the 10 be installed, 180 for Sea level. By using the conver- 180 main jet would at soa lovel Ear, ta BING JET CHART {9 on nto 88 wag dav eohGvons (lr ere es KON GU aRO San, Ch rae Neemey ip, TANT bd JW be SINT | RE P.0. Box 728 © Caldwoll, Idaho 83606 © (208) 454-2600 NOTICE YOUR ROTAX ENGINE HAS A TWELVE (12) MONTH WARRANTY WHEN IT REACHES THE AVID AIRCRAFT FACTORY. IF UPON RECEIPT OF YOUR ENGINE KIT, YOU FIND YOU ARE GO- ING TO BE DELAYED, BEFORE YOU CAN INSTALL AND USE YOUR ENGINE, A SIX MONTH, ONE TIME FACTORY WARRANTY EXTENSION IS AVAILABLE TO YOU, THE BUILDER. SUBMIT IN WRITING THAT YOU WILL BE DELAYED BEFORE PUTTING YOUR ENGINE INTO SERVICE. (BE SURE TO INCLUDE THE SERIAL NUMBER). THEN MAIL YOUR EXTENSION REQUEST TO AVID AIR- CRAFT, WHO WILL FORWARD IT TO THE ROTAX SUPPLIER.NOTE ON PROPELLER INSTALLATION The AN-4-27H or AN-4~30H bolts, used for mounting the pro- peller to the prop flange of the engine, are only threaded enough to go through the prop flange plus 2 to 3 threads. One fourth inch (%") washers may need to be installed be— tween the head of the AN-4-27H or AN-4-30H bolts and the prop backing plate to prevent these bolt threads from bot- toming out at the prop flange. For instance, if you lett plus 2 to 3° washers. A minumim of one (1) thread must ex. tend thru the prop flange. All washers must go between the bolt head and the prop backing plate.fSgROTAX|SERVICE INFORMATION| ==4] ine installation with spark plugs down For this installation position, a vent tube has to be connected on ‘top of the water pump housing (4) leading to the expansion chamber (8) resp. to the water chamber of the radiator. ° The cooling system has to be vented well, to be checked efter a short gperating period, and cooling Liquid has to be refilled, if necessery. | Only @ perfectly vented cooling system will function satisfactorily © (1) crankcase (71 tube from cylinder heed to radistor (2) cylinder (83 expansion chamber (3). cylinder head (8) vent tube from water (4) water pump pump to radietor (5) radiator * (18) temperature ga cooling weter tor (6) tube from radiator to water pump Recommended