Kitfox Super Sport

KITFOX AIRCRAFT
KITFOX SUPER SPORT
LANDING GEAR INSTALLATION

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Contents
Section A. Main Landing Gear Assembly ........................................................................................................ 4
Section B. Wheel and Brake Assembly .......................................................................................................... 10
Section C. Tailwheel Installation .................................................................................................................... 14
Section D. Nose Gear Assembly .................................................................................................................... 16
Section E. Tail Skid Installation ..................................................................................................................... 26

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Section A. Main Landing Gear Assembly
The Super Sport aircraft can have either a conventional or tricycle landing gear
configuration. The configuration can be changed at any time during assembly
or even after the aircraft has been completed and flown.
These instructions describe the installation of the landing gear as though this
were the final assembly, however the gear will have to be removed to cover and
paint the aircraft. Therefore, all illustrations showing finalization of hardware
(such as torqued nuts, cotter pins, safety wire, etc.) are there for your future
reference.
The Super Sport main landing gear consists of a single-piece aluminum gear
bow that is mounted to the fuselage between two points that allow the gear to
pivot as loads are applied.
Axles bolt to the gear legs to mount the wheels and disc brake assemblies.
This gear design has proven to be extremely rugged, has low aerodynamic drag,
and is virtually maintenance free.
This section is illustrated with the landing gear in its normal, upright position.
You may find it advantageous to invert the fuselage while installing the gear this helps keep the hardware in place while you get the nuts threaded on the
bolts. If you choose to invert the fuselage, invert the illustrations as well to
reduce confusion while you are working.

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Kitfox Super Sport

NOTE
PORT FACES
FORWARD

DISC BRAKE
ASSEMBLY

FWD
AXLE
ASSEMBLY

WHEEL & TIRE

ASSEMBLY
WHEEL ATTACH
HARDWARE

Figure A-1
Main Gear Assembly Overview

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1.
Completion Date
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Cut four Delrin separator disks from the supplied material. A bandsaw
works well for the initial cut. Clean up the edges with sandpaper or a
file. Make sure that the disks do not exceed the 2" outside dimension.

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Kitfox Super Sport

SEPARATOR DISK
(FABRICATE FROM
P/N 13016.106 DELRIN, x 4)

2" (51mm)

Figure A-2
Separator Disk Fabrication

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2.

Ream the four fuselage gear attach bushings to .3750". Drill out the
5
/16" holes in P/N: 13016.102 lower pivot blocks to 3/8"

3.

Press the four roll pins into the gear leg at the locations shown. Use an
arbor press if one is available. If not, the pins can be carefully driven in
with a small hammer. If you use a hammer to drive the pins in, hold them
with a pair of pliers initially to keep your fingers out of the way.

4.

Attach the gear leg to the fuselage with the hardware called out in Figure
A-3. Note that the gear is not symmetrical - the tapered face must be
installed toward the rear. Figure A-3 shows the tricycle (aft mounting)
configuration. The conventional landing gear configuration is similar,
although longer bolts are used.
NOTE
To help you achieve the proper fit of the gear leg between the rocker and
separator disks, the mounting hole through the rocker disks has been
drilled .010" off center. If the gear leg seems too tight or too loose between the disks, rotate one or both of the disks on each side 180 until the
leg is held with as little play as possible without binding.

NOTE
There are threaded holes in the Delrin gear rocker blocks. They will not
affect the installation - they are from the tooling process. Deburr the threaded
holes as required to remove any remaining material on the surface from
the threading process.
OPTIONAL WHEEL PANTS
If you are installing wheel pants, refer to the instructions that came with
the wheel pant kit before installing the axles.
5.
Completion Date
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Bolt the axles and brake torque plates to the gear legs using the
hardware shown. The plates should be oriented at about the 4 oclock
position, viewed from the axle end. Torque the nuts to 50 to 70 inchpounds.

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FWD
AN380-2-2 COTTER PIN (x 2)
AN310-5 NUT (x 2)

IF GEAR LEG HAS TWO SETS OF

HOLES, PRESS PINS INTO INNER
SET AND FILL OUTER SET WITH
STRUCTURAL ADHESIVE

AN960-516 WASHER (x 2)

FUSELAGE

.3750" (x 2)

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Section A. Main Landing Gear Assembly

P/N 13016.101
UPPER PIVOT BLOCK

P/N 91310.000
ROLL PIN (x 4)

P/N 13016.106
SEPARATOR DISK (x 2)

BRAKE LINE PORT (x 2)

4
5

P/N 13013.201
GEAR SPRING

AXLE ASSEMBLY DETAIL

GEAR LEG

TAPERED FACE IS
ORIENTED REARWARD
P/N 13016.103
GEAR ROCKER DISK (x 2)

P/N 13012.101
AXLE
50-70 IN/LB
TORQUE
PLATE

P/N 13016.104
GEAR ROCKER (x 2)
P/N 13016.102
LOWER PIVOT BLOCK
DRILL OUT TO .375" (9.5mm)

AN960-416 WASHER

NOTE

AN4-21A BOLT

- USE AN6-40 BOLTS TO MOUNT MAIN GEAR IN AFT

POSITION FOR TRICYCLE CONFIGURATION (SHOWN)
- USE AN6-51 BOLTS TO MOUNT MAIN GEAR IN FORWARD
POSITION FOR CONVENTIONAL CONFIGURATION (NOT SHOWN)

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Figure A-3
Main Landing Gear and Axle Installation

Kitfox Super Sport

AN365-428 NUT

Kitfox Aircraft LLC

Section B. Wheel and Brake Assembly
1.

Working on a clean workbench, remove the wheel bearing retaining

spring ring, the cover washers, the felt wiper, and the bearing from the
wheel halves. Work on one wheel half and bearing at a time to prevent
mixing the parts. Pack the bearing with wheel bearing grease by putting
a golf ball sized lump of grease in the palm of one hand and pressing the
edge of the bearing into the grease. Rotate the bearing a little and repeat
the packing motion. You should see the grease oozing up between the
rollers. Turn the bearing over and pack the grease in from the other side,
all the way around. When the bearing is fully packed with grease, put
it and the rest of the bearing hardware back into the wheel half and
reinstall the retaining ring, making sure that it is fully seated in its
groove. Repeat for the bearing in the other wheel half and repeat the
whole process on the other wheel.

2.

Remove the nuts and bolts holding the wheel halves together and
separate the wheel. Insert a tire tube into a tire, dusting the tube with tire
talc to eliminate friction between the two. If the tire has a red dot painted
on the sidewall, align the valve stem with the dot. Press the valve stem
through the hole in the wheel half, and then press the wheel half fully
into the tire. It is helpful to put a very small amount of air in the tube,
just enough to help it hold its shape. Press the opposite wheel half into
the tire from the other side, visually aligning the mounting holes. Pass
a bolt through the wheel halves and brake disc, press the halves
together, and start a nut on the bolt threads. Install the other bolts in a
similar manner and torque them to 90 inch-pounds.
CAUTION
Be careful not to pinch the tube between the halves of the wheel as
they come together. Listen and feel for crisp, metal-to-metal contact
of the wheel halves before tightening the bolts. If you have difficulty
ensuring that the tube is not caught between the wheel halves, a ring
of thin cardboard can be taped in place around the wheel half split
line to help guard the tube.
WARNING

Completion Date
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Never inflate the tire unless all the wheel bolts are installed and properly torqued. Always deflate the tire before loosening any wheel bolt.
The wheel halves will be very forcefully ejected by the tire pressure if
these precautions are overlooked.

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WHEEL
BEARING
DETAIL

GREASE (x 2)
1

BEARING
2

WHEEL ASSEMBLY
HARDWARE

WASHER
FELT WIPER RING
WASHER
RETAINING RING

BRAKE DISC

P/N 39019.000
WHEEL (INNER HALF)

TIRE
TUBE

90 IN-LB
P/N 39019.000
WHEEL (OUTER HALF)

Figure B-1
Wheel and Tire Assembly

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Completion Date
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3.

Slip the inner brake pads onto the caliper pins if they were removed for
any reason. Lubricate the brake caliper pins with a dry film lubricant
such as LPS-1.

4.

Slide the brake caliper onto the brake torque plate from the inboard side.
The caliper should have its bleeder fitting oriented downward.

5.

Slide the wheel and tire assembly onto the axle, followed by the axle
spacer and the axle nut. Tighten the axle nut firmly and rotate the tire
by hand to squeeze out the extra grease from the bearing rollers and
races. Loosen the nut one-half turn, then re-tighten it slowly until all
play has been removed from the bearings. This play can be felt by
grasping the tire at the top and pushing it in and out. When the nut is
adjusted, advance or retreat it just far enough to align the closest cotter
pin hole. Double check the bearing play and readjust as required. A
very small amount of play is preferable to having the bearing being too
tightly preloaded.

6.

Install a cotter pin to secure the axle nut.

7.

Set the outer brake pad in place, trapping the brake disc between the two
pads. Secure it with the bolts that were supplied with the wheel and
brake kit. Torque the nuts to 75 to 80 inch-pounds for final assembly.

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BRAKE LINE FITTING PORT

BLEEDER FITTING ON OPPOSITE SIDE (BOTTOM)

BRAKE ASSEMBLY

75-80 IN-LB
3

INNER BRAKE PAD

7 OUTER BRAKE PAD

LPS-1
LUBRICANT
BRAKE DISC

WHEEL ASSEMBLY
(TIRE & TUBE REMOVED FOR CLARITY)

AXLE ASSEMBLY

P/N 13012.102
SPACER
AN380-4-8 6
COTTER PIN

5 P/N 91258.000
1-1/4 x 16 AXLE NUT

Figure B-2
Wheel and Brake Installation

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Section C. Tailwheel Installation
The tailwheel assembly consists of an aluminum tail spring, a steerable, fullswiveling tailwheel, and steering chains and springs that are connected to the
rudder to allow maneuverability of the aircraft during ground operations.
1.

Round the corners of the tailspring clamp plate with a file.

2.

Ream the mounting holes in the clamp plate to .1875"

3.

Ream the fuselage bushing to .3125" for the tailspring mounting bolt.

4.

Ream the two holes in the fuselage mounted tailspring clamp plate to
.1875".

5.

Install the tailwheel springs using the hardware shown. Torque the
tailspring clamp plate bolts to 20 to 25 inch- pounds and the forward tail
spring attach bolt to 100-140 inch-pounds.

6.

Bolt the tailwheel assembly to the tailwheel spring using the bolt, nut,
and washer shown. Torque the tailwheel mounting bolt to 270 to 300
inch-pounds.
NOTE
The steering springs and chains will be installed when the aircraft is complete and is at its empty weight (refer to the Final Assembly chapter for the
weight and balance definitions and procedures) prior to initial taxi testing.

7.

Completion Date
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Install a tailwheel steering chain to each lower control horn on the

rudder using a P/N: 10055.000 wire clip. Attach a steering spring
between each steering arm on the tailwheel and the corresponding
chains with a minium of slack. Leave two or three extra links on the
chain to allow for further adjustments until you are satisfied with the
ground handling characteristics of the aircraft.

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P/N 82099.000
TAILSPRING CLAMP

20-25 IN-LB
AN365-1032
AN365-1032 NUT (x 2)

.3125"

AN960-10 WASHER (x 2)
AN5-22A BOLT

1
.1875"
1/4" (7mm) R
.1875"
AN960-716 WASHER (x 2)
4

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Section C. Tailwheel Installation

270-300 IN-LB
AN364-720 NUT
FUSELAGE

"C" CHANNEL SHIM

SUPPLIED WITH
TAILWHEEL

P/N 10768.000
TAIL WHEEL ASSEMBLY

P/N 33009.000
TAILWHEEL STEERING
SPRING (x 2)

P/N 10001.124
BUSHING (x 2)

AN7-21A BOLT
P/N 13022.101
TAILWHEEL SPRING

5
P/N 82099.000
TAILSPRING CLAMP

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AN365-524 NUT

P/N 10055.000
ATTACHMENT CLIP (x 2)

AN3-12A (x 2)

P/N 33005.000
TAILWHEEL STEERING
CHAIN (x 2)

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Figure C-1
Tailwheel Installation

Kitfox Super Sport

TO LOWER
RUDDER HORN

AN960-516 WASHER (x 2)

Kitfox Aircraft LLC

Section D. Nose Gear Assembly
The nose gear assembly consists of a steel fork mounted to a streamlined steel
tube strut. The strut is attached to the fuselage by pivot blocks, and an
elastomeric shock assembly handles the shock absorption.
The wheel bearings are completely sealed, keeping the grease in and the dirt and
moisture out.

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GEAR ASSEMBLY PIVOTS
ENGINE MOUNT
SHOCK ASSEMBLY

NOSE GEAR STRUT

WHEEL AND TIRE

FORK ASSEMBLY

Figure D-1
Nose Gear Assembly

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Completion Date
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1.

Press the pivot bearings into the pivot brackets. Use an arbor press if one
is available. A smooth-jaw vice can be used to press the bearings in, but
you must be careful to keep the parts in alignment to prevent binding
and distortion of the bearings. Secure the bearings with a liquid bearing
locking compound.

2.

Ream the four pivot bracket mounting tabs on the fuselage to .1875".

3.

Slip the pivot brackets onto the gear strut pins with the flanged side of
the bearing toward the strut. Bolt the pivot blocks to the fuselage with
the proper bolts, washers, and nuts as shown. Torque the nuts to 50 to
70 inch-pounds.

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LIQUID BEARING
LOCK (x 2)

P/N 33030.000
PIVOT BRACKET (x 2)

50-70 IN-LB

.2500"
AN365-428
NUT (x 4)

P/N 33038.000
PIVOT BEARING (x 2)

FUSELAGE TABS

AN960-416 WASHER (x 8)

AN4-21A BOLT (x 4)

P/N 35027.000
NOSE GEAR STRUT

Figure D-2
Nose Gear Strut Installation

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NOTE
The engine mount must be installed to complete the installation of the
nose gear assembly.

Completion Date
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4.

To allow the nose gear piston to move freely in the piston rod bearing,
file the inside of the bearing to the profile shown.

5.

Press the piston rod bearing into the engine mount weldment as shown.
A large C-clamp can be used, however you must keep the parts in
alignment to prevent the bearing from binding in the mount.

6.

Thread the check nut onto the rod end all the way and thread the rod end
into the piston shaft as far as it will go. Attach the piston/rod end
assembly to the nose gear strut using the hardware shown.

7.

Install the elastomer springs and friction washers onto the nose gear
piston in the order shown. The AN4-5A bolt, washers, and rubber stop
washer are installed by lining up the piston in the piston rod bearing and
compressing the elastomer springs by using the strut as a lever.
Carefully thread in the AN4-5A bolt a minimum of one turn and then
you can relax pressure on the strut. Use a liquid thread locker on the
AN5-4A bolt to back up the lock washer for final assembly and torque
the bolt to 60 to 85 inch-pounds. As with the main gear legs, the system
is very robust and virtually maintenance free.

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LIQUID THREAD LOCK
AN5-4A BOLT

60-85 IN-LB
AN935-516 WASHER
P/N 32010.000 WASHER
P/N 44024.000
RUBBER STOP WASHER

P/N 33032.000
PISTON ROD BEARING

ENGINE MOUNT

LIQUID BEARING LOCK

P/N 33032.000
PISTON ROD BEARING

P/N 34017.000
PLASTIC WASHER

P/N 34011.000
ELASTOMER SPRING (x 4)

P/N 32710.000
FRICTION WASHER (x 3)

P/N 35020.000
NOSE GEAR PISTON

AN316-5
CHECK NUT
P/N 93000.000
ROD END
NOSE GEAR
STRUT
AN4-7A BOLT
AN960-416 WASHER
AN365-428 NUT

Figure D-3
Nose Gear Shock Mount Installation

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Completion Date
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8.

Fabricate a foam plug from some scrap 1/2" material and shape it to fit
in the end of the nose gear strut. This plug will serve as a moisture barrier
to protect the interior of the strut from corrosion. Bond the plug in place
with structural adhesive and let cure. When positioning the plug, be sure
to get it far enough into the pivot shaft to clear the cotter pin hole.

9.

Press the nose wheel fork bearings in place using a liquid bearing lock
to secure the installation. The upper fork bearing will need to have a flat
section filed into the flange to clear the wheel pant attach tab.

10.

Lubricate the lower end of the nose gear strut with wheel bearing
grease. Assemble the stack of Belleville washers, being very careful to
orient them as shown. Place a thrust washer above and below the stack.
Install the fork assembly and washer stack on the gear strut and secure
with the axle nut and cotter pin. Attach a fish scale to one of the ends
of the axle. Tighten the nut until it requires a pull of 10 to 12 lbs on the
fish scale to keep the fork moving. Note that the force required to start
the fork moving will likely be higher than this. You may wish to only
temporarily install the cotter pin in the strut at this time, as the nut may
need slight adjustment later once taxi testing begins and all of the
components have 'seated' in their proper positions.

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Kitfox Super Sport

NOSE GEAR STRUT

BEARING
GREASE

FOAM PLUG
MOISTURE BARRIER

1/2" (13mm)

PREP

FILE TO CLEAR
NOSE WHEEL FORK
PIVOT STOP

P/N 33031.000
FORK BEARING (x 2)

NOSE WHEEL FORK

PIVOT STOP

P/N 53014.101
NOSE WHEEL FORK

10

LIQUID BEARING LOCK (x 2)

P/N 98007.000
THRUST WASHER (x 2)

P/N 98003.000
BELLEVILLE WASHER
STACKING DETAIL

P/N 98003.000
BELLEVILLE WASHER (x 6)

P/N 91258.000
AXLE NUT
AN380-4-8
COTTER PIN

Figure D-4
Nose Gear Fork Installation
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11.

Remove the nuts and bolts holding the halves of the nose wheel together
and separate them. Insert the inner tube into the tire, dusting the tube
with tire talc to eliminate friction between the two. If the tire has a red
dot painted on the sidewall, align the valve stem with the dot. Press the
valve stem through the hole in the wheel half, then press the wheel half
fully into the tire. If the valve stem comes equipped with a nut and
washer, remove them and press the stem through the wheel hole. Once
the stem is in place, reinstall the nut and washer and carefully tighten.
It is helpful if you put a very small amount of air in the tube, just enough
to help the tube hold its shape. Insert the bearing spacer into the wheel
and press the opposite wheel half into the tire from the other side,
visually aligning the mounting holes. Put a bolt through the wheel
halves, press the halves together, and start a nut on the bolt threads.
Install the other bolts in a similar manner and torque the nuts to 100 to
140 inch-pounds. Inflate the tire to 20-25 psi.

CAUTION
Be careful not to pinch the tube between the halves of the wheel as
they come together. Listen and feel for crisp metal-to-metal contact of
the wheel halves before tightening the bolts. If you have difficulty
ensuring that the tube is not caught between the wheel halves, a ring
of thin cardboard can be taped in place around the wheel half split
line to help guard the tube.
WARNING
Never inflate the tire unless all the wheel bolts are installed and properly torqued. Always deflate the tire before loosening any wheel bolt.
The wheel halves will be forcefully ejected by the tire pressure if these
precautions are overlooked.
12.

Completion Date
_______________

Install the two spacers into the wheel and install the wheel assembly
onto the fork. Slide the nose wheel axle into the wheel until the same
amount of axle shows on both sides of the fork. Install a washer and an
axle nut evenly onto each end of the axle. Put a cotter pin through one
of the axle nuts to hold it in place and adjust the wheel bearing preload
by tightening the other nut until all bearing play is eliminated. Rotate the
tire to ensure that it does not bind or drag, then install the final cotter pin.
Again, do not completely bend over the legs of the cotter pins until final
assembly.

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11 WHEEL HALVES (x 2)

WHEEL ASSEMBLY
HARDWARE (x 3)

100-140 IN-LB
5 x 5.00 TIRE
5 x 5.00 TUBE

P/N 31002.000 SPACER

P/N 13035.201
SPACER (x 2)

AN960-1016
WASHER (x 2)

12

NOSE GEAR
FORK ASSEMBLY

P/N 13035.101
NOSE WHEEL AXLE
AN320-10 NUT (x 2)
AN380-4-5 COTTER PIN (x 2)

Figure D-5
Wheel and Tire Installation

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Section E. Tail Skid Installation
A tail skid is mounted to the aft, lower empennage to prevent damage in the
event of over-rotation during takeoff or landing. It also provides an excellent tiedown point for the tail of the aircraft.

Completion Date
_______________

1.

Ream the forward attachment bushing in the fuselage to .3125".

2.

Ream the mounting holes in the clamp plate and the tail skid plate to
.1875".

3.

Attach the tail skid to the fuselage at the aft attachment plate.

4.

Align the tail skid so the forward attachment tab is centered over the
forward attachment bushing. Match-drill the forward attachment tab on
the tail skid with a 5/16" bit. Remove the tail skid and deburr.

5.

Install the tail skid using the hardware shown. The skid will need to be
removed during the fuselage covering process.

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Kitfox Super Sport

AN365-524 NUT
AN960-516 WASHER

20-25 IN-LB
AN365-1032
AN960-10 WASHER (x 2)

.1875" (x 4)

P/N 51069.101

AN3-4A BOLT (x 2)

5/16"

AN5-14A BOLT
AN960-516 WASHER
.3125"

Figure E-1
Tail Skid Installation

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