ASSEMBLY MANUAL FOR THE LANCAIR LEGACY

Transcription

1 ASSEMBLY MANUAL FOR THE LANCAIR LEGACY Chapter 1 REV. 0/ INTRODUCTION

2 Chapter 1 REV. 0/ INTRODUCTION

3 Contents Chapter 1: Introduction INTRODUCTION A. Recommended Background Information B. Manual Layout and Use Chapter Organization Revisions C. Setting Up Your Shop Cutting Tables D. Terms and Definitions E. Structural Adhesive F. AN- Bolt and Hardware Guide G. Basic Shop Tools Specialized Tools Supplies H. Premolded Parts - Exploded View Premolded Parts List - not included in figure I. Procedures Cleaning, care, and handling of parts J. Joint Description K. Trimming Procedure L. Drilling Alignment Holes M. Removing the Protective Coating - Peelply N. Fastening Parts Together O. Fiberglass Strip Installation P. Cutting on the Bias Q. The Plastic Sandwich R. Tongue Depressors and Micro Radii About those Micro Radii S. Those Annoying 2"-Wide Bid Tapes T. Cardboard Templates U. Building Light V. Building Straight Straight Trailing Edges W. Control Systems Pushrod Tips X. Hydraulic Systems Tube flaring Y. Painting Z. Building a Jack Stand Chapter 2: Horizontal Stabilizer and Elevator INTRODUCTION PARTS LIST CONSTRUCTION PROCEDURES A. Building the Horizontal Stabilizer Assembly Cradle B. Horizontal Stabilizer Hinge Brackets C. Elevator Hinge Installation D. Elevator Trim Tab Setting the Trim Tab E. Couterbalancing the Elevators F. Closing the Horizontal Stabilizer and Elevator Closing the Elevators G. Elevator Travel Stops Chapter 3: Wing Systems INTRODUCTION PARTS LIST CONSTRUCTION PROCEDURES A. Pitot Tube (Optional) B. Installing the Marker Beacon Antenna (Optional) C. Communications Antenna (Optional) D. Spar Closeout E. Main Gear Doors Fitting the Gear Doors Gear Doors - Release Tape (Optional) Gear Doors - Outboard Hardware Mounting Gear Doors - Installing the Outboard Attachment Receptacles Installing the Inboard Gear Door TOC-I

4 F. Main Gear Installation G. Main Gear Wheels and Tires H. Center Wing Section Hydraulics I. Aft Spar Transition Holes J. Landing and Taxi Lights (Optional) K. Speed Brakes (Optional) L. Fuel and Hydraulic Lines Schematics Chapter 4: Fuel Systems INTRODUCTION PARTS LIST CONSTRUCTION PROCEDURES A. Legacy Fuel System - General Overview B. Fuel Selector Valve (Optional) C. Fuel Supply Lines D. Fuel Vent Line Check Valve E. Fuel Return Lines F. Fuel Probe (Optional) G. Fuel Boost Pump (Optional) H. Fuel Drain Covers Chapter 5: Outboard Wing Section Installation INTRODUCTION PARTS LIST CONSTRUCTION PROCEDURES A. Wing Installation and Removal Chapter 6: Aileron Controls INTRODUCTION PARTS LIST CONSTRUCTION PROCEDURES A. Control Stick Installation B. Aileron Controls Rigging C. Counterbalancing Ailerons D. Aileron Trim System How the Trim System Works Instructions for Adjusting the Aileron Trim Servo Chapter 7: Aircraft Alignment Jig INTRODUCTION PARTS LIST Supplies List CONSTRUCTION PROCEDURE A. Wing Jig Alignment Criteria B. Aft Fuselage Jig C. Vertical Tail Supports Chapter 8: Outboard Wing Section Closing PARTS LIST CONSTRUCTION PROCEDURES A. Closing the Wings Understanding the Relative Percentage Chordline B. Pressure Testing the Wings Fixing a Leak C. Strobe and Nav Lights Chapter 9: Canopy INTRODUCTION PARTS LIST CONSTRUCTION PROCEDURES A. Canopy Latch Mechanism B. Canopy Stiffener Alignment C. Canopy Hinge Alignment D. Gas Strut E. Canopy Stricker Metchanism TOC-II

5 F. Canopy Alignment Mechanism G. Windshield Installation Canopy Alignment H. Canopy Defroster I. Canopy Skin Bonding J. Canopy Seal Proper Orientation Chapter 10: Center Wing Section Installation PARTS LIST CONSTRUCTION PROCEDURES A. Bonding the Center Wing Section B. Installing Load Pads C. Installing the Aft Closeout Rib D. Closing the Center Wing Section Chapter 11: Horizontal Tail Installation INTRODUCTION PARTS LIST CONSTRUCTION PROCEDURES A. Bonding the Horizontal Stabilizer Trimming the Left Vertical Skin Proper Horizontal Stabilizer Installation during Bonding B. Vertical Web Installation Chapter 12: Vertical Closeout PARTS LIST CONSTRUCTION PROCEDURES A. Counterweight Installation B. Left Vertical Skin Installation Typical Vertical Tail Cross Section C. Elevator Weldment Access Panel D. Bonding the Vertical Stabilizer Chapter 13: Firewall Forward INTRODUCTION PARTS LIST CONSTRUCTION PROCEDURES A. Firewall Closeout B. Firewall Flame Blanket C. Engine Mount Installation Mounting Holes # Nose Gear Brace Mounts Mounting Holes # Nose Gear Brace Mounts D. Nose Gear Installation Left Side View E. Nose Wheel and Tire F. Nose Gear Doors G. Nose Gear Micro Switch Nose Gear Down Switch Chapter 14: Center Console INTRODUCTION PARTS LIST CONSTRUCTION PROCEDURE A. Center Console Glove Box Glove Box Lid B. Fitting the Center Console C. Seat Belt Reinforcement D. Forward Access Panel E. Dump Valve Mounting F. Throttle - Prop - Mix G. Fuel Selector Valve Handle H. Center Console Bonding TOC-III

6 Chapter 15: Seats & Seat Belts INTRODUCTION PARTS LIST CONSTRUCTION PROCEDURES A. Fitting the Seat Pans B. Outboard Seat Supports C. Center Seat Supports D. Installing the Seat Belts Chapter 16: Hydraulic Systems Completion INTRODUCTION PARTS LIST CONSTRUCTION PROCEDURES A. Hydraulic Lines - Aft of Aft Spar B. Hydraulic Lines - Forward of Main Spar C. Adjusting the Inboard Main Gear Doors Trimming the Sleeve to Length Adjusting the Inboard Main Gear Doors D. Setting the Main Gear UP Stop Setting the UP Stop E. Adjusting the Outboard Main Gear Doors F. Gear Switch and Lights Gear Transition Light Gear Down Lights G. Gear Micro Switch Wiring H. Gear Pressure Switch Wiring I. Gear Wiring Schematic J. Hydraulic Gear Start Up and Test Operations Adding Hydraulic Fluid Start up of the Hydraulic Gear K. Pressure Switch Adjustment L. Free Fall Test M. In-flight Free Fall Testing N. Hydraulic Pump Conversion (Optional) Chapter 17: Rudder Completion INTRODUCTION PARTS LIST CONSTRUCTION PROCEDURES A. Trimming the Rudder B. Rudder Leading Edge Closeout C. Rudder Trim System (Optional) D. Adjusting the Rudder Counter Weights E. Rudder Pedal Installation F. Floorboard Installation Version Version G. Rudder Bellcrank H. Rudder Pushrod I. Rudder Cable Adjusting the Pedal Position Aft Adjusting the Pedal Position Forward Chapter 18: Brake System INTRODUCTION PARTS LIST CONSTRUCTION PROCEDURES A. Brake System B. Installing the Brake Assemblies C. Filling and Bleeding the Brakes TOC-IV

7 Chapter 19: Elevator Controls INTRODUCTION PARTS LIST CONSTRUCTION PROCEDURES A. Elevator Controls Rigging Control Stick Elevator Idler Arm Elevator B. Trimming Inboard Ends for the Rudder Chapter 20: Instrument Panel INTRODUCTION PARTS LIST CONSTRUCTION PROCEDURES A. Instrument Panel Installation B. Dust Cover Trimming the Dust Cover C. Avionics Mounting Shelf D. Typical Panels Chapter 21: Flap System Completion INTRODUCTION PARTS LIST CONSTRUCTION PROCEDURES A. Center Torque Tube Support B. Flap Installation C. Flap Motor Installation Flap Motor Alignment Flap Adjustments D. Bonding the Wing Trailing Edge Chapter 22: Cabin Ventilation INTRODUCTION PARTS LIST CONSTRUCTION PROCEDURES A. Fresh Air (Unheated) B. Cabin Heat*/Cabin Defroster* Chapter 23: Baggage Compartment INTRODUCTION PARTS LIST CONSTRUCTION PROCEDURE A. Control Tube Cover B. Bulkhead Cover C. Overhead Console* D. Floorboards* Installing Floorboard Access Panels E. Oxygen System (Optional) Chapter 24: Miscellaneous Systems INTRODUCTION PARTS LIST CONSTRUCTION PROCEDURES A. Pitot Static System Static Port Installation B. ELT Installation C. Storm Scope Installation* D. Transponder Antenna Installation TOC-V

8 Chapter 25: Aft Windows INTRODUCTION PARTS LIST CONSTRUCTION PROCEDURE A. Preparing the Fuselage Shell B. Preparing the Windows C. Window Installation Chapter 26: Firewall Forward (part 2) Continental INTRODUCTION PARTS LIST CONSTRUCTION PROCEDURES A. Mounting the Engine B. Propeller/Spinner C. Cowling D. Baffling E. Engine Control Systems F. Manifold Pressure and Tachometer Tachometer G. Fuel Systems H. Oil Systems Oil Temperature Sensor Oil Pressure Sensor I. Vacuum System Installation (Optional) E. Lights Wiring F. Electric Fuel Pump G. Trim System Wiring H. Flap Wiring Setting the Flap Limit Stops I. Pitot Tube Heat Wiring J. Electric Door Seal Wiring K. Antenna Placement Chapter 28: Finishing Techniques INTRODUCTION Painting and Interiors PARTS LIST CONSTRUCTION PROCEDURES A. Bid Tapes B. Mixing Micro C. General Surface Preparation D. Priming Materials E. Paint Preparations F. Painting G. Base Colors H. Trim Colors Chapter 27: General Wiring INTRODUCTION PARTS LIST CONSTRUCTION PROCEDURES A. Basic Wiring Techniques B. Legacy General Wiring C. Basic Aircraft Wiring D. Landing Gear Wiring TOC-VI