Standard Retractable Gear Contents June 2005 EGR-Contents Page 1
EGR-Contents Chapter 1 - Introduction 1.1 - Overview...1-4 1.1.1 - Description... 1-4 1.1.2 - Getting Started... 1-4 1.1.3 - Video Tapes... 1-5 1.1.4 - Contents of Manual... 1-5 1.1.5 - Getting Help While Building... 1-5 1.1.6 - Modifications... 1-6 1.2 Materials...1-7 1.2.1 - Epoxies... 1-7 1.2.2 - Glass Cloth... 1-7 1.2.3 - Fillers... 1-8 1.2.4 - Glues... 1-8 1.2.5 - Foam... 1-9 1.2.6 - Plywood... 1-9 1.2.7 - Hardware... 1-9 1.2.8 - O.E.M. Equipment... 1-9 1.2.9 - Machined Parts... 1-9 1.3 Construction Techniques...1-10 1.3.1 - Mixing Epoxy... 1-10 1.3.2 - Cutting Cloth... 1-11 1.3.3 - Sanding... 1-11 1.3.4 - Glassing Foam... 1-11 1.3.5 - Using Hot Glue, Bondo or 5-Minute Epoxy... 1-12 1.3.6 - Glassing Cloth... 1-12 1.3.7 - Filling... 1-12 1.3.8 - Attaching / Joining... 1-13 1.3.9 - Hardware...1-13 1.3.10 - Work Habits... 1-13 1.3.11 - Patching Foam... 1-14 1.3.12 - Use of a Level... 1-14 1.3.13 - Micro-Glass / Micro-Slurry... 1-14 1.3.14 - Peel Ply... 1-14 1.3.15 - Tapping... 1-15 1.3.16 - Fluid Lines and Fittings... 1-15 1.3.17 - Countersinking... 1-15 1.4-Quality Assurance...1-17 1.4.1 - Quality Control... 1-17 1.4.2-Mindset of a builder... 1-17 1.5 Tools...1-18 1.5.1 - Water Level... 1-18 1.5.2 - Benches... 1-18 1.5.3 - Necessary Tools... 1-18 1.5.4 - Nice To Have Tools...1-18 Page 2 EGR-Contents June 2005
Chapter 2 - Wings / Winglets 2.0 - Chapter Preface...2-4 2.0.1 - Parts...2-4 2.0.2 - Tools List...2-5 2.0.3 - Supplies List...2-5 2.0.4 - Glass List...2-6 2.0.5 - Process Overview...2-7 2.1 - Wing Core...2-8 2.1.1 - Joining Leading Edge Wing Cores to Spar...2-8 2.1.2 - Joining Trailing Edge Wing cores to Spar....2-9 2.1.3 - Navigation (VHF) Antenna...2-10 2.2 - Wing Skins...2-12 2.2.1 - Lower Skin...2-12 2.2.2 - Wing Leading Edge Rib...2-15 2.2.3 - Wing Root Ribs...2-15 2.2.4 - Glassing...2-16 2.2.5 - Rudder Conduit Installation...2-18 2.2.4 - Top Wing Skin...2-19 2.2.6 - Wing Attach Bolt Access Holes...2-20 2.3 Winglets...2-22 2.3.1 - Preparing Winglets for Glassing...2-22 2.3.2 Glassing Inboard surface...2-23 2.3.3 - Glassing Outboard Surface...2-23 2.3.4 - Winglet Marking...2-24 2.4 Wingtip Trimming...2-25 2.5 Winglet to wing attachment...2-26 2.5.1 Overview of Winglet to Wing Attachment...2-26 2.5.2 Winglet and Wing Preparation...2-26 2.5.3 - Set-Up and Alignment...2-27 2.5.4 - Winglet Attachment Lay-Ups...2-28 2.6 Filling and Sanding Wings and Winglets...2-32 2.7 Ailerons...2-33 2.7.1 - Aileron Cutouts...2-33 2.7.2 - Aileron Wells...2-34 2.7.3 - Glassing Aileron Well and Ribs...2-35 2.7.4 - Aileron Construction...2-36 2.7.5 - Torque Tube and Hinge Backing Plates...2-37 2.7.6 - Hinge Installation...2-39 2.8 Rudders...2-42 2.8.1 - Rudder Cut-Outs...2-42 2.8.2 - Rudder and Rudder Wells...2-42 2.8.3 - Rudder Hinge Installation...2-43 2.8.4 - Rudder Horn Installation...2-43 2.8.5 - Rudder Return Spring...2-44 2.9 Winglet Bottom...2-45 2.9.1 - Prepare Winglet Bottom...2-45 2.9.2 - Attaching Winglet Bottom to Wing...2-45 June 2005 EGR-Contents Page 3
EGR-Contents Chapter 3 - Canard / Elevator 3.0 - Chapter Preface...3-4 3.0.1 - Parts List... 3-4 3.0.2 - Tools List... 3-4 3.0.3 - Supplies List... 3-5 3.0.4 - Glass List... 3-5 3.0.5 - Process Overview... 3-5 3.1 - Critical Dimensions...3-6 3.1.1 - Reference list... 3-6 3.2 - Canard Core Preparation...3-7 3.2.1 - Installation of Lift Tabs... 3-7 3.2.2 - Foam Cores... 3-7 3.2.3 - Preparation for Skinning... 3-8 3.3 - Glassing the Canard...3-10 3.3.1 - Canard Lay-up Schedule... 3-10 3.3.2 - Canard Lay-up #1... 3-11 3.3.3 - Canard Lay-up #2... 3-11 3.3.4 - Canard Lay-ups #3 and #4... 3-12 3.4 - Elevator Construction...3-13 3.4.1 - Assemble Cores... 3-13 3.4.2 - Lay-up Procedure - Side One... 3-13 3.4.3 - Lay-up Side Two... 3-14 3.4.4 - Elevator to Canard Fit... 3-16 3.4.5 - Elevator Hinge Installation... 3-17 3.4.6 - Hinge Arm Installation... 3-18 3.5 - Canard Final Preparation for Elevators...3-20 3.5.1 - Positioning the Elevator... 3-20 3.5.2 - Positioning torque / counterweight arms... 3-21 3.5.3 - Elevator Balancing... 3-26 Chapter 4 - Bulkheads 4.0 - Chapter Preface...4-4 4.0.1 - Parts List... 4-4 4.0.2 - Tools List... 4-4 4.0.3 - Supplies List... 4-4 4.0.4 - Glass List... 4-4 4.0.5 - Process Overview... 4-5 4.1 - Bulkhead Preparation...4-6 4.1.1 - Locate Bulkhead Placement... 4-6 4.2 - Install Bulkheads...4-9 4.2.1 - Preliminary Fitting of Parts... 4-9 4.2.2 - Bonding Procedures... 4-10 4.2.3 - Glassing Bulkheads... 4-10 4.2.4 - Engine Bulkhead... 4-10 4.2.5 - Engine and Gear Bulkheads... 4-11 4.2.6 - Cowl... 4-11 4.2.7 - Canard Bulkhead... 4-12 4.2.8 - Battery Shelf... 4-13 4.2.9 - Landing Light... 4-13 Page 4 EGR-Contents June 2005
Chapter 5 - Doors and Windows 5.0 - Chapter Preface...5-4 5.0.1 - Parts List...5-4 5.0.2 - Tools List...5-4 5.0.3 - Supplies List...5-4 5.0.4 - Glass List...5-4 5.0.5 - Process Overview...5-5 5.1 - Windows...5-6 5.1.1- Window Cutouts...5-6 5.1.2 - Fit Windows...5-6 5.1.3 - Install Windows...5-8 5.2. - Fuselage Top Installation...5-10 5.2.2 - Door Cutout... 5-11 5.2.3 - Fuselage Door Hole Treatment...5-12 5.2.4 - Door Hinge Installation...5-13 5.2.5 - Install Door with Hinges to Fuselage...5-14 5.3 - Latches...5-15 5.3.1 - Install Door Latch Mechanism...5-15 5.3.2 - Latch Base Assemblies...5-15 5.3.3 - Pilot Door Security Lock...5-18 5.3.4 - Installing Door lock...5-19 5.3.5 - Install Windows in Doors...5-19 5.3.6 - Install the Latch Pin Tubes in Fuselage...5-20 5.4 - Carbon Beams...5-21 5.4.1 - Install Carbon Beams...5-21 5.4.2 - Install Door Seal...5-21 5.5 - Finishing the Doors...5-22 5.5.1 - Install Door Gas Springs...5-22 Chapter 6 - Fuselage 6.0 - Chapter Preface...6-4 6.0.1 - Parts List...6-4 6.0.2 - Tools List...6-4 6.0.3 - Supplies List...6-5 6.0.4 - Glass List...6-5 6.0.5 - Process Overview...6-5 6.1 - Keel...6-6 6.1.1 - General...6-6 6.1.2 - Forward Keel Access Hole...6-6 6.1.3 - Aft Keel Access Holes...6-7 6.1.4 - Fitting the Keel...6-7 6.1.5 - Keel Hard points...6-8 6.2 - Seats and Hardpoints...6-9 6.2.1 - Fuselage Hardpoints...6-9 6.2.2 - Seat Belt Hardpoints...6-10 6.2.3 - Front Seats...6-10 6.3.4 - Rear Seats...6-13 June 2005 EGR-Contents Page 5
EGR-Contents 6.3 - Keel Controls...6-15 6.3.1 - Keel Control Assembly Locations... 6-15 6.3.2 - Forward Aileron Torque Tube Bearing... 6-16 6.3.3 - Rear Aileron Control Bracket... 6-17 6.3.4 - Mid-bearing Support... 6-18 6.3.5 - Control Stick Assembly... 6-19 6.3.6 - Keel Installation... 6-20 6.3.7 - Keel Stiffening Lay-ups... 6-21 6.4 - Forward Fuselage Treatments...6-22 6.4.1 - Nose Access Cover... 6-22 6.5 - Pedal System / Brake Cylinders...6-23 6.5.1 - Mount Master Cylinders... 6-23 6.5.2 - Assemble Rudder Pedals... 6-25 6.5.3 - Mount Pedals... 6-25 6.5.4 - Install Nylaflow Tubing for Rudder Cables... 6-26 6.6 - Instrument Panel...6-27 6.6.1 - Locate Panel... 6-27 6.6.2 - Install Panel... 6-27 6.7 - Installing Main Spar...6-28 6.7.1 - Spar Positioning... 6-28 6.7.2 - Spar Installation... 6-29 6.7.3 - Lay-ups... 6-29 6.7.4 - TRIAX Reinforcement... 6-30 6.8 - Canard Reinforcements...6-35 6.8.1 - Canard Attachment Reinforcement... 6-35 6.8.2 - Canard Top Attachment Points... 6-36 Chapter 7 - Landing Gear 7.0 - Chapter Preface...7-4 7.0.1 - Parts List... 7-4 7.0.2 - Tools List... 7-5 7.0.3 - Supplies List... 7-6 7.0.4 - Glass List... 7-6 7.0.5 - Process Overview... 7-6 7.1 - Nose Gear Door Installation...7-8 7.1.1 - Nose Gear Door Cutout... 7-8 7.2 - Nose Gear Installation...7-12 7.2.1 - Nose Gear Bushings... 7-12 7.2.2 - Overcenter Linkage... 7-14 7.2.3 - Sequence Valve... 7-14 7.2.4 - Gas Spring... 7-15 7.2.5 - Nose Gear Guides... 7-15 7.3 - Nose Gear Templates...7-17 7.3 - Main Gear Preparation...7-19 7.3.1 - Gear Leg Preparation... 7-19 7.3.2 - Gear Leg Torsional Reinforcement... 7-19 Page 6 EGR-Contents June 2005
7.4 - Fuselage Preparation...7-20 7.4.1 - Gear leg cut out... 7-20 7.4.2 - Drilling Holes for Main Gear Bushings... 7-20 7.4.3 Transverse Bulkhead Install... 7-21 7.5 Installation of Main Gear Bushings...7-23 7.6 Main Gear Cables and Cylinder...7-24 7.6.1 - Pulley Assembly... 7-24 7.6.2 - Main Gear Overcenter Linkage and Sockets... 7-26 7.6.3 - Hydraulic Cylinder... 7-30 7.6.4 - Cables... 7-30 7.7 - Installing the Main Gear...7-31 7.7.1 - Gear Legs... 7-31 7.7.2 - Brake Lines... 7-31 7.7.3 - Main Gear Doors... 7-31 7.8 - Hydraulic System...7-35 7.8.1 - Hydraulic Power Pack and Nose Gear Door Cylinder... 7-35 7.8.2 - Plumbing... 7-36 7.8.3 - Pressure switch adjustment.... 7-36 7.8.4 - Electrical... 7-39 7.8.5 - Final System Adjustments... 7-40 7.9 - Emergency Extension...7-42 7.9.1 - Basics... 7-42 7.9.2 - Nose Gear Safety Stick... 7-42 Chapter 8 - Wheels / Axles 8.0 - Chapter Preface...8-4 8.0.1 - Parts List...8-4 8.0.2 - Tools List...8-4 8.0.3 - Supplies List...8-4 8.0.4 - Glass List...8-4 8.0.5 - Process Overview...8-5 8.1 - Wheels and Axles...8-6 8.1.1 - Install Main Gear Axles...8-6 8.2 - Nose Wheel Installation...8-10 Chapter 9 - Fuel System 9.0 - Chapter Preface...9-4 9.0.1 - Parts List...9-4 9.0.2 - Tools List...9-4 9.0.3 - Supplies List...9-5 9.0.4 - Glass List...9-5 9.0.5 - Process Overview...9-6 9.1 - Transfer Template...9-7 9.1.1 - Transfer Template...9-7 June 2005 EGR-Contents Page 7
EGR-Contents 9.2 - Lower Fuel Strake...9-9 9.2.1 - Wheel Well Measurements... 9-9 9.2.2 - Preparation... 9-9 9.2.3 - Lower Strake Alignment... 9-10 9.2.4 - Cut out Lower Baggage Access Openings... 9-13 9.2.5 - Lower Strake Half Glassing... 9-14 9.3 - Internal Strake Structures...9-18 9.3.1 - Fitting Wheel Well... 9-18 9.3.2 - Baffles and Bulkheads... 9-19 9.3.3 - Install Strake Baffles... 9-22 9.3.4- Bulkhead Fuel Fittings... 9-22 9.3.5 - Fuel system venting... 9-24 9.4 - Upper Strake Half...9-26 9.4.1 - Fuel Cap Installation... 9-26 9.4.2 - Fitting the Upper Strake Half... 9-26 9.4.3 - Upper Strake Half Installation... 9-27 9.3.4 - Outboard End Strake Reinforcement... 9-29 9.5 - Sump Tank and Fuel Lines...9-30 9.5.1 - Fuel lines... 9-30 9.5.2 - Install the Sump Tank Cover... 9-31 9.5.3 - Install Mounting Tabs... 9-31 9.5.5 - Sump Tank Installation... 9-31 9.6 - Wing Strake Cutout...9-32 9.6.1 - Wing Strake Cutout... 9-32 9.6.2 - Wing Strake to Beam Support... 9-32 9.6.3 - Installing Leading Edge of Strake onto Door... 9-33 9.7 - Fuel System Plumbing...9-35 9.7.1 Solid fuel line Installation... 9-35 Chapter 10 - Control System 10.0 - Chapter Preface...10-4 10.0.1 - Parts List... 10-4 10.0.2 - Tools List... 10-5 10.0.3 - Supplies List... 10-5 10.0.4 - Glass List... 10-5 10.0.5 - Process Overview... 10-5 10.1 - Elevators...10-6 10.1.0 - Introduction... 10-6 10.1.1 - Installing Control Stick Push-Tube Assembly... 10-6 10.1.2 - Elevator Trim... 10-8 10.1.3 - Aerodynamic Trim (Sparrow Strainer)... 10-9 10.2 - Rudders... 10-11 10.2.1 - Rudder Cable Installation... 10-11 10.3 - Ailerons...10-14 10.3.1 - Rigging of the Roll System (Ailerons)...10-14 Page 8 EGR-Contents June 2005
Chapter 11 - Fairings 11.0 - Chapter Preface... 11-4 11.0.1 - Parts List... 11-4 11.0.2 - Tools List... 11-4 11.0.3 - Supplies List... 11-4 11.0.4 - Glass List... 11-5 11.0.5 - Process Overview... 11-5 11.1 - Cowl Treatments... 11-6 11.1.1 - Relocating Upper to Lower Cowl Joint... 11-6 11.1.2 - Wing Root Fairings... 11-6 11.1.3 - Premolded NACA Scoop Installation... 11-8 11.1.4 - Oil Access Door... 11-8 11.2 - Canard Tips... 11-10 11.2.1 - Installation... 11-10 11.2.2 - Counterweight Fairings... 11-11 Chapter 12 - Engine / Propeller 12.0 - Chapter Preface...12-4 12.0.1 - Parts List...12-4 12.0.2 - Tools List...12-4 12.0.3 - Supplies List...12-4 12.0.4 - Glass List...12-4 12.0.5 - Process Overview...12-5 12.1 - Engine Installation...12-6 12.1.1 - Introduction...12-6 12.1.2 - Engine Mounts...12-6 12.2 - Fluid Lines...12-7 12.2.1 - Aluminum Oil Lines...12-7 12.2.2 - Fuel Plumbing...12-9 12.3 - Controls, Cooling and Prop... 12-11 12.3.1 - Throttle, Mixture, and Prop Controls... 12-11 12.3.2 - Pressure Checking Fuel System...12-12 12.3.3 - Fuel Sight Gauges...12-12 12.3.4 - Cooling Plenum Chamber...12-13 12.3.5 - Propeller...12-15 12.3.6 - Nose Mounted Cooler...12-15 Chapter 13 - Electrical / Instrumentation 13.0 - Chapter Preface...13-4 13.0.1 - Parts List...13-4 13.0.2 - Tools List...13-4 13.0.3 - Supplies List...13-4 13.0.4 - Glass List...13-4 13.0.5 - Process Overview...13-5 June 2005 EGR-Contents Page 9
EGR-Contents 13.1 - Antennas...13-6 13.1.1 - Introduction... 13-6 13.1.4 - Glideslope Antenna... 13-6 13.1.5 - Marker Beacon... 13-6 13.1.6 - Transponder... 13-7 13.1.8 - GPS... 13-7 13.1.9 - ELT... 13-7 13.2 - Instrument Panel...13-8 13.2.1 - Instrument Panel... 13-8 13.2.2 - Engine Instruments... 13-10 13.3 - Electrical System Completion... 13-11 13.3.1 - Introduction... 13-11 13.3.2 - Basic Electrical System... 13-11 13.3.3 - Trim, Speed Brake, & Speed Brake Warning... 13-13 13.3.4 - Switches and Circuit Protection... 13-14 13.3.5 - Avionics... 13-15 13.3.6 - P-Leads... 13-15 13.4 - Pitot - Static and Vacuum Instruments... 13-17 13.4.1 - Vacuum System... 13-17 13.4.2 - Static Port... 13-17 13.4.3 - Pitot Tube... 13-18 Chapter 14 - Final Assembly and Finishing 14.0 - Chapter Preface...14-4 14.0.1 - Parts List... 14-4 14.0.2 - Tools List... 14-4 14.0.3 - Supplies List... 14-4 14.0.4 - Glass List... 14-4 14.0.5 - Process Overview... 14-4 14.1 - Final Assembly Procedures...14-5 14.1.1 - Canard / Elevators... 14-5 14.1.2 - Aircraft Tie Downs... 14-6 14.1.3 - Wings to Aircraft... 14-6 14.1.4 - Ailerons... 14-8 14.1.5 - Control System... 14-9 14.1.6 - Rudder Pedals, Cables,... 14-10 14.1.7 - Vortilon Installation... 14-11 14.1.8 - Brake Bleeding... 14-11 14.1.9 - Landing Gear, Wheels, Brakes, Fairings... 14-12 14.1.10 - Fuel System... 14-13 14.1.11 - Powerplant / Propeller... 14-14 14.1.12 - Pitot / Static System... 14-15 14.1.13 - Electrical System... 14-15 14.1.14 - Alternator... 14-16 14.1.15 - Vacuum Pump System... 14-16 Chapter 15 - Interior 15.0 - Chapter Preface...15-4 15.0.1 - Parts List... 15-4 15.0.2 - Tools List... 15-4 15.0.3 - Supplies List... 15-4 15.0.4 - Glass List... 15-4 15.0.5 - Process Overview... 15-4 Page 10 EGR-Contents June 2005
15.1 - Materials...15-5 15.1.1 - Headliner... 15-5 15.1.2 - Carpet... 15-5 15.1.3 - Upholstery... 15-5 15.1.4 - Seat Foam... 15-5 15.1.5 - Glue for Installation... 15-5 15.1.6 - Trim and Weather-stripping... 15-5 15.2 - Installation...15-6 15.2.1 - Fuselage Headliner... 15-6 15.2.2 - Window Frames... 15-6 15.2.3 - Carpeting... 15-6 15.2.4 - Side Panels... 15-7 15.2.5 - Interior Door Cover... 15-7 15.2.6 Glare shield... 15-7 15.2.7 Rear Cover Panel... 15-7 Chapter 16 - Flight Testing 16.0 - Chapter Preface...16-4 16.0.1 - Parts List... 16-4 16.0.2 - Tools List... 16-4 16.0.3 - Supplies List... 16-4 16.0.4 - Glass List... 16-4 16.0.5 - Process Overview... 16-4 16.1 - Final Preparation...16-5 16.1.1 - Placarding and Markings... 16-5 16.1.2 - Inspections... 16-5 16.1.3 - Pilot Qualifications... 16-6 16.1.4 - True Story... 16-7 16.2 - Testing...16-8 16.2.1 - Taxi Testing... 16-8 16.2.2 - High Speed Taxiing... 16-8 16.2.3 - High Speed Taxi Nose Wheel Liftoffs... 16-9 16.2.4 Runway Hops... 16-9 16.2.4 - First Flight... 16-10 16.2.5 - Envelope Expansion... 16-11 16.2.6 - High Speed Flight Envelope Expansion... 16-12 16.2.7 - Flying the Velocity... 16-13 16.2.8 - Crosswind Landings... 16-13 June 2005 EGR-Contents Page 11