AEROCET 2200 User manual

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MAINTENANCE MANUAL AND INSTRUCTIONS FOR CONTINUED
AIRWORTHINESS
FOR
AEROCET MODEL 2200 TWIN SEAPLANE FLOATS
INSTALLED ON A SUPER CUB AIRPLANE
Aerocet, Inc.
P.O. Box 2119
265 Shannon Lane
Priest River, Idaho 83856
Phone: [phone]
Fax: [phone]
This ICA must be followed when Aerocet 2200 Floats are installed in
accordance with Supplemental Type Certificate (STC) No. SA02000SE.
The information contained in this document supplements or supercedes the basic
manuals only in those areas listed herein. For limitations, procedures, and
performance information not contained in this manual, consult the basic aircraft
ICA or maintenance manual.

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LOG OF REVISIONS
Revision Pages Affected Description Date Approved
00 All Initial Release 4/14/2009 --
01 All Re-arranged and added multiple per FAA
comments. Added 1.2 Availability and
Revisions. Added Heading 1.4
Dimensions, Locations and
Nomenclature. Moved all of Sec. 4 to
Section 2. Added 2.6 Inspections
Heading; 2.10.10 Placards; 2.11
Troubleshooting. Sec. 4 changed to
Airworthiness Limitations, all new.
4/30/09
02 10
21
31, 34 & 38
89-97 [New]
Spelling correction, Fig. 1.4.6.
Corrected Fig. # from 8 to 2.9.1.1.
Added references to applicable drawings
for PA-18 Wide Body Installations.
Added Appendix A.
No changes to limitations. No FAA
review required.
6/16/09
03 (Old pg. #’s 59,
61, 62) (Figures)
65, 67, 68
Flying wires corrected, 22-34035 and
22-34036 were reversed fore and aft.
Formatting – all Sections to start on odd
pages.
3/4/10
This document is maintained by Fliegen Works Inc. and is on file as FW-ART481-13

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TABLE OF CONTENTS
Log of Revisions .....................................................................................................3
Table of Contents.....................................................................................................................5
1. Introduction............................................................................................................7
1.1. How to Use This Supplemental Manual..........................................................7
1.2. Availability and Revisions................................................................................8
1.3. General Description..........................................................................................9
1.4. Dimensions, Locations and Nomenclature....................................................10
2. Maintenance Manual...........................................................................................15
2.1. General Practices ............................................................................................15
2.2. Product Listings ..............................................................................................15
2.3. Fastener Torque..............................................................................................16
2.4. Fastener Torque Values (Except where otherwise noted)...........................17
2.5. Fastener Use and Discretion...........................................................................19
2.6. Inspections .......................................................................................................20
2.7. Special Inspections..........................................................................................22
2.8. Float Handling and Jacking...........................................................................23
2.9. Floats Installation............................................................................................23
2.10. Conversion from Wheels to Floats.................................................................35
2.11. Troubleshooting ..............................................................................................46
2.12. Conversion from Floats to Wheels.................................................................46
3. Repair Manual .....................................................................................................49
3.1. Struts ................................................................................................................49
3.2. Composite Float Hulls ....................................................................................49
3.3. Repair Types and Procedures........................................................................50
3.4. Impregnation of Fabric ..................................................................................51
3.5. Resin Mixing....................................................................................................51
3.6. Preparation of Fiberglass Materials..............................................................52
3.7. Surface Coat Application (Gel Coat) ............................................................53
3.8. Keel and Wear Strip Attachment..................................................................53
4. AIRWORTHINESS LIMITATIONS ................................................................55
5. Illustrated Parts Catalogue.................................................................................57
5.1. List of Figures..................................................................................................57
APPENDIX A. Catalog Pages for PA-18 “Wide Body”.....................................................89

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1. INTRODUCTION
Thank you for choosing Aerocet Floats. This manual covers the installation and
maintenance of the 2200 floats as installed on the PA-18 Piper Super Cub airplane (and
similar models), including instructions for installing the struts, steps, water rigging, and
float structure. An IPC is also provided.
1.1. How to Use This Supplemental Manual
Used in conjunction with the Piper Owner's Manual, and Illustrated Parts Catalogue
for a Super Cub, airplane, this supplemental manual provides the operator with a source
of information for installing, removing, repairing, and maintaining Aerocet Model 2200
Twin Seaplane Floats on a Super Cub.
This manual is organized as follows:
Maintenance Manual. Instructions and information necessary to maintain, install,
and remove the Aerocet Model 2200 Twin Seaplane Floats on a Piper Super Cub
airplane.
Repair Manual. Instructions necessary to repair Aerocet Model 2200 Twin
Seaplane Floats installed on a Piper Super Cub airplane.
Instructions for Continued Airworthiness. Instructions necessary to inspect and
maintain an airworthy state with Aerocet Model 2200 Twin Seaplane Floats on a Piper
Super Cub airplane. These instructions include Preflight, Daily, Periodic, and Special
inspections.
Illustrated Parts Catalog. Drawings and parts necessary to use the Aerocet Model
2200 Twin Seaplane Floats on a Piper Super Cub airplane.

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1.2. Availability and Revisions
One complete, hard (paper) copy of this manual shall be provided with each new set
of Aerocet Model 2200 floats. Additional copies and minor revisions shall be available
via email, U.S.P.S (Mail), UPS or FedEx by request. Fees and delivery charges may
apply.
Notification of any changes that require service for airworthiness shall be
distributed to all applicable Aerocet owners on record with Aerocet, Inc. In such a case,
copies of the applicable, revised portions of this manual shall be provided.
Aerocet, Inc. maintains record of purchasers and/or owners collected at the time of
purchase in order to comply with the above as well as to maintain a high standard of
service. If you have moved since your original purchase, have purchased a used product
or otherwise have reason to believe that the contact information on file is incorrect,
please provide the following information to Aerocet, Inc: (Aerocet contact information is
on the front of this document.)
Float Information:
Float Model: _________________________________
Float S/N (R/L) _______________________________
Aircraft Information:
Aircraft Make/Model __________________________
Aircraft Registration ___________________________
Aircraft S/N _________________________________
Owner Information: (as applicable)
Previous Owner ______________________________
Previous Address _____________________________
Present Owner _______________________________
Present Address ______________________________
Present Phone Number ________________________
Present Email Address _________________________

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1.3. General Description
The Aerocet Model 2200 Twin Seaplane Floats are all-composite float hulls. The
float hulls are separated by spreader bars that slide into the float assemblies. The float
design uses a double-fluted bottom contour from the step forward, and has a flat top deck
design with built-in antiskid. Each float offers a large storage locker.
Water rudders are mounted on the stern of each float for water-taxi operations, and
are connected directly to the airplane’s rudder. The retract system, which is compatible
with OEM and other approved cockpit handles, is installed in the standard manner.
Each float is attached to the airplane by forward, mid, and aft struts. Bolted to the
upper end of the forward and mid struts is an attachment block, and to the upper end of
the aft struts, a swivel fitting. The forward and mid struts are attached to the landing gear
fitting. At the lower end, the forward struts are bolted to an attachment fitting, which in
turn, is bolted to the forward attachment lug on the float. The mid and aft struts' forked
attachment fitting is bolted to the rear lug on the float.

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1.4. Dimensions, Locations and Nomenclature
Figure 1.4.1
Figure 1.4.2

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Figure 1.4.3
Figure 1.4.4

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Figure 1.4.5

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Figure 1.4.6

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2.
2. MAINTENANCE MANUAL
2.1. General Practices
1. Metal Parts: check for corrosion (rust), stress cracks or metal distortion, elongation of
holes, and rivet damage.
2. Critical Bolts: check for corrosion (rust), wear, and torque. It is recommended that
some form of corrosion-inhibiting compound be applied to all threaded fasteners and
other similar parts. Possible products used include those listed in the Product Listings
that follow, but are not limited to these products. Apply per manufacturer
recommendations only.
3. Composite Parts: check for stress cracks, gel coat presence (UV protection), and
punctures. (Section 5 covers repair and re-work of composite parts.)
4. All parts/fasteners that penetrate float structures, such as a bulkhead or the float deck,
must be sealed with marine-grade urethane adhesive such as Sikaflex 292.
2.2. Product Listings
1. Float Sealant for Bolts and Chine Strip Attachment: Sika Manufacturing
Sikaflex 292.
2. Rust (corrosion) Protection: ACF-50, Corrosion X, Boeing Company Boeshield T9.
3. Bolt Protection: PUR-AL-KETONE, which is distributed by Lake and Air; LPS
Industries LPS 3; Zip Chemical Company Zip D-5029NS.
4. United EZ Turn Lubricant: Produced by United Erie 1-800-377-7561, and available
through distributors.
5. Composite Materials for Hull Repair: Contact Aerocet, Inc., for resin, cloth, gel-coat,
resin thickeners.

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2.3. Fastener Torque
2.3.1. Torque Value Conversion:
To convert in.-lbs. to ft.-lbs: Value (ft.-lbs.) x 12 = Value (in-lbs.)
To convert ft.-lbs. to in.-lbs: Value (in-lbs.) x 0.0833 = Value (ft.-lbs.)
2.3.2. Tooling Requirements:
Calibrated torque wrench
Adapters that affect the length of the torque wrench will affect the required
torque indication and must be calculated according to Figure 1.4.3.
2.3.3. Hardware Cleanliness
All hardware is to be free of dirt, grit and grease. All dirty hardware shall be
thoroughly cleaned and lubricated with a dry film lubricant such as LPS 1, or
Teflon products per manufacturer instructions. It is recommended that all
stainless hardware be thoroughly lubricated with anti-seize lubricant of good
quality to prevent galling upon assembly.
2.3.4. Torque Procedure
Assure that hardware is clean and properly prepared for installation. Assemble
nuts to bolts, measuring the tension required to turn the nut and add this to the
required final torque. Where possible apply torque to the nut, and not to the
fastener head. Apply a smooth, even pressure, stopping and re-torquing if
chattering or premature loading occurs. This may warrant disassembly and
subsequent inspection for burrs or galling. Replace any damaged hardware.
Access panels should be torqued only to "hand tight", the fiberglass should
exhibit only mild deformation. A portable hand drill could be used, provided
that the clutch is set properly. Do not apply more pressure to the hatch screws
than is necessary to engage the tool to the fastener head as this will risk
damaging the Tinnerman style nuts below.
All other nuts shall be torqued per Section 1.4 unless otherwise noted.

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2.4. Fastener Torque Values (Except where otherwise noted)
Figure 2.4.1 Recommended Torque Values (inch-pounds)
(from AC43.13-1B, Table 7-1)
Figure 2.4.2 Minimum Prevailing Torque Values for Re-used Self-Locking Nuts
(from AC43.13-1B, Table 7-2)
Self-Locking Nuts:
Self-locking nuts, when re-used, must
have at least the minimum prevailing
torque listed in figure to the left. Nuts that
are smaller than those listed in the table
shall not be used if they can be run up by
hand.

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Figure 2.4.3 Torque Wrench with Various Adapters
(from AC43.13-1B, Figure 7-2)

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2.5. Fastener Use and Discretion
2.5.1. Fastener Lengths
Rivets: Where replacement or repair of rivets is required, use rivets of proper
specifications only. For instance, MS203426AD4-xxx. Lengths may be
determined by measuring the thickness of the material(s) to be assembled and
adding 1.5" X Diameter of the rivet to be used. Over-sized rivets may be
substituted where holes have been drilled out.
Bolts and screws shall have a minimum of one thread visible through the nuts upon
final torque.
Washers may be rearranged if necessary to accommodate proper fit, up to two
washers beneath the nut and one beneath the fastener head. Typically, Aerocet
intends to put one thin washer beneath the fastener head and one thicker washer
beneath the nut.
2.5.2. Fastener Reuse
Fasteners are to be inspected per Section 4 of this manual for condition. Such
fasteners that are acceptable, may be cleaned, re-lubricated and re-installed as
determined. Self-locking nuts shall meet the minimum prevailing torque as listed in
Figure 1.4.2, or shall be replaced.

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2.6. Inspections
2.6.1. Part 1, Preflight
Conduct Preflight inspections according to existing Piper owner's manual, and
add the following to the Airframe group:
1. Check Float lockers secured.
2. Pump out all compartments to assure no damage has occurred.
Anything more than 4-5 full pumps should be investigated.
2.6.2. Part 2, Daily Inspections
Conduct daily inspections according to existing Piper Owner's Manual, and
refer to Table 1, Recommended Airworthiness Service Schedule, below.
2.6.3. Part 3, Periodic Inspections
Conduct periodic inspections according to existing Piper owner’s Manual
section 4, and add the following inspections in Table 4.5, Recommended
Service Schedule, below.