Kitfox Aircraft Super Sport 2017 User manual
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Kitfox Aircraft LLC ©2008 - 2018
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KITFOX SUPER SPORT
FINAL ASSEMBLY
KITFOX AIRCRAFT
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Table of Contents
Table of Contents
Section A. Instrument Panel Installation .....................................................................................................4
Section B. Fuel System Installation ..........................................................................................................12
Section C. Airframe Electrical Installation ...............................................................................................20
Section D. Flight Control Rigging ............................................................................................................32
Section E. Windshield and Glare Shield Installation ................................................................................44
Section F. Quarter Window Installation ....................................................................................................52
Section G. Turtledeck Assembly and Installation .....................................................................................54
Section H. Tail Access Cover Installation .................................................................................................60
Section I. Wing Root Fairing Installation .................................................................................................66
Section J. Brake System Routing and Bleeding ........................................................................................70
Section K. Antenna Installation ................................................................................................................80
Section L. Systems Checkout ...................................................................................................................82
Section M. Weight and Balance ................................................................................................................84
Section N. Paperwork ...............................................................................................................................90
Section O. Final Inspection Checklist .......................................................................................................94
Section P. Airworthiness Certication Inspection ..................................................................................104
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Table of Contents
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Section A. Instrument Panel Installation
Section A. Instrument Panel Installation
The standard instrument panel for the Super Sport is made from a single piece
of aluminum sheet that is mounted to the fuselage on four welded tabs and two
steel tube panel braces. The braces attach to the fuselage with cushioned loom
clamps, and the welded tabs use rubber grommets as shock absorbers.
Panel space is sufcient for a well-equipped layout, and more than ample for
the most common instrument combinations.
The panel comes uncut so you can determine your own specic layout. A
template of standard instrument cutouts is provided on the fuselage template
sheet and on Figure A-2. The nonstandard Rotax tachometer cutout pattern is
also shown on Figure A-2.
Be patient and give the layout plenty of consideration. As you will spend many
hours ying behind your panel, a little forethought now will go a long way
toward your future ying satisfaction.
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AVIONICS RACK ANGLES (x 2)
AVIONICS
PANEL OPENING
INSTRUMENT
PANEL BRACE (x 2)
INSTRUMENT PANEL BRACE
FUSELAGE ATTACHMENT
POINTS LOWER PANEL
MOUNTING POINTS (x 4)
FUSELAGE
INSTRUMENT
PANEL ASSEMBLY
Figure A-1
Instrument Panel Overview
Section A. Instrument Panel Installation
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DATE
1. Trim the instrument panel with a le until the desired shape is achieved.
Hold the panel in the fuselage, centered over the panel mounting tabs,
and mark the location of each tab on the panel.
NOTE
When planning the layout of the instruments and components in the panel,
avoid placing them in the areas near the mounting tabs to prevent conicts
with the mounting hardware.
2. Make a list of every instrument and component that will be immediately
installed in your panel, along with any instruments or components that
you might be installing in the future. Create your desired panel layout,
giving thought to the visibility of the instruments, accessibility of switch-
es, interference with fuselage tubing or conict with other instruments,
possible resale value, and every other possible consideration that you can
think of. When you are completely satised with your planning, cut the
panel for the instruments and avionics. A y-cutter mounted in a drill
press is probably the best technique for making the larger instrument
panel holes.
NOTE
Since instrument sizes can vary, we suggest that you actually obtain the
instruments you desire to install and measure them prior to cutting the
panel. This is especially true of automotive gauges and stereos, which do
not conform to any aircraft standards.
Completion Date
_______________
Section A. Instrument Panel Installation
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LAYOUT AND FABRICATE
PANEL AS DESIRED
TYP
3-1/8"
(79mm)
TYPICAL 3-1/8"
INSTRUMENT HOLE
PATTERN
#18 DRILL TYP
45°
TYP
TYPICAL 2-14"
INSTRUMENT HOLE
PATTERN
TYP
ROTAX TACHOMETER
INSTRUMENT HOLE
PATTERN
2-17/64"
(57mm)
2-21/32"
(67mm)
SOME INSTRUMENTS
3-1/2"
(90mm)
14
GPS
COMM
XPDR
SAMPLE INSTRUMENT PANEL LAYOUT
NOTE:
ENGINE CONTROL HOLE SIZES
AND LOCATIONS VARY BY ENGINE TYPE
15
C
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
AIRSPEED INDICATOR
ALTIMETER
TURN COORDINATOR
VERTICAL SPEED INDICATOR
'QUAD' ENGINE INSTRUMENT
TACHOMETER
VOLT/AMMETER
LOW FUEL LIGHT & TEST SWITCH
KEYED IGNITION SWITCH
MASTER SWITCH
AVIONICS MASTER SWITCH
SYSTEMS SWITCHES
THROTTLE MOUNTING HOLE
ENGINE CONTROL MOUNTING HOLE
ENGINE CONTROL MOUNTING HOLE
CIRCUIT BREAKERS OR FUSES
PASSENGER WARNING PLACARD
AUDIO INTERCOM
ACCELEROMETER
SAMPLE INSTRUMENT PANEL LEGEND
2-5/16"
(58mm)
2-5/8"
(67mm)
7
19
16
17
18
4-7/8"
(124mm) 13/16"-1" TYPICAL
(20-25mm)
1
2
6
5
1-3/8"(35mm)
1
3
910 11 12
8
13/16"-1" TYPICAL
(20-25mm)
7/8"(22mm)
TYPICAL
2
4
1"(25mm) N194SD
6
5
13 14 15
45°
45°
Figure A-2
Instrument Panel Layout and Preparation
Section A. Instrument Panel Installation
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Kitfox Aircraft LLC ©2008 - 2018
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3. Place the panel in the aircraft and clamp it to the fuselage mounting
tabs. Drill up through the steel tabs and into the lower mounting ange
of the panel using a 3/16” bit. Deburr the panel holes after drilling.
4. Cut the supplied avionics rack angles to the required lengths for your
installation. If necessary, trim the width of the avionics rack angle anges
to clear any instruments or components immediately next to the radios.
5. Drill the avionics rack angles and instrument panel for the angle mounting
hardware and deburr, as shown in Detail “A” of Figure A-3. Countersink
the lower ve holes in the panel face; do not countersink the top hole
on each side. Bond prep the mating surfaces of the angles and panel
with Scotch-Brite and clean with denatured alcohol. Rivet and bond
the angles in place using structural adhesive and the pop rivets shown.
6. Enlarge the two top holes to 9/64” for the AN526-632R8 screws. Cut
two pieces of tubing to t between the panel and fuselage as shown.
Flatten about 1” of each end to creat mounting tabs. Bend and drill the
tabs to t on the panel with the hardware shown. Mount the instrument
panel braces to the instrument panel using the top hole of the avionics
rack angles on each side. Install the braces loosely at this time.
7. Enlarge the holes in the four fuselage mounting tabs to 5/16” and deburr.
Install the grommets into the tabs and temporarily install the panel in
the aircraft using the hardware shown in Detail “B”.
8. The forward ends of the instrument braces mount to the fuselage tubing
with clamps as shown in Detail “C”. Adjust the locations of the clamps
and braces until the panel face is perpendicular to the longitudinal axis
of the aircraft (instrument panel is plumb when fuselage is leveled
longitudinally).
9. Fabricate and install the ve glare shield mounting angles in the locations
shown in Detail “D”. The glare shield itself will be installed after the
windshield installation. Remove the instrument panel from the aircraft.
Completion Date
_______________
Section A. Instrument Panel Installation
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3/16" (5mm)
(x 4)
3
"D"
"B"
1"
LTR DESCRIPTION PART NO QTY
A AVIONICS RACK ANGLE 12912.000 2
B ALUMINUM TUBE 3/8" x .035 21902.000 1
C ALUMINUM ANGLE 52907.000 1
D CLAMP, MS21919-DG-10 96025.000 2
E GROMMET, AN931-3-5 91289.000 4
F GROMMET, AN931-4-12 91128.000 4
G SCREW, AN526-632R8 91278.000 2
H SCREW, AN526-1032R8 91119.000 2
J SCREW, AN526-1032R16 91199.000 4
K NUT AN364-632 91062.000 2
L NUT AN364-1032 91064.000 6
~
N WASHER AN960-6 91143.000 2
P WASHER AN960-10 91147.000 2
Q WASHER AN960-10L 91148.000 4
R WASHER AN970-3 91151.000 4
S RIVET, 1/8" x 1/8" AL FH 90035.000 10
T RIVET, AN426AD-3-3 91099.000 10
U INSTRUMENT PANEL 11067.101 1
L
"A"
Q
F
E
R
J
H
D
P
L
"C"
DETAIL "A"
AVIONICS RACK
ANGLE INSTALLATION
#30 (x5)
BOTTOM 5
HOLES ONLY
9/64"
(4mm)
4
5
6
3/4"
3/4"
1/2"
1-3/8" TYP.
1/2"
COUNTERSINK
G
K
#35 (7/64")
DETAIL "D"
GLARE SHIELD
MOUNTING ANGLES
FABRICATE FROM [ C ]
(TYPICAL 5 PLACES)
9
1"
(25mm)
DETAIL "B"
LOWER INSTRUMENT
PANEL INSTALLATION
(TYPICAL 4 PLACES)
INSTRUMENT
PANEL
FUSELAGE STRUCTURE
7
5/16"
(8mm)
DETAIL "C"
INSTRUMENT PANEL
SUPPORT INSTALLATION
(TYPICAL 2 PLACES)
8
B
K
N
A
U
6
Figure A-3
Instrument Panel Installation
Section A. Instrument Panel Installation
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NOTE
The panel should be surface prepped, nish painted, and labeled prior to
installing the instruments and components.
10. With the panel on the bench, install all instruments, switches, avionics
mounting trays, etc. Wire the panel as much as possible, as it is much
easier to do on the bench than in the aircraft.
11. Reinstall the panel in the aircraft and permanently mount it with the
hardware previously utilized in the initial installation.
NOTE
Depending on the weight of your avionics installation, you may need to
fabricate an avionics rack support to prevent the panel from sagging. At-
tach the support to the side or back of the avionics trays and secure it to
the nearest structural tubing.
12. Make the various connections to the aircraft as required by your equip-
ment. (Further information on airframe electrical installation is given
in Section C of this chapter).
CAUTION
The airspeed indicator will need to be properly marked for the oper-
ating range for the Kitfox Super Sport. These marks allow the pilot
to quickly verify certain operating parameters in ight. Four colored
bands are used which are described below.
RED LINE - 140 mph. The red mark is called the Never Exceed Speed
(VNE). This airspeed should never be exceeded.
YELLOW ARC - 120 to 139 mph. The yellow band is an airspeed range
that should not be used unless in smooth air and then only with caution.
GREEN ARC - ?? to 119 mph. The green band is the normal airspeed
operating range for the aircraft. The bottom of the green arc represents
the airspeed that the aircraft will stall at under the following conditions:
level ight, idle throttle, no aps, and at gross weight. This speed must be
determined during ight testing. The top of the green arc is the maximum
structural cruising speed.
WHITE ARC - ?? to 80 mph. The white band is the ap operating air-
speed range for the aircraft. The bottom of the white arc represents the
airspeed that the aircraft will stall at under the following conditions: level
ight, idle throttle, full aps, and at gross weight. This speed must also be
determined during ight testing. The top of the white arc is the maximum
speed at which the aps may be used.
Completion Date
_______________
Section A. Instrument Panel Installation
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Kitfox Super Sport
Kitfox Aircraft LLC ©2008 - 2018
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6-32 INSTRUMENT SCREWS
ALTERNATE METHOD - A8944-(XXX)-493
INSTRUMENT MOUNTING NUTS
6-32 NUT AND #6 WASHER
TYPICAL INSTRUMENT
MOUNTING DETAIL
CIRCUIT BREAKERS
10
11
INSTALL PANEL
IN AIRCRAFT
WIRE AND PLUMB
VERTICAL SPEED
INDICATOR
ALTIMETER
AIRSPEED INDICATOR
TO PITOT TUBE
TO STATIC PORT
KEYED IGNITION
SWITCH
OPTIONAL LOW FUEL
INDICATOR LIGHT &
TEST SWITCH
12
WIRE AND PLUMB
TO AIRCRAFT
Figure A-4
Typical Instrument and Pitot-Static System Installation
Section A. Instrument Panel Installation
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Section B. Fuel System Installation
The Kitfox Super Sport fuel system uses two wing-mounted fuel tanks which
gravity-feed fuel to a vented header tank. From the header tank, the fuel ows
forward to a fuel shut-off valve, through the rewall, and to the engine fuel
pump. The fuel system components downstream of the header tank are supplied
with the engine component kit due to variations dependent upon the engine
type selected.
A quick-drain tting is provided in the bottom of the header tank for removal
of water and sediment from the fuel (this is the fuel system’s lowest point, and
therefore acts as a sump). This drain should be checked during every preight
inspection. Quick-drain ttings are also provided in the sump of each fuel tank.
A simple sight gauge is provided on each fuel tank for an accurate indication
of fuel remaining. An optional low fuel level warning system can provide you
with a warning of impending fuel starvation, allowing you time to land the
aircraft safely. A Low Level Fuel Sensor kit is available from Kitfox Aircraft
part number 73504.000
The fuel system is vented by means of vented fuel tank caps. The header tank
is vented to the right wing tank to allow trapped air to be easily vented to the
wing tank.
CAUTION
Because of the added weight and possible loss of fuel, the wing tanks should
be empty (or nearly so) before the wings are folded.
Section B. Fuel System Installation
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TYGON
HEADER TANK
VENT LINE
HEADER TANK
DRAIN FLANGE
VENTED FUEL
FILLER CAP
RIGHT SIDE 13-GALLON
FIBERGLASS FUEL TANK
ALUMINUM HEADER TANK
FEED LINE TO FUEL VALVE
ON CONSOLE
WING TANK
QUICK DRAIN
RUBBER
WING TANK
FEED LINES
LEFT SIDE 13-GALLON
FIBERGLASS FUEL TANK
FWD
ALUMINUM
HEADER TANK
HEADER TANK
QUICK DRAIN
WING TANK SIGHT GAUGE
Figure B-1
Fuel System Installation Overview
Section B. Fuel System Installation
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DATE
Completion Date
_______________
Section B. Fuel System Installation
1. Install the ttings in the header tank appropriate for your particular en-
gine installation. Use a fuel-resistant, paste-type thread sealant such as
Permatex® Tack & Seal 9AR on the ttings before installing them in the
header tank.
NOTE
The header tank outlet tting will vary depending on engine choice. The Rotax
912, 912S, and 914 engine installations use the P/N: 43036.000 (AN822-5-
4D) elbow tting for use with 5/16” O.D. fuel lines while the O-200, O-235,
and IO-240 use a P/N: 90138.000 AN822-6D elbow tting for use with 3/8”
O.D. lines.
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DATE
ELBOW SUPPLIED
IN ENGINE KIT
LTR DESCRIPTION PART NO QTY
A HEADER TANK 74005.301 1
B QUICK DRAIN 24012.000 1
C FITTING, 1/4" NPT x 1/4" BARB 94014.000 1
D FITTING, 1/4" NPT x 5/16" BARB 90064.000 2
E PLUG, AN913-2D 94016.000 1
FWD
(x 2)
A
B
OPTIONAL FUEL RETURN LINE
C
D
E
Figure B-2
Header Tank Assembly
Section B. Fuel System Installation
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2. Install the header tank onto the fuselage tubing, forward of the rear seat
bulkhead tubing on the right side. The angled top of the header tank
faces forward to ensure ample clearance with the seat back. You’ll nd
that by adjusting the location of the header tank in relation to the tubing
that there is one point where all the tabs will align with the mounting
ears of the tank. Match drill the four mounting tabs. Use the hardware
shown to install the tank.
3. Test t and trim the P/N: 14042.103 shielding tube that seals the area
between the header tank and the ange as required until the ange will
sit ush against the inside face of the bottom fuselage fabric (stretch
a scrap piece of fabric or an old cotton sheet across the bottom of the
fuselage to simulate the approximate fabric line if the fuselage fabric
is not installed).
4. During the fabric covering process, install a fabric reinforcing patch that
is 2” larger in diameter than the P/N: 90068.000 ange to the bottom
fuselage fabric directly under the header tank quick-drain.
5. With the shielding tube and ange installed on the header tank, apply
Poly-Tak to the ange where it contacts the fabric and quickly, but
lightly, press it against the inside face of the bottom fuselage fabric.
When the adhesive has cured, cut open the fabric to allow access to the
quick-drain tting from outside the aircraft. The easiest and most secure
way to do this is to make a series of slits with a razor blade across the
inside diameter of the ange, forming pie-shaped sections of fabric. Do
not completely cut away these sections of fabric; leave them attached
to the ring formed by the outside diameter of the ange. Cement these
pie-shaped sections of fabric to the wall of the ange with Poly-Tak.
Completion Date
_______________
Section B. Fuel System Installation
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APPROX 1-5/8"
(40mm) LONG
FABRIC REINFORCING
PATCH
FWD
2
4 5 3
REAR SEAT
BULKHEAD
TUBING
LTR DESCRIPTION PART NO QTY
A FLANGE 90068.000 1
B SHIELDING TUBE 14042.103 2"
C BOLT, AN3-4A 91030.000 4
D NUT, AN365-1032 91069.000 4
E WASHER, AN960-10 91147.000 4
D
E(x 4)
(x 4)
(x 4) C
B
A
.1875
2
HEADER TANK
ASSEMBLY
Figure B-3
Header Tank Installation
Section B. Fuel System Installation
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DATE
6. Install the fuel supply hoses and the fuel vent hose between the wing
tanks and the header tank. Begin with the wings unfolded and start
with the wing tank end of the hoses. Tape (or otherwise temporarily
attach) the hose to its appropriate tank tting and route the hose in a
service loop around the aft spar bolt location and along the fuselage
tubing to the header tank. With the tubing temporarily routed, test for
sufcient service loop by having a helper fold the wings while you
observe the hoses. Ensure that they are not stressed by the folding
procedure and that they are not kinked or pinched with the wing in
either position. When you are certain that the hose routings are correct,
push the hoses onto the wing tank ttings and go through the folding
procedure again. If all is still well, slide the loosened hose clamps onto
the hoses and secure the hoses to the fuselage tubing with cable ties.
Cut the hoses to length and push them onto the header tank ttings.
Tighten the hose clamps to secure the installation.
WARNING
Ensure that the hoses run continuously downhill from the wing tank
to the header tank without any high spots that could entrap air and
cause an interruption in the supply of fuel to the engine. Check for
this condition with the fuselage in a level ight attitude (fuselage level).
WARNING
Be careful not to pinch the vent hose shut with an overly tight cable tie.
CAUTION
Be certain that there is sufcient service loop to allow the wings to
fold without distressing or kinking the fuel hoses.
Completion Date
_______________
Section B. Fuel System Installation
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Kitfox Aircraft LLC ©2008 - 2018
DATE
(x 2) LEFT TANK
FWD
VENT LINE
RIGHT TANK
LTR DESCRIPTION PART NO QTY
A HOSE, MIL-H-6000-5/16" 04076.000 X
B TUBING, TYGON 04080.000 X
C HOSE CLAMP 96022.000 4
D CLAMP, PLASTIC 96014.000 2
A
B
C
D
D
A
FROM
HEADER
TANK
RIGHT WING FUEL TANK SHOWN
LEFT MIRROR IMAGE (LESS VENT LINE)
VENT LINE
TO
LEFT TANK
Figure B-4
Fuel Hose Installation
Section B. Fuel System Installation
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DATE
Section C. Airframe Electrical Installation
For the installation of the airframe electrical system we are going to start with the
basic concepts and use an example of a single circuit to illustrate correct aircraft
wiring principles. If you are already familiar with electrical system fundamentals
you might wish to skip ahead. If electrical systems are a mysterious magic, and
the thought of wiring your own aircraft makes your hands tremble, read on - it’s
much easier than you think.
Electricity, at its base level, is a bunch of electrons looking for a place to go.
An electrical system, therefore, is a means of controlling travelling electrons by
providing them with discrete paths of travel. EVERY component in an electrical
system will have one of three functions: producing electrons that want to get
somewhere, providing a path for the electrons to travel, or keeping the electrons
on the desired path.
Components which provide electrons are generators, alternators, and batteries.
Components which provide a path are metallic conductors (wire, or the airframe
tubing), wire terminals, solenoids, switches, circuit breakers, motors, lights, and
avionics.
Components which keep electrons on the desired path are insulation (on the wire),
circuit boards, grommets, wire ties, chafe protection, heat shrink, battery boxes,
terminal screws, and nuts.
For the anxious-to-travel electrons, the path must form a complete loop, or circuit,
for them to go anywhere. How many of the electrons travel down any given path
depends on the resistance to electron ow of that path. A path with zero or very
little resistance will have a great many electrons moving along it; a path with
high resistance will have relatively few. Imagine a funnel full of sand with a large
opening on the neck. The sand will run through it quickly. If the funnel neck is
a bit smaller, not as many grains can get through in the same period of time. If
the neck is so small that only one grain at a time can pass, you still have owing
sand, but at a very slow rate. Electrical circuits are the same way - the number of
electrons that can ow in a circuit is limited by the highest restriction in that circuit.
Section C. Airframe Electrical Installation
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