Lancair Legacy Fixed Gear Owner's manual

LEGACY FG 033-0004 Page S.A REV. 1/08-10-2007
Revision List: Supplement – Legacy Fixed Gear
Lancair International Inc., Represented by Neico Aviation Inc., Copyright 2007 Redmond, OR 97756
Revision List: Supplement – Legacy Fixed Gear
The following list of revisions provides the updates to the Legacy Fixed Gear (FG) construction supplement.
Under the “Action” column, “R&R” directs you to remove and replace the pages affected by the revision. “Add”
directs you to insert the pages shows and “R” to remove the pages.
Pages Affected Revision # and Date Action Description
S.1 1/08-10-2007 R & R Updated table of contents for new page S.23B.
S.2 - S.4 1/08-10-2007 R & R Updated part number lists for changes made in supplement’s instructions and graphics.
S.8, S.13, S.21, S.23, S.32, S. 33 1/08-10-2007 R & R Updated part numbers in graphics and in instructions.
S.23B 1/08-10-2007 Add New page describing the assembly of the nose wheel and tire.
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LEGACY FG 033-0004 Page S.1 REV. 0/04-23-2007
Supplement–Legacy Fixed Gear
Lancair International Inc., Represented by Neico Aviation Inc., Copyright 2007 Redmond, OR 97756
Supplement–Legacy Fixed Gear S.1 Introduction
The Legacy Fixed Gear Kit is shipped with the standard Legacy Assembly Manual. You will need to use that manual
for the majority of the building of your Legacy Fixed Gear. But there are some sections that are different. This Legacy
FG Supplement provides the instructions for, and replaces the following sections of the Legacy Assembly Manual:
Supplement Section Replaces Chapter in Legacy Assembly
Manual Replaces these Sections of the Chapter
Main Gear Installation
Ch. 3 - Wing Systems
Ch. 16 - Hydraulic Systems Completion
E. Main Gear Doors
F. Main Gear Installation
H. Center Wing Section Hydraulics
Entire chapter 16 is not installed.
Nose Gear Installation Ch. 13 - Firewall Forward D. Nose Gear Installation F. Nose Gear Doors
G. Nose Gear Micro Switch
Wheel Pants and Fairings All New Material (Not in standard assembly manual)
Aileron Idler Modifications Ch. 6 - Aileron Controls B.3 on page 6-6
Fuel System Modifications Ch. 4 - Fuel Systems C. Fuel Supply Lines on page 4-5
E. Fuel Return Lines on page 4-9
Appendix – Alternate Air
Assembly for the IO 360 New Information New Information
S.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .S.1
S.2 Parts Used in this Supplement . . . . . . . . . . . . . . . . . . . . . . . . . . . .S.2
S.3 Preparing for the Main Gear Installation . . . . . . . . . . . . . . . . . . . . .S.5
S.3.A Leveling the Fuselage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .S.5
S.4 Installing the Gear Legs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .S.6
S.4.A Positioning the Gear Leg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S.6
S.4.B Installing the Gear Leg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .S.6
S.4.C Setting the Toe-in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .S.11
S.4.D Installing the Axle and the Wheel . . . . . . . . . . . . . . . . . . . . . .S.14
S.5 Installing the Main Gear Fairings . . . . . . . . . . . . . . . . . . . . . . . . . .S.17
S.5.A Main Gear Fairings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .S.17
S.5.B Fuselage Gear Fairings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .S.22
S.6 Installing the Nose Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .S.23
S.6.A Installing the Nose Gear Strut . . . . . . . . . . . . . . . . . . . . . . . . .S.23
S.6.B Connections Between the Nose Gear Fork and Wheel BracketS.23
S.6.C Assembling the Nose Wheel and Tire . . . . . . . . . . . . . . . . . . .S.23B
S.6.D Installing the Nose Gear Fork . . . . . . . . . . . . . . . . . . . . . . . . .S.24
S.6.E Installing the Nose Gear Mounting Plate . . . . . . . . . . . . . . . . .S.25
S.6.F Nose Gear Leg Fairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .S.27
S.7 Installing the Idler Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .S.29
S.7.A Aligning the Idler’s Base Bracket . . . . . . . . . . . . . . . . . . . . . .S.29
S.7.B Installing the Idler’s Base Bracket . . . . . . . . . . . . . . . . . . . . . . S.30
S.8 Modifications to the Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . .S.31
S.9 Appendix A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .S.32
S.9.A Alternate Air Assembly for the TNIO 360/390 . . . . . . . . . . . . .S.32
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LEGACY FG 033-0004 Page S.2 REV. 0/04-23-2007
Supplement–Legacy Fixed Gear
Lancair International Inc., Represented by Neico Aviation Inc., Copyright 2007 Redmond, OR 97756
S.2 Parts Used in this Supplement
Aileron Idler
Item Part Number QTY Description
1) 209-0001 1 Bracket for aileron idler
2) 4581 1 Bellcrank assembly with bearing
3) AN3-11A 2 Bolt
4) AN365-1032A 2 Nylock nut
5) AN365-428A 5 Nylock nut
6) AN4-11 1 Bolt
7) AN4-11A 2 Bolts
8) AN960-416 7 Washers
9) CD315-12 4 Washers, special/tapered
10) F35-14 2 Rod-end bearing
11) MS24694-S104 4 Bolts (bracket to spar)
Composite parts for Wheel Pants and Fairings
Item Part Number QTY Description
1) 2044A 1 Nose gear leg fairing
2) 2044F 1 Nose gear fuselage fairing
3) 7043 2 Gear leg fairings
4) 7045 1 Nose gear pant
5) 7045L 1 Main gear pant, left
6) 7045R 1 Main gear pant, right
7) 7045LA 1 Main gear pant brake cover, left
8) 7045RA 1 Main gear pant brake cover, right
9) 7048L 1 Fuselage gear fairing, left
10) 7048R 1 Fuselage gear fairing, right
Nose Gear
Item Part Number QTY Description
1) 212-0041 1 Nut plate, nose fork
2) 212-0073 2 Plate, Keeper, Nose Gear
3) 229-0005 1 Link, Nose Gear
4) 432-0002 1 Nose Gear Cylinder
5) 433-0000 1 Nose Fork
6) 3455 1 Nose gear fearing mounting plate
7) 4717-01 1 Pivot Bearing Block, Left
8) 4717-02 1 Pivot Bearing Block, Right
9) 4717-03 2 Bearing
10) 4798 1 Spacer, Axle, Nose Wheel
11) 3326381K103 2 Nose Gear Bushings
12) 6381K103 2Bushing, Nose Gear
13) AN3-3A 4 Bolt
14) AN363-428 3 Lock Nut 1/4"
15) AN365-428 1 Nylock nut
16) AN365-528A 3 Nut, Nylock
17) AN4-23A 3 Bolt
18) AN426AD-4-4 8 Solid rivets
19) AN4-47A AN4-51 1 Bolt
20) AN5-17A 3 Bolts
21) AN960-10L 4 Washer, Lite
22) AN960-416L 8 Washer Thin
23) AN960-516 3 Washer, 5/16"
24) GM035-2 1 Nose gear wheel with bearings
25) GM035-2 1Nose gear wheel with bearings
26) GM038 2 Bushing, Axle, for nose wheel
27) K1000-5 4 Nut plates
28) AN960-516 MS20002C5 4Washers
29) AN5-11A MS21250-05013 2 Bolt
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LEGACY FG 033-0004 Page S.3 REV. 0/04-23-2007
Supplement–Legacy Fixed Gear
Lancair International Inc., Represented by Neico Aviation Inc., Copyright 2007 Redmond, OR 97756
30) AN5-12A MS21250-05015 2Bolt
31) RR-01 2Circlip
32) TB-1-05 1 Tow Bar Adapter
33) TR-5 x 8ply 1 Tire Nose Gear
34) Z02E276 1 Axle, Nose Gear
35) AN365-524A 4 Nuts
Main Gear
Item Part Number QTY Description
1) 075-00800 2 Torque Plate
2) 117-0005 4 Main axle spacer
3) 121-0000 2 Axle, FG
4) 209-0029 1 Bracket, Left Wheel Pant
5) 209-0030 1 Bracket, Right Wheel Pant
6) 7702 2 Main Landing Gear Legs
7) 7703-01 1 Upper Leg Attach, left
8) 7703-02 1 Upper Leg Attach, right
9) 7705-01 1 Axle Mount, Left
10) 7705-02 1 Axle Mount, Right
11) 7707 2 Link, Upper Leg Attach Assembly
12) AN365-428A 9 Nut, Nylock
13) AN365-528A 10 Nut, Nylock
14) AN4-12A 8 Bolt
15) AN4-16A 4 Bolt
16) AN4-20A 4 Bolt
17) AN4-22A 2 Bolt
18) AN5-6A 12 Bolt
19) AN960-416 12 Washer
20) AN960-416L 4 Washer, Thin
Nose Gear (Continued)
Item Part Number QTY Description
21) AN960-516 18 Washer
22) AN970-4 4 Large Area Washer
23) MS24694-S154 8 Screw countersunk
Fuel System
Item Part Number QTY Description
1) 4805 2 Fuel hose #8, straight-to-straight.
2) 2240-6-8S 1 Bulkhead fitting (3/8” NPT to #8 flare)
3) C5205x8x4 1 Pipe connector fitting (1/2” tube, 1/4” male pipe)
4) C5365x8 1 45 deg. elbow fitting with O-ring (1/2” tube, 1/2” pipe)
5) C5405x6x8 2 Male elbow fitting (3/8” tube, 1/2” male)
Alternate Air Assembly - For TNIO 360/390 as installed in Supplement Appendix
Item Part Number QTY Description
1) 212-0046 1 Plate and Tube Assembly
2) 557-24 1 Phenolic block
3) 118-0003A 1 Shim
4) 212-0040A 1 Door
5) 308L-045 1 Safety wire
6) 333-04B 1 Bracket, Spring Attach
7) 557-20B 1 Bellcrank
8) 557-22B 1 Door Bracket
9) 8356A37 1 Magnet
10) AN426A3-5 24 Rivet, Flat Head
11) AN470AD3-5 2 Rivet
12) AN470AD4-4 3 Rivet
13) AN525-832-R6 1 Screw, Washer Head
14) AN525-832-R7 12 Screw, Washer head
15) AN960-416 2 Washer
Main Gear (Continued)
Item Part Number QTY Description
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LEGACY FG 033-0004 Page S.4 REV. 0/04-23-2007
Supplement–Legacy Fixed Gear
Lancair International Inc., Represented by Neico Aviation Inc., Copyright 2007 Redmond, OR 97756
16) AN960-8 4 Washer
17) C81 1 Spring
18) K1000-08 12 Nut Plate
19) MS20001 1 Hinge
20) MS21042-06 1 Stop Nut, Plated
21) MS21042-08 4 Stop Nut, Plated
22) MS21042-4 1 Nut
23) 101-0050 MS24693-C32 1 Socket head Screw, Countersunk
24) MS24693-S50 3 Screw, Plated
25) AN4-10A MS24694-S103 1BoltScrew, Countersunk
Alternate Air Assembly - For TNIO 360/390 as installed in Supplement Appendix
Item Part Number QTY Description
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LEGACY FG 033-0004 Page S.5 REV. 0/04-23-2007
Supplement–Legacy Fixed Gear
Lancair International Inc., Represented by Neico Aviation Inc., Copyright 2007 Redmond, OR 97756
S.3 Preparing for the Main Gear Installation
S.3.A Leveling the Fuselage
Steps...
1. Set the fuselage to level for pitch and roll.
Remember to rest the fuselage high enough to allow room for the gear legs. Allow approximately 32” from the
floor to the bottom of the wing stubs.
Secure the fuselage in its level position.
2. Mark a center line on the floor. For more information on locating a center line, see Chapter 7, page 7-3 of the
Legacy Assembly Manual. This will refresh your memory on drawing a center line.
Figure S.3.A.1 Leveling the fuselage
S.4 Installing the Gear Legs
S.4.A Positioning the Gear Leg
The top of the gear leg needs to be 50° from horizontal.
Figure S.4.A.1 Cross-section view of the gear leg angle

LEGACY FG 033-0004 Page S.6 REV. 0/04-23-2007
Supplement–Legacy Fixed Gear
Lancair International Inc., Represented by Neico Aviation Inc., Copyright 2007 Redmond, OR 97756
S.4.B Installing the Gear Leg
Steps...
1. Locate the upper-leg attachment on the inside of the
forward wing spar. Position using the following
guidelines:
• Set as low as possible on the wing spar. Leveling
may require up to two tongue depressors between
the wing floor and the bottom of the upper-leg
attachment on the inboard side.
• Locate the inboard edge at 3” (75 mm) outboard
from the inboard spar bolt hole in the forward wing
spar. See the dimension location in Figure S.4.B.1.
2. Verify the position of the upper-leg attachment by
testing the aileron push-pull tube for clearance. The
aileron push-pull tube must clear the upper-leg
attachment.
For information on the location and assembly of the
aileron push-pull tube, see Chapter 6, Section B in the
Legacy Assembly Manual.
3. Clamp the upper-leg attachment in place.
4. Cut the gear leg hole so it is large enough to slide the
gear leg in place.
5. Insert the gear leg through the opening and into
position in the upper-leg attachment. See Figure
S.4.B.1.
6. Insert the bolt (AN4-22A) that holds the gear leg in
place.
Figure S.4.B.1 Locating the gear leg opening and attaching the upper-leg attachment.
3” (75 mm)
Two tongue depressors
should fit between wing
floor (spar cap) and
upper-leg attachment
Aileron push-pull tube.
Forward wing
spar
Upper-leg
attachment
Gear leg
Angle should be 50
° .
Gear leg opening
Check clearance!
Check clearance!
Set as low as possible on
the wing spar.
Inboard spar
bolt hole
50°

LEGACY FG 033-0004 Page S.7 REV. 0/04-23-2007
Supplement–Legacy Fixed Gear
Lancair International Inc., Represented by Neico Aviation Inc., Copyright 2007 Redmond, OR 97756
7. Check the angle of the gear leg.
• Needs to be at approx. 50° from horizontal.
• And, needs to be within 0.5°.
8. Adjust the position of the upper-leg attachment on the
wing spar as needed to obtain the 50° angle and re-
clamp.
9. Recheck the angle of the gear leg and make any
necessary adjustments.
10. Back drill and install the screws that hold the upper-leg
attachment in place.
Countersink from the front and insert a screw
(MS24694-S154) in each hole.
Add a washer (AN960-516) to the back and secure
with a nut (AN365-528A).
Now you are ready to install the gear leg.
Attaching the Gear Leg
You may have temporarily inserted the gear leg into the
upper gear attachment in the previous section when you
checked the angle of the leg, now you will finish the
installation.
±
Figure S.4.B.2 Completed upper-leg attachment with gear leg
Upper-leg
attachment
Gear leg
Installing the Gear Leg
The gear leg is already inserted into
the upper gear attachment.
1. Insert a bolt (AN4-22A), from the
top, through the sleeve and the
gear leg.
2. Secure the bolt with a washer
(AN960-416) and a locknut
(AN365-428A).
50DEG.

LEGACY FG 033-0004 Page S.8 REV. 0/04-23-2007
Supplement–Legacy Fixed Gear
Lancair International Inc., Represented by Neico Aviation Inc., Copyright 2007 Redmond, OR 97756
Securing the Upper-Leg Link
Now you will finish installing the upper-leg assembly by
installing the upper-leg link. First you need to determine
the fit of the upper-leg link and complete a release before
installing the remaining assembly.
See the next page for instructions.
Figure S.4.B.3 Securing the upper-leg attachment and link to the wing spar
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LEGACY FG 033-0004 Page S.9 REV. 0/04-23-2007
Supplement–Legacy Fixed Gear
Lancair International Inc., Represented by Neico Aviation Inc., Copyright 2007 Redmond, OR 97756
Steps...
1. Hold the upper-leg link (7707) in place against the
upper-leg attachment.
2. Check the aft wing spar and determine how much of a
release needs to be installed.
3. Tape the end of upper-leg link with clear tape. Add
flox and set the link in place. Use a tongue depressor to
create a clean fillet around the end of the link.
4. Install the six bolts that secure together the two
sections of the upper-leg attachment.Secure each bolt.
5. From the inside, mark the four bolt locations for
securing the upper-leg link’s aft end to the inside of the
aft wing spar.
6. Mark and back drill four holes.
7. Insert the four bolts from the inside and secure them on
the aft outside of the wing stub.
Now you are ready to check the toe-in angle as described in
the next section, Setting the Toe-in on page S.10.
Figure S.4.B.4 Upper-leg link held in place between upper-leg attachment and aft wind spar
Upper-leg link, 7707.
Upper-leg attachment
7703-01
Bolt, AN5-6A
Washer, AN960-516
Nylock nut, AN365-528A
(6 pieces of each)
Release tape end of
upper-leg link.
Bolt, AN4-12A
Washer, AN970-4
Nuts AN365-428A
(4 pieces of each)
Aft wing spar
Area for release

LEGACY FG 033-0004 Page S.10 REV. 0/04-23-2007
Supplement–Legacy Fixed Gear
Lancair International Inc., Represented by Neico Aviation Inc., Copyright 2007 Redmond, OR 97756
S.4.C Setting the Toe-in
In this section you will be setting the main gear’s toe-in
angle to 0.5°. We want to emphasize that the precision of
this setting is extremely important for ground handling and
tire wear.
Steps...
1. Attach the axle mount to the gear leg by slightly
snugging the set screw.
2. Using the fuselage center line that you drew on the
floor in Leveling the Fuselage on page S.5, find the
location for the toe-in lines:
The toe-in lines must:
• Be parallel to the fuselage center line.
• Be directly below the alignment tool using a plumb
bob as shown.
• Extend 3’(1 meter) in front of the gear leg.
3. Attach a 3.5’ (1.25 meters) or longer alignment tool to
the end of the gear leg.
Notice that the forward hole on the end of the axle
mount has some slack and the set screw can be
loosened and tightened as needed for leveling the
alignment tool.
4. Hang a plumb-bob as shown in Figure S.4.C.2 and
mark its position on the floor.
5. Make a mark on the alignment tool, 3’ (1 meter)
forward of the center of the end of the gear leg.
6. Hang a plumb bob at this spot. See Figure S.4.C.4 on
the next page.
Note: This process can also be done using a laser level.
Figure S.4.C.1 Alignment tool
Figure S.4.C.2 Marking the gear leg location in relation to the toe-in base line
Gear leg
7702
Set screw
Axle mount
7705-01
Alignment tool
Toe-in line
Leave some slack
in the forward hole.
Make sure the
alignment tool is level.
Rotate the gear leg until the
alignment tool is level.
This toe-in line is placed:
– Parallel to the fuselage
center line.
– Directly below the
alignment tool by using a
plumb bob as shown.
– Extends 3’ (1 meter) in
front of the gear leg.
Tip: Once the alignment
tool is level, cut two
wooden blocks of equal
height. Place one directly
behind the plumb bob
hanging from the gear leg
and place the other 3’ in
front of the gear leg.
Center Line

LEGACY FG 033-0004 Page S.11 REV. 0/04-23-2007
Supplement–Legacy Fixed Gear
Lancair International Inc., Represented by Neico Aviation Inc., Copyright 2007 Redmond, OR 97756
Again, make sure the alignment tool is level!
7. Mark the location of the plumb bob, at the 3’ (1 meter) forward location.
8. Measure the distance from the toe-in line on the floor to the mark at the end of the plumb bob.
This distance needs to be 5/16” (8 mm). Or, in other words the toe-in needs to be 0.5°.
You may need to rotate the axle mount to get the correct amount of toe in. Do this by loosening the set screw,
adjust as needed, and re-tighten the set screw. Now re-level the alignment tool.
Adjust as needed so the distance from the toe-in line to the plumb bob mark is 5/16” (8 mm) more at the 3’
(1 meter) forward mark than the mark at the end of the gear leg.
Figure S.4.C.3 Top view of the gear legs, the lines on the floor and the alignment tools
9. Re-check the dimensions.
• At 3’ (1 meter) in front of the center of the axle mount, the plumb bob needs to be 5/16” (8 mm) inside the line
on the floor.
10. Tighten all screws holding the gear leg and the alignment tool in place.
11. Re-check both plumb bobs, level the alignment tool and the toe-in angle.
Tip: If the alignment tool is not level, the toe-in angle will not be correct!
When you are satisfied that the toe-in angle is correct, you are ready to mark the bolt locations on the gear leg.
Figure S.4.C.4 Marking the second location at three feet in front of the gear leg
Alignment tool
Toe-in line
3’ (1 meter) forward
of the middle of the
axle mount.
5/16 (8 mm)
Plumb bob needs to be 5/16” (8 mm)
inside the line on the floor.

LEGACY FG 033-0004 Page S.12 REV. 0/04-23-2007
Supplement–Legacy Fixed Gear
Lancair International Inc., Represented by Neico Aviation Inc., Copyright 2007 Redmond, OR 97756
Securing the Axle Mount
Now that you have the gear leg correctly aligned, you are
ready to secure the axle mount with the two bolts.
Steps...
1. Remove the gear leg with the axle mount attached.
2. Mark the bolt locations used to secure the axle mount
using a drill bit or a transfer punch.
3. Create a small pilot hole in the gear leg, starting at 1/8”
and enlarge to 1/4”.
4. Using the pilot holes, drill the holes to final size with a
1/4” (6.3 mm) diameter drill. Drill the holes from both
sides.
WARNING: Do not drill the holes all the way
through from one side.
5. Slide a washer (AN960-416) over each of the bolts
(AN4-20A).
6. Slide the bolts through the axle mount and the gear leg.
7. Secure the bolts with another washer (AN960-416) and
a locknut (AN365-428A).
Figure S.4.C.5 Securing the axle mount to the gear leg
Procedure for drilling the gear legs and axle mounts
Using a drill press or a hand drill, with a letter C drill bit:
– Drill one side of the leg.
– Use cutting oil and turn the bit slowly. It may take a few
drill bits to get through the hardened steel gear legs. (Use a
cobalt steel drill.)
– Turn the leg over and drill from the other side.
– Now using a 1/4” drill bit or ream both holes in one go.

LEGACY FG 033-0004 Page S.13 REV. 0/04-23-2007
Supplement–Legacy Fixed Gear
Lancair International Inc., Represented by Neico Aviation Inc., Copyright 2007 Redmond, OR 97756
S.4.D Installing the Axle and the Wheel
In this section you will install the axle and attach it to the
axle mount.
Installing the Axle
• Notice you are using two different bolts, AN4-12A in
the top two holes and AN4-16A in the bottom two
holes.
Figure S.4.D.1 Securing the axle mount to the gear leg
Tip: Check the top bolt for bottoming out
before you tighten it. You may need to use a thick washer in
order to keep the threads from bottoming out.
Top bolt locations
1/08-10-2007

LEGACY FG 033-0004 Page S.14 REV. 0/04-23-2007
Supplement–Legacy Fixed Gear
Lancair International Inc., Represented by Neico Aviation Inc., Copyright 2007 Redmond, OR 97756
Assembling the Wheels and Tires
Securing the Wheels to the Axle
Use the Legacy Assembly Manual for the following
installations:
• Installing the wheels to the axle as described on
page 3-22.
• Installing the Cleveland Brake Assemblies.
Preparing for the Brake Installation
The following items must be complete before you can
install the Cleveland brake assemblies.
• The brake discs must be secured to the wheels.
• The wheels must be mounted on the axle.
Refer to the Legacy Assembly Manual, page 18-3, to
complete the brake installation.
Figure S.4.D.2 Securing the wheels to the axle
Tip: The chamfer side of the
axle needs to face away from
the tire.
Torque the wheel half bolts
to the specified torque
stated on the wheels.

LEGACY FG 033-0004 Page S.15 REV. 0/04-23-2007
Supplement–Legacy Fixed Gear
Lancair International Inc., Represented by Neico Aviation Inc., Copyright 2007 Redmond, OR 97756
S.5 Installing the Main Gear Fairings
S.5.A Main Gear Fairings
The main gear is covered by fairings to reduce drag and to
improve appearance. Each main gear is covered by three
fairings.
Fitting Guidelines
• Always start with the wheel pant fitting and move up
to the gear leg.
• The fairings and the wheel pant need to parallel the
stream lines.
• The top of the gear leg fairing should fit in the contour
of the fuselage gear fairing.
• The bottom contour of the gear leg fairing needs to fit
the stem of the wheel pant.
It may be necessary to make some adjustments to get the
fairings to fit smoothly.
Figure S.5.A.1 View of the Legacy Fixed Gear fairings
Fuselage gear fairing – Covers the gear leg
where it attaches to the fuselage. Includes
part numbers 7048L and 7048R.
Gear leg fairing – A streamlined piece that
covers the tubular gear leg. Includes part
number 7043.
Wheel pant – Another streamlined piece
that covers the wheel plus a brake cover.
Part numbers are 7045L and 7045R for the
left and right wheel pants and 7045LA and
7045RA for the brake covers.
Tip: Make sure the contour of the gear
leg fairing fits inside the fuselage gear
fairing.
Tip: Make sure the contour of the gear
leg fairing fits over the wheel-pant
stem.

LEGACY FG 033-0004 Page S.16 REV. 0/04-23-2007
Supplement–Legacy Fixed Gear
Lancair International Inc., Represented by Neico Aviation Inc., Copyright 2007 Redmond, OR 97756
Gear Leg Fairings
There are two methods for completing the gear leg fairing.
Bonding – the bonding method is described below. If
you use this method, the gear leg fairing must be in
place before the axle is installed and the fairing cannot
be removed without remove the axle mount.
– Or –
Hinged – split the back and use a piano hinge or
nutplates to join the back joint. This method allows the
fairing to be removed when necessary, without
removing the axle mount and the brake assembly.
Steps...
1. Remove the peelply from the gear leg fairings and
clean the molded side with Acetone.
2. Pre-fit the gear leg fairings to get an idea of how each
one mounts.
Both the fuselage gear fairing and the wheel pant need
to be pre-fit to the gear leg fairing. Match the contours
where they meet the gear leg fairing.
Now you can either bond or hinge the aft side of the
fairing.
Bonding Method Only
Bond the trailing edges of the gear leg fairings together
with a thick epoxy/flox mixture. See Figure S.5.A.2.
• Sand the aft 1" of the inside of the gear leg fairing.
Clean with Acetone and apply the epoxy/flox mixture.
• Clamp angle iron to the fairings to ensure a straight
trailing edge.
While curing, the contour of the gear leg fairing should be
matched to that of the fuselage gear fairing and the wheel
pant. This will ensure the right shape for the gear leg
fairing.
Figure S.5.A.2 Top-end view of the gear leg fairing
Tip: After the T.E. of the gear leg
fairing is glued together, you will have
to remove the axle mount to slide it off.
Note: This graphic applies to both methods of
completing your gear leg fairings. Except that the
bonding method of completion is the only method that
uses epoxy/flox with the straight edge and a clamp.

LEGACY FG 033-0004 Page S.17 REV. 0/04-23-2007
Supplement–Legacy Fixed Gear
Lancair International Inc., Represented by Neico Aviation Inc., Copyright 2007 Redmond, OR 97756
Wheel Pants
In this section you will fit the wheel pant and attach the
brake cover access panel that fits on the inboard side of
each wheel pant.
Steps...
1. If the gap between the brake cover and the wheel pant
access panel opening is uneven, clean it up with epoxy/
micro.
2. Tape a 1/2" (15 mm) foam spacer to the top of the tire.
This is to ensure adequate clearance between the tire
and the wheel pant.
Trimming the Wheel Pant
The trimming of the wheel pant should be done
concurrently with aligning it. If and when the bottom edge
of the wheel pant is trimmed, the trimming should occur
during the positioning and trimming for the axle bolt
locating.
Trim to these guidelines:
• From the side, the bottom edge of wheel pant and the
rim should be at the same level.
• When the plane is sitting on its gear, the tire must not
hit the wheel pant.
Optional – Adding a Wheel-Pant Bulkhead
If you plan to land on unimproved airstrips, you will also
need to add a wheel-pant bulkhead.
The purpose of the bulkhead is to prevent dirt and other
debris from accumulating inside the wheel pant. The exact
location is not critical, just ensure that there is adequate
clearance between the tire and the bulkhead.
Steps...
• Install a wheel-pant bulkhead by cutting a piece to fit
behind the tire in the aft section of the wheel pant.
Use 2 PPS prepreg and secure with a 2" wide 2-BID on
the front side.
• Drill a vent hole in the upper part of the bulkhead.
Figure S.5.A.3 Attaching the wheel pant
Wheel pant fits over the wheel and a
brake cover is secured on the
inboard side.
Wheel pant bracket – Attaches to the wheel pant.
Nutplates, K1000-3 (3 pcs.
per side of brake cover).
After the wheel pant is aligned, a bolt will slide
through this location in the wheel pant to secure
it to the axle. But first, you need to make a
standoff of 1” to 1.5” (25 to 38 mm).
Tip: When the wheel pant is
aligned on the next page, it
may be necessary to trim areas
of the bottom edge.

LEGACY FG 033-0004 Page S.18 REV. 0/04-23-2007
Supplement–Legacy Fixed Gear
Lancair International Inc., Represented by Neico Aviation Inc., Copyright 2007 Redmond, OR 97756
Installing and Aligning the Wheel Pants
To install the wheel pants you need to jack up the aircraft.
You may also want to put the gear leg fairing in place to
check how the fairing pieces fit to each other.
Alignment Guidelines...
Align using the following guidelines:
• Tilt the wheel pant until it is approximately level.
• The wheel pant’s center line should be parallel to the
aircraft’s center line.
The easiest method of accomplishing this is to draw a line
on the floor showing the center line of the wheel. Then
simply sight from above the wheel pant and align the wheel
pant to the center line. You can also use the fuselage center
line for aligning the wheel pant.
The fairings should be level and straight when the aircraft
is in flight.
Figure S.5.A.4 Main wheel pant alignment
Bottom edge of the wheel pant
and the edge of the wheel rim
should be aligned (at the same
level).
Trim as necessary all the way
around the bottom edge of the
wheel pant.
Bend bracket tabs or do a flox
release (or both) to make the
bracket and wheel pant connect.
Then secure the wheel pant to the
bracket using #10 crews and
nutplates.
Place the wheel pant in position by:
• Jack up the plane.
• Slide the front over the bracket and wheel.
• Next slide the rear of the wheel pant back and
down into place.
The wheel pant should be in a horizontal position as you
proceed to align it.
Tip: When the plane is set back on the floor, roll it
back and forth to allow the gear to relax into its
normal position.
Outboard side of wheel pant.
Steps....
1. Cut the head off and sharpen the shank of an
appropriate length AN4 bolt.
2. Screw the bolt into the axle under the wheel
fairing.
3. Align the wheel pant using the Alignment
Guidelines... instructions.
4. When the wheel pant is positioned set the bolt
location by tapping the side of the wheel pant so
the bolt you placed in the axle leaves an
indentation on the inside of the wheel pant.
• The washer and standoff set the inboard/
outboard alignment of the wheel pant.
5. Drill out the resulting hole.
6. Cut the bushing to match the gap between
fairing and axle.
7. On the inboard side, match drill through the
wheel pant and the bracket.
8. Install nutplates in the resulting holes in the
bracket.

LEGACY FG 033-0004 Page S.19 REV. 0/04-23-2007
Supplement–Legacy Fixed Gear
Lancair International Inc., Represented by Neico Aviation Inc., Copyright 2007 Redmond, OR 97756
Final Mounting of the Wheel Pants and Brake Cover
Steps...
1. Install a AN4 bolt on the outboard side of the wheel
pant using the following steps:
• Sand the area washer with 40-grit sandpaper.
• Sand the inside of the wheel pant around the hole
you drilled out with 40-grit sandpaper.
• Clean all the sanded areas.
• Bond the area washer in place and reinforce with
2-BID.
• Install the aluminum standoff, the outside washer
and the AN4 bolt.
2. Countersink the brake cover for the MS24693-S28
screws.
3. Install six nutplates, three (K1000-3) along both the
forward and aft edges of the flange on the wheel pant.
These will be used later for securing the brake cover.
Figure S.5.A.5 Nutplate locations for wheel pant cover
The wheel pants must be aligned before they are mounted.
See Installing and Aligning the Wheel Pants on page S.18.
Install six nutplates, three on
each side of the gear leg, to
secure the wheel pant cover.
Figure S.5.A.6 Front view of the wheel pant
Tip: Make sure the contour of the gear
leg fairing fits over the wheel-pant stem.