Lancair ES User manual

Lancair International Inc., Represented by Neico Aviation Inc., Copyright 2008 Redmond, OR 97756
Chapter 1 Page 1.1 REV. 2nd Ed./08-15-06
Introduction to the Lancair ES FastBuild Kit
ES
Chapter 1 Introduction to the Lancair ES FastBuild Kit 1.1 Introduction
The purpose of this chapter is to familiarize you with the use of this manual, the general
philosophy behind its layout, how to set up your shop and what supplies you will need. You
should also read the recommended books to familiarize yourself with glassworking if you are a
newcomer to fiberglass construction techniques.
Always refer to the Glossary on page G.1 for definitions of unfamiliar terms.
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1
1.2 Recommended Reading and Background Information . . . . . . 1.2
1.3 The Manuals, Blueprints and the ES CD. . . . . . . . . . . . . . . . . 1.3
1.3.A Manual Layout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
1.3.B Blueprints. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
1.3.C The ES CD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
1.4 Setting up your Shop. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
1.4.A Shop Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
1.4.B Temperature Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
1.4.C Cutting and Layup Tables . . . . . . . . . . . . . . . . . . . . . . . . 1.6
1.4.D Making a Useful Jack Stand . . . . . . . . . . . . . . . . . . . . . . 1.7
1.5 Shop Tools and Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8
1.5.A Basic Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8
1.5.B Specialized Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10
1.5.C Supplies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.14

Lancair International Inc., Represented by Neico Aviation Inc., Copyright 2008 Redmond, OR 97756
Chapter 1 Page 1.2 REV. 2nd Ed./08-15-06
Introduction to the Lancair ES FastBuild Kit
ES
1.2 Recommended Reading and Background Information
This manual provides detailed step-by-step instructions for assembling the Lancair ES Kit.
Hands-on experience with fiberglass construction techniques and various hand tools is assumed.
If you do not have this background knowledge, we recommend that you study the following
texts.
Composite Materials Practice Kit
This kit contains various materials with which to practice and develop your fiberglass
construction technique. It also contains a copy of Burt Rutan's Moldless Composite
Sandwich Homebuilt Aircraft Construction book described below. This kit is recommended
for all newcomers to fiberglass construction and is a good refresher for everyone else.
Moldless Composite Sandwich Homebuilt Aircraft Construction by Burt Rutan
Though the hot-wire shaping technique covered by this book is not used on the Lancair, this
book has a great deal of other excellent, basic fiberglass construction information. Highly
recommended.
Building Rutan Composites Video tape by Burt Rutan
Although it covers some techniques not used on the Lancair, it shows you how the experts
handle fiberglass construction. Highly recommended.
Composite Construction for Homebuilt Aircraft by Jack Lambie
This book is an additional source of useful construction information and goes into the theory
of aircraft design as well. Jack's Chapter 9, Safety in Working With Composite Construction,
is particularly worth reading. This book would be a useful addition to the above.
Kitplane Construction by Ron Wenttaja
This is a resourceful book with information on metal, wood, and composites.
The above publications, practice kit and video tape are available from:
Aircraft Spruce and Specialty Company
Address: 225 Airport Circle
Corona, CA 91720
Toll-free order line: [phone]
Customer service: [phone]
Fax: [phone]
Email: [email protected]
The following recommended books largely describe aspects of aircraft construction other than
working with fiberglass:
Firewall Forward by Tony Bingelis
This book is filled with vital information about engine installation. You'll need this when
you're getting ready to install the engine.
The Sportplane Builder by Tony Bingelis
This book has useful information on aircraft construction in general such as electrical
systems, instrumentation and fuel systems. The chapter entitled You and the FAA gives
important information on the procedures that you will need to follow during construction in
order to get your homebuilt's airworthiness certificate.
These two books can be obtained from:
EAA Aviation Foundation
Address: Whittman Airfield
Oshkosh, WI 59403-3065
Phone: [phone]
Internet: www.eaa.org

Lancair International Inc., Represented by Neico Aviation Inc., Copyright 2008 Redmond, OR 97756
Chapter 1 Page 1.3 REV. 2nd Ed./08-15-06
Introduction to the Lancair ES FastBuild Kit
ES
1.3 The Manuals, Blueprints and the ES CD
Please read this manual! We encourage you to read this manual and then use it as your reference
tool as you build your airplane. In this age of computers that are user friendly, cars that provide a
warning light for every change in status, many people are out of the habit of reading manuals.
That philosophy will not work here. While there really aren't any complex steps to building this
aircraft, there are many that must not be overlooked. So, please do read this manual.
Each chapter should be read entirely and understood before beginning the work it describes. The
equipment and supplies called for in each chapter should be on hand and ready for use.
1.3.A Manual Layout
For ease of use and understanding, this assembly manual is laid out in a logical progression of
assembly steps. This manual is organized as follows:
Chapter 1 – Provides an overview of the shop requirements and necessary tools to build your
homebuilt airplane.
Chapter 2 – Describes safety considerations for building, general building procedures and how
to prepare and join parts.
Chapter 3 and all following chapters contain the actual assembly instructions. The chapters are
presented in the order your plane should be built. Assembly instructions are in a sequence that
either is a convenient construction order or is necessary due to the kit design.
Chapter Organization
Each assembly chapter is organized in the same sequence.
1. Introduction – Briefly describes the work that will be completed in this chapter, and special
construction requirements and if a pre-fit is necessary.
2. Parts List – Provides a complete list of the parts used in the construction procedures in the
chapter. Parts lists may not match a kit. A parts list can include all or part of a kit plus other
hardware from the H or K kit lists.
3. Construction procedures – this section is divided into specific areas of assembly. Each
division is defined by an alphabetic prefix: A, B, C, etc.
4. Graphics, including drawings and photographs – each graphic is numbered within an
alphabetic prefix: A.1, A.2, A.3, B.1, B.2, etc.
Symbols
The following symbols are used in the manual.
Revisions
Occasionally revisions to the manuals may be necessary. Updates are posted on the Lancair web
page. When updates are available, you need to immediately replace all outdated pages with the
revised pages. Discard the outdated pages.
The lower right corner of each manual page contains a revision date. The final edition of this
manual will have a zero followed by the date printed, for example, Rev. 0–06/12/2005. All
subsequent revisions will have the revision number followed by the date of that revision. All
revisions include a List of Revisions page for each chapter with updated pages When you receive
a List of Revisions page, you will need to inserted it in front of the first page of each revised
chapter.
Click on this symbol to view the photograph of the procedure that has just been
described.
Click on this symbol to view a series of photographs.
This symbol indicates a pre-fit is required.
This symbol indicates there is a detail view of the area covered by the magnifying
glass.

Lancair International Inc., Represented by Neico Aviation Inc., Copyright 2008 Redmond, OR 97756
Chapter 1 Page 1.4 REV. 2nd Ed./08-15-06
Introduction to the Lancair ES FastBuild Kit
ES
1.3.B Blueprints
The blueprints included with this ES manual can be considered tools in the contribution they
make in the building of your airplane. They are mechanical drawings which present a picture of
the parts and assemblies you need to complete. But they are only useful if you can read them.
We suggest you spend the necessary time to become familiar with the blueprints prior to
building the specific portion of your airplane that they address.
A list of blueprints for the ES Super Fastbuild Kit are included at the beginning of the Parts List
section of each chapter. The lists contain only the blueprints that are provided after the
completion of the two week builder assist program.
1.3.C The ES CD
The CD included with the manual contains an electronic version of the manual that you can view
or print from your computer. In addition the CD manual provides the following:
• Includes color photographs of various construction processes and specific assembly
techniques.
• Ability to search the entire manual for a specific word or phrase.
• Includes a linked table of contents and index.
• All drawings and photographs are organized in a slideshow presentation, in the same order
as the manual’s chapters.
CD Tips
The manual on the CD is in a PDF format. This means that Adobe Acrobat Reader is required
for viewing and printing the manual. If you do not have Adobe Acrobat Reader on your
computer, download the latest free version of the Reader from www.adobe.com or
www.downloads.com.
Using Adobe Acrobat
When you have the Reader installed, you can double-click on any file ending with PDF to view
it on your screen.
To use the ES CD, insert it in your CD drive and double-click on the MainMenu.pdf. Select one
of the menu items to use a feature on the CD. Please read the insert that is included with the CD
to learn how to navigate through the manual, search the manual, or view only photos from a
specific chapter.

Lancair International Inc., Represented by Neico Aviation Inc., Copyright 2008 Redmond, OR 97756
Chapter 1 Page 1.5 REV. 2nd Ed./08-15-06
Introduction to the Lancair ES FastBuild Kit
ES
1.4 Setting up your Shop
This section contains the following topics:
• Shop size considerations
•Temperature
• Building shop tables, a jackstand and cradles
Introduction
Your work area needs to be well lit, clean and uncluttered. It
needs to have at least one large table to cut on and work with
the fiberglass. Since parts will be placed on the floor
occasionally, the floor needs to be cleaned and free of oil,
grease and dirt. A dirty floor can contaminate parts.
1.4.A Shop Size
The minimum size for your shop floor should be
approximately 20 ft. by 30 feet. This will accommodate the
building of your Lancair. Figure 1.4.B.1provides an overview
of the ES dimensions.
Since the wings are pre-fit to the wing fairings and then
removed for the remainder of the building process, it is not
necessary to have a shop that will accommodate the finished
dimensions with the wings on. You can temporarily move
your plane outside to work with the wings.
Tip: Remember that removing the wing requires
approximately four extra feet beyond the wing tip.
1.4.B Temperature Control
If you plan to work in your shop when the outside
temperature is less than 70°F, a heat source may be
necessary. When working with fiberglass adhesive or resin at
low temperatures, wetting out the fiberglass becomes
difficult. The ideal shop temperature is between 68° and
78°F.
Figure 1.4.B.1 Shop floor area

Lancair International Inc., Represented by Neico Aviation Inc., Copyright 2008 Redmond, OR 97756
Chapter 1 Page 1.6 REV. 2nd Ed./08-15-06
Introduction to the Lancair ES FastBuild Kit
ES
1.4.C Cutting and Layup Tables
Cutting Table
One of the focal points of any composite shop is the fiberglass cutting table. Those of us who
previously built composite planes without a cutting table can't believe we were so naive. We
recommend building a cutting table in your shop!
At one end of the cutting table mount the fiberglass roll so you can unwind the cloth onto the
table. You need to be able to unroll at least four feet of cloth onto the flat cutting surface. A PVC
or any type of pipe can be used as a roller for the cloth roll. Mount the pipe through two plywood
supports nailed to the sides of your table.
Figure 1.4.C.1 Fiberglass cutting table
The cutting surface should be a hard plastic such as an 1/8" thick, high density polyethylene
(HDPE). Some home supply stores have similar sheets of this material called tileboards for use
as shower liners. Also check a plastic supply store. After you have been using the cutting surface
for awhile, you may not achieve clean cuts. Simply flip the plastic sheet over and use the other
side.
When the cutting table is not in use, it's a good idea to at least cover the fiberglass roll with
plastic to keep dust from settling on it.
Layup Table
A layup table is handy when it is time to start your wet layups. Construct a table about 3' by 8' in
size, and mount the exhaust hood low over the table surface. Use the same type of hard plastic
surface you installed on the cutting table.
Figure 1.4.C.2 Layup table

Lancair International Inc., Represented by Neico Aviation Inc., Copyright 2008 Redmond, OR 97756
Chapter 1 Page 1.7 REV. 2nd Ed./08-15-06
Introduction to the Lancair ES FastBuild Kit
ES
1.4.D Making a Useful Jack Stand
The jack stand is ideal for lifting the wings and a number of
other tasks including checking the weight and balance. In
addition the ES fuselage bottom may have optional
jackpoints.
Steps...
1. Cut two pieces of plywood, one 8”x 8” and the other 4”x
4”.
2. Glue the two pieces of plywood together with the 4”x 4”
centered on the larger piece.
3. Drill a 1” deep and 3/8” diameter hole in the center of the
4”x 4” piece.
4. Install the JP-325 jack point in the hole.
5. Glue soft padding on the top of the 8” x 8” piece of
plywood.
6. Insert the Jack port on the jack stand.
Figure 1.4.D.1 Jack stand

Lancair International Inc., Represented by Neico Aviation Inc., Copyright 2008 Redmond, OR 97756
Chapter 1 Page 1.8 REV. 2nd Ed./08-15-06
Introduction to the Lancair ES FastBuild Kit
ES
1.5 Shop Tools and Supplies
This section contains the following topics:
• Tool suppliers
• Descriptions of basic shop tools
• Descriptions of specialized shop tools
• Shop supplies
In addition, Appendix E Tool s on page E.1 contains a shopping list of the tools listed in this
section and also a list of the tools that we supply during the builder assist program. We
recommend that you obtain all of these tools for your shop.
Introduction
The tools and supplies described in this section are extremely useful in your shop. They are not
mandatory but we highly recommend all of these tools. The tools we feel are most important are
included in the Appendix E Too ls on page E.1.
Since you may not be familiar with all of the tools, we have included a description of each.
Tools and supplies that are available through Kit Components, Inc. (KCI) can be ordered from:
Kit Components, Inc.
Address: 2244 Airport Way
Redmond, OR 97756
Phone: [phone]
Email: [e-mail]
Other locations for buying tools and aircraft supplies are:
Aircraft Spruce & Specialty Co.
Address: 225 Airport Circle
Corona, CA 92880-2527
Phone: 1-877-4-SPRUCE
Email: [email protected]
1.5.A Basic Tools
Saber saw (jig saw)
This saw is very handy for cutting out large or complex shapes from prepreg material. You can
use a manual saw but it won't be fun. Always have plenty of sharp blades and change them often.
Dull blades create rough edges and create more sanding/smoothing work later in the building
process. We use carbide-tipped blades exclusively for the composite cutting.
Electric or cordless drill motor
Most of the material you drill on a glass kit is fairly soft and thin and should require no more
than a small drill motor with at least a 3/8" chuck. We recommend a variable speed over a two
speed. Also buy one with a 1/2" chuck. When you drill plastic parts they must be drilled at a very
slow speed that is below the range of all single and most two-speed drill motors.
Drill press
One of the most useful tools is the drill press. It is a necessity for precision drilling. It can be
used in drilling out broken bolts, and it can cut holes using a fly-cutting tip.
Drill bits (numbered and fractional)
It takes a lot of cheap drill bits to make a lousy hole that one good bit could have made quickly
and perfectly. We recommend that you buy a good set of numbered drill bits. Lettered drills are
also handy like the "E" (.250") or the “D” (.246") with a reamer.
Carpenter's levels (2 and 4 foot lengths)
Levels are indispensable in a good shop and essential for building straight. Buy good aluminum
levels. Make sure they have straight edges and then round the sharp ends a bit so you won't
gouge any holes into your precious prepared surfaces.

Lancair International Inc., Represented by Neico Aviation Inc., Copyright 2008 Redmond, OR 97756
Chapter 1 Page 1.9 REV. 2nd Ed./08-15-06
Introduction to the Lancair ES FastBuild Kit
ES
Carpenter's square
Buy this when you get the carpenter's levels and for the same reason. Don't round the ends, just
be careful.
Clamps
You will need a number of the following types of clamps.
• Spring clamps –Buy a number of these including three or four large ones and about a dozen
that you can use with one hand while you try to hold six other parts in exactly the proper
position.
• Vise grip clamps – These are useful for forcing pieces together. Never use these on any
fiberglass, prepreg, or carbon composite parts. They grip with enough force to do great
damage to these parts, which may not be visible to the naked eye. Buy several of these.
• C clamps – Buy an assortment of these and three or four in each size. Again, use caution
when applying these to any glass parts. Tighten slowly and only until just snug.
Pop rivet tool
When you clamp parts together and drill the holes you’ll insert pop rivets. The best method to do
this is with a pop rivet tool. It should come with three extra tips for use with all four common
sizes of pop rivets, 3/32", 1/8", 5/32", and 3/16"

Lancair International Inc., Represented by Neico Aviation Inc., Copyright 2008 Redmond, OR 97756
Chapter 1 Page 1.10 REV. 2nd Ed./08-15-06
Introduction to the Lancair ES FastBuild Kit
ES
Rotary sander (rotary or orbital type)
This tool definitely makes it easier to sand and smooth rough edges. A good orbital sander with
a trapper bag will keep particles out of the air and your clothing and your lungs.
Reamer
A reamer or ream is a tool for enlarging holes. For hand tools the drive will usually be a square
drive, intended for use with the same type of wrench used to turn a tap for the cutting of screw
threads. They should only be used to remove small amounts of material. This ensures a long life
for the reamer and a superior finish to the hole.
1.5.B Specialized Tools
We refer to the following tools as specialized shop tools because it makes it a little easier to
overlook their higher price tags. Again, the tools listed are not mandatory for your shop but we
have found them extremely useful. The tools we think are the most important are included on the
shopping list.
Angle grinder
This is a powerful tool that can help you to custom fit your ribs and bulkheads quickly. Be very
careful though, if the high speed grinder surface gets away from you, it can quickly customize
everything in the general vicinity.