Lancair Legacy User manual

Chapter 1 REV. 0/02-15-02

INTRODUCTION

1-1

ASSEMBLY MANUAL

FOR THE LANCAIR LEGACY

Chapter 1 REV. 0/02-15-02

INTRODUCTION

1-2

REV. 3/12-15-04

Table of Contents

TOC-I

Contents

Chapter 1: Introduction........................................................... 1-3

1. INTRODUCTION ...................................................................................... 1-4

A. Recommended Background Information .................................................................... 1-4

B. Manual Layout and Use ............................................................................................ 1-7

Chapter Organization.................................................................................................... 1-7

Revisions ...................................................................................................................... 1-7

C. Setting Up Your Shop ............................................................................................... 1-7

Cutting Tables ............................................................................................................... 1-7

D. Terms and Definitions ................................................................................................ 1-8

E. Structural Adhesive ................................................................................................. 1-10

F. AN- Bolt and Hardware Guide ............................................................................... 1-11

G. Basic Shop Tools .................................................................................................... 1-14

Specialized Tools ........................................................................................................ 1-16

Supplies ....................................................................................................................... 1-19

H. Premolded Parts - Exploded View .......................................................................... 1-21

Premolded Parts List - not included in figure ............................................................. 1-22

I. Procedures ............................................................................................................. 1-23

Cleaning, care, and handling of parts.......................................................................... 1-23

J. Joint Description ..................................................................................................... 1-23

K. Trimming Procedure ................................................................................................ 1-24

L. DrillingAlignment Holes .......................................................................................... 1-25

M. Removing the Protective Coating - Peelply .............................................................. 1-25

N. Fastening Parts Together ......................................................................................... 1-27

O. Fiberglass Strip Installation ...................................................................................... 1-30

P. Cutting on the Bias .................................................................................................. 1-31

Q. The Plastic Sandwich .............................................................................................. 1-32

R. Tongue Depressors and Micro Radii ....................................................................... 1-33

About those Micro Radii ............................................................................................ 1-34

S. Those Annoying 2"-Wide Bid Tapes ........................................................................ 1-35

T. Cardboard Templates ............................................................................................. 1-35

U. Building Light .......................................................................................................... 1-35

V. Building Straight ...................................................................................................... 1-36

Straight Trailing Edges ................................................................................................ 1-36

W. Control Systems ..................................................................................................... 1-38

Pushrod Tips ............................................................................................................... 1-38

X. Hydraulic Systems .................................................................................................. 1-40

Tube flaring................................................................................................................. 1-41

Y. Painting .................................................................................................................. 1-43

Z. Building a Jack Stand .............................................................................................. 1-45

Chapter 2: Horizontal Stabilizer and Elevator ........................ 2-1

1. INTRODUCTION ...................................................................................... 2-1

2. PARTS LIST ............................................................................................... 2-1

3. CONSTRUCTION PROCEDURES .......................................................... 2-3

A. Building the Horizontal Stabilizer Assembly Cradle ..................................................... 2-3

B. Horizontal Stabilizer Hinge Brackets .......................................................................... 2-6

C. Elevator Hinge Installation ......................................................................................... 2-7

D. Elevator Trim Tab ................................................................................................... 2-10

Setting the Trim Tab ................................................................................................... 2-10

E. Couterbalancing the Elevators ................................................................................. 2-11

F. Closing the Horizontal Stabilizer and Elevator .......................................................... 2-12

Closing the Elevators .................................................................................................. 2-13

G. Elevator Travel Stops .............................................................................................. 2-14

Chapter 3: Wing Systems ........................................................ 3-1

1. INTRODUCTION ...................................................................................... 3-1

2. PARTS LIST ............................................................................................... 3-1

3. CONSTRUCTION PROCEDURES .......................................................... 3-4

A. Pitot Tube (Optional) ................................................................................................ 3-4

B. Installing the Marker Beacon Antenna (Optional) ....................................................... 3-5

C. Communications Antenna (Optional) ......................................................................... 3-5

D. Spar Closeout .......................................................................................................... 3-6

E. Main Gear Doors ..................................................................................................... 3-7

Fitting the Gear Doors .................................................................................................. 3-8

Gear Doors - Release Tape (Optional) ........................................................................ 3-9

Gear Doors - Outboard Hardware Mounting ..............................................................3-11

Gear Doors - Installing the Outboard Attachment Receptacles .................................. 3-11

Installing the Inboard Gear Door ................................................................................ 3-12

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Table of Contents

TOC-II

F. Main Gear Installation ............................................................................................. 3-15

G. Main Gear Wheels and Tires ................................................................................... 3-21

H. Center Wing Section Hydraulics .............................................................................. 3-24

I. Aft Spar Transition Holes ........................................................................................ 3-31

J. Landing and Taxi Lights (Optional) .......................................................................... 3-32

K. Speed Brakes (Optional) ........................................................................................ 3-35

L. Fuel and Hydraulic Lines Schematics ....................................................................... 3-36

Chapter 4: Fuel Systems ......................................................... 4-1

1. INTRODUCTION ...................................................................................... 4-1

2. PARTS LIST ............................................................................................... 4-1

3. CONSTRUCTION PROCEDURES .......................................................... 4-3

A. Legacy Fuel System - General Overview ...................................................................4-3

B. Fuel Selector Valve (Optional) .................................................................................. 4-4

C. Fuel Supply Lines ..................................................................................................... 4-5

D. Fuel Vent Line Check Valve ...................................................................................... 4-8

E. Fuel Return Lines ...................................................................................................... 4-9

F. Fuel Probe (Optional) ............................................................................................. 4-10

G. Fuel Boost Pump (Optional) ................................................................................... 4-10

H. Fuel Drain Covers .................................................................................................. 4-12

Chapter 5: Outboard Wing Section Installation ...................... 5-1

1. INTRODUCTION ...................................................................................... 5-1

2. PARTS LIST ............................................................................................... 5-1

3. CONSTRUCTION PROCEDURES .......................................................... 5-2

A. Wing Installation and Removal ................................................................................... 5-2

Chapter 6: Aileron Controls ..................................................... 6-1

1. INTRODUCTION ...................................................................................... 6-1

2. PARTS LIST ............................................................................................... 6-1

3. CONSTRUCTION PROCEDURES .......................................................... 6-3

A. Control Stick Installation ........................................................................................... 6-3

B. Aileron Controls Rigging ........................................................................................... 6-4

C. Counterbalancing Ailerons ......................................................................................... 6-8

D. Aileron Trim System ................................................................................................. 6-9

How the Trim System Works ....................................................................................... 6-9

Instructions for Adjusting the Aileron Trim Servo ........................................................ 6-9

Chapter 7: Aircraft Alignment Jig ........................................... 7-1

1. INTRODUCTION ...................................................................................... 7-1

2. PARTS LIST ............................................................................................... 7-1

Supplies List ...................................................................................................................... 7-1

3. CONSTRUCTION PROCEDURE ............................................................ 7-3

A. Wing Jig ................................................................................................................... 7-3

Alignment Criteria ........................................................................................................ 7-6

B. Aft Fuselage Jig ........................................................................................................ 7-7

C. Vertical Tail Supports .............................................................................................. 7-11

Chapter 8: Outboard Wing Section Closing ........................... 8-1

1. PARTS LIST ............................................................................................... 8-1

2. CONSTRUCTION PROCEDURES .......................................................... 8-2

A. Closing the Wings ..................................................................................................... 8-2

Understanding the Relative Percentage Chordline... ................................................... 8-5

B. Pressure Testing the Wings ........................................................................................ 8-9

Fixing a Leak ................................................................................................................ 8-9

C. Strobe and Nav Lights ............................................................................................ 8-10

Chapter 9: Canopy .................................................................. 9-1

1. INTRODUCTION ...................................................................................... 9-1

2. PARTS LIST ............................................................................................... 9-1

3. CONSTRUCTION PROCEDURES .......................................................... 9-3

A. Canopy Latch Mechanism ........................................................................................ 9-3

B. Canopy StiffenerAlignment ....................................................................................... 9-9

C. Canopy Hinge ........................................................................................................ 9-17

Alignment ................................................................................................................... 9-17

D. Gas Strut ................................................................................................................ 9-23

E. Canopy Stricker Metchanism .................................................................................. 9-26

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Table of Contents

TOC-III

F. CanopyAlignment Mechanism ................................................................................ 9-30

G. Windshield Installation ............................................................................................. 9-32

Canopy Alignment ..................................................................................................... 9-32

H. Canopy Defroster ................................................................................................... 9-35

I. Canopy Skin Bonding ............................................................................................. 9-37

J. Canopy Seal ........................................................................................................... 9-39

Proper Orientation ...................................................................................................... 9-39

Chapter 10: Center Wing Section Installation ...................... 10-1

1. PARTS LIST ............................................................................................. 10-1

2. CONSTRUCTION PROCEDURES ........................................................ 10-2

A. Bonding the Center Wing Section ............................................................................ 10-2

B. Installing Load Pads ............................................................................................. 10-12

C. Installing the Aft Closeout Rib ............................................................................... 10-14

D. Closing the Center Wing Section ........................................................................... 10-15

Chapter 11: Horizontal Tail Installation ................................ 11-1

1. INTRODUCTION .................................................................................... 11-1

2. PARTS LIST ............................................................................................. 11-1

3. CONSTRUCTION PROCEDURES ........................................................ 11-2

A. Bonding the Horizontal Stabilizer ............................................................................. 11-2

Trimming the Left Vertical Skin ..................................................................................11-2

Proper Horizontal Stabilizer Installation during Bonding .............................................11-3

B. Vertical Web Installation .......................................................................................... 11-5

Chapter 12: Vertical Closeout ............................................... 12-1

2. PARTS LIST ............................................................................................. 12-1

3. CONSTRUCTION PROCEDURES ........................................................ 12-2

A. Counterweight Installation ....................................................................................... 12-2

B. Left Vertical Skin Installation ................................................................................... 12-3

Typical Vertical Tail Cross Section .......................................................................... 12-3

C. Elevator Weldment Access Panel ............................................................................ 12-7

D. Bonding the Vertical Stabilizer ................................................................................. 12-8

Chapter 13: Firewall Forward ................................................ 13-1

1. INTRODUCTION .................................................................................... 13-1

2. PARTS LIST ............................................................................................. 13-1

3. CONSTRUCTION PROCEDURES ........................................................ 13-3

A. Firewall Closeout .................................................................................................... 13-3

B. Firewall Flame Blanket ........................................................................................... 13-5

C. Engine Mount Installation ...................................................................................... 13-10

Mounting Holes #1 - 5 .......................................................................................... 13-10

Nose Gear Brace Mounts ..................................................................................... 13-10

Mounting Holes #1 - 5 ........................................................................................... 13-11

Nose Gear Brace Mounts ...................................................................................... 13-11

D. Nose Gear Installation .......................................................................................... 13-12

Left Side View ......................................................................................................... 13-13

E. Nose Wheel and Tire ............................................................................................ 13-15

F. Nose Gear Doors ................................................................................................. 13-17

G. Nose Gear Micro Switch ...................................................................................... 13-26

Nose Gear Down Switch ...................................................................................... 13-26

Chapter 14: Center Console.................................................. 14-1

1. INTRODUCTION .................................................................................... 14-1

2. PARTS LIST ............................................................................................. 14-1

3. CONSTRUCTION PROCEDURE .......................................................... 14-2

A. Center Console ...................................................................................................... 14-2

Glove Box ................................................................................................................... 14-3

Glove Box Lid ............................................................................................................ 14-4

B. Fitting the Center Console ....................................................................................... 14-6

C. Seat Belt Reinforcement .......................................................................................... 14-8

D. Forward Access Panel ............................................................................................ 14-9

E. Dump Valve Mounting .......................................................................................... 14-10

F. Throttle - Prop - Mix ............................................................................................ 14-12

G. Fuel Selector Valve Handle ................................................................................... 14-13

H. Center Console Bonding ....................................................................................... 14-14

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Table of Contents

TOC-IV

Chapter 15: Seats & Seat Belts ............................................. 15-1

1. INTRODUCTION .................................................................................... 15-1

2. PARTS LIST ............................................................................................. 15-1

3. CONSTRUCTION PROCEDURES ........................................................ 15-2

A. Fitting the Seat Pans ............................................................................................... 15-2

B. Outboard Seat Supports ......................................................................................... 15-3

C. Center Seat Supports ............................................................................................. 15-4

D. Installing the Seat Belts ........................................................................................... 15-5

Chapter 16: Hydraulic Systems Completion .......................... 16-1

1. INTRODUCTION .................................................................................... 16-1

2. PARTS LIST ............................................................................................. 16-2

3. CONSTRUCTION PROCEDURES ........................................................ 16-3

A. Hydraulic Lines - Aft of Aft Spar ............................................................................. 16-3

B. Hydraulic Lines - Forward of Main Spar ................................................................. 16-7

C. Adjusting the Inboard Main Gear Doors ................................................................ 16-10

Trimming the Sleeve to Length .................................................................................. 16-11

Adjusting the Inboard Main Gear Doors ................................................................... 16-11

D. Setting the Main Gear ‘UP’ Stop ........................................................................... 16-12

Setting the ‘UP’ Stop................................................................................................ 16-12

E. Adjusting the Outboard Main Gear Doors ............................................................. 16-13

F. Gear Switch and Lights ......................................................................................... 16-14

Gear Transition Light ............................................................................................. 16-14

Gear Down Lights .................................................................................................... 16-15

G. Gear Micro Switch Wiring .................................................................................... 16-16

H. Gear Pressure Switch Wiring ................................................................................. 16-17

I. Gear Wiring Schematic ......................................................................................... 16-18

J. Hydraulic Gear Start Up and Test Operations ........................................................ 16-19

Adding Hydraulic Fluid ............................................................................................. 16-19

Start up of the Hydraulic Gear ................................................................................. 16-19

K. Pressure SwitchAdjustment .................................................................................. 16-21

L. Free Fall Test ....................................................................................................... 16-21

M. In-flight Free Fall Testing ....................................................................................... 16-22

N. Hydraulic Pump Conversion (Optional) ................................................................. 16-23

Chapter 17: Rudder Completion ............................................ 17-1

1. INTRODUCTION .................................................................................... 17-1

2. PARTS LIST ............................................................................................. 17-1

3. CONSTRUCTION PROCEDURES ........................................................ 17-3

A. Trimming the Rudder ............................................................................................... 17-3

B. Rudder Leading Edge Closeout ............................................................................... 17-5

C. Rudder Trim System (Optional) ............................................................................. 17-10

D. Adjusting the Rudder Counter Weights .................................................................. 17-13

E. Rudder Pedal Installation ...................................................................................... 17-14

F. Floorboard Installation .......................................................................................... 17-19

Version 1 ............................................................................................................... 17-19

Version 2 ................................................................................................................... 17-21

G. Rudder Bellcrank .................................................................................................. 17-25

H. Rudder Pushrod ................................................................................................... 17-26

I. Rudder Cable ....................................................................................................... 17-27

Adjusting the Pedal Position Aft ............................................................................... 17-32

Adjusting the Pedal Position Forward ...................................................................... 17-32

Chapter 18: Brake System .................................................... 18-1

1. INTRODUCTION .................................................................................... 18-1

2. PARTS LIST ............................................................................................. 18-1

3. CONSTRUCTION PROCEDURES ........................................................ 18-2

A. Brake System ......................................................................................................... 18-2

B. Installing the Brake Assemblies ................................................................................ 18-3

C. Filling and Bleeding the Brakes ................................................................................ 18-6

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Table of Contents

TOC-V

Chapter 19: Elevator Controls .............................................. 19-1

1. INTRODUCTION .................................................................................... 19-1

2. PARTS LIST ............................................................................................. 19-1

3. CONSTRUCTION PROCEDURES ........................................................ 19-2

A. Elevator Controls Rigging ........................................................................................ 19-2

Control Stick ............................................................................................................... 19-4

Elevator Idler Arm ...................................................................................................... 19-4

Elevator ...................................................................................................................... 19-4

B. Trimming Inboard Ends for the Rudder .................................................................... 19-5

Chapter 20: Instrument Panel ............................................... 20-1

1. INTRODUCTION .................................................................................... 20-1

2. PARTS LIST ............................................................................................. 20-1

3. CONSTRUCTION PROCEDURES ........................................................ 20-2

A. Instrument Panel Installation .................................................................................... 20-2

B. Dust Cover ............................................................................................................. 20-6

Trimming the Dust Cover ........................................................................................... 20-7

C. Avionics Mounting Shelf.......................................................................................... 20-8

D. Typical Panels ......................................................................................................... 20-9

Chapter 21: Flap System Completion ................................... 21-1

1. INTRODUCTION .................................................................................... 21-1

2. PARTS LIST ............................................................................................. 21-1

3. CONSTRUCTION PROCEDURES ........................................................ 21-3

A. Center Torque Tube Support .................................................................................. 21-3

B. Flap Installation ...................................................................................................... 21-7

C. Flap Motor Installation ............................................................................................ 21-9

Flap MotorAlignment ............................................................................................... 21-10

Flap Adjustments ...................................................................................................... 21-10

D. Bonding the Wing Trailing Edge ............................................................................. 21-11

Chapter 22: Cabin Ventilation ............................................... 22-1

1. INTRODUCTION .................................................................................... 22-1

2. PARTS LIST ............................................................................................. 22-1

3. CONSTRUCTION PROCEDURES ........................................................ 22-2

A. Fresh Air (Unheated) .............................................................................................. 22-2

B. Cabin Heat*/Cabin Defroster* ................................................................................ 22-3

Chapter 23: Baggage Compartment ....................................... 23-1

1. INTRODUCTION .................................................................................... 23-1

2. PARTS LIST ............................................................................................. 23-1

3. CONSTRUCTION PROCEDURE .......................................................... 23-3

A. Control Tube Cover ................................................................................................ 23-3

B. Bulkhead Cover ..................................................................................................... 23-5

C. Overhead Console* ................................................................................................ 23-6

D. Floorboards* ......................................................................................................... 23-7

Installing Floorboard Access Panels ........................................................................... 23-8

E. Oxygen System (Optional) .................................................................................... 23-15

Chapter 24: Miscellaneous Systems...................................... 24-1

1. INTRODUCTION .................................................................................... 24-1

2. PARTS LIST ............................................................................................. 24-1

3. CONSTRUCTION PROCEDURES ........................................................ 24-2

A. Pitot Static System .................................................................................................. 24-2

Static Port Installation ................................................................................................ 24-3

B. ELT Installation ....................................................................................................... 24-4

C. Storm Scope Installation* ....................................................................................... 24-5

D. Transponder Antenna Installation ............................................................................. 24-6

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Table of Contents

TOC-VI

Chapter 25: Aft Windows ..................................................... 25-1

1. INTRODUCTION .................................................................................... 25-1

2. PARTS LIST ............................................................................................. 25-1

3. CONSTRUCTION PROCEDURE .......................................................... 25-2

A. Preparing the Fuselage Shell .................................................................................... 25-2

B. Preparing the Windows ........................................................................................... 25-3

C. Window Installation ................................................................................................ 25-5

Chapter 26: Firewall Forward (part 2) Continental 550 ........ 26-1

1. INTRODUCTION .................................................................................... 26-1

2. PARTS LIST ............................................................................................. 26-1

3. CONSTRUCTION PROCEDURES ........................................................ 26-4

A. Mounting the Engine ............................................................................................... 26-4

B. Propeller/Spinner .................................................................................................... 26-5

C. Cowling .................................................................................................................. 26-6

D. Baffling ................................................................................................................... 26-9

E. Engine Control Systems ........................................................................................ 26-22

F. Manifold Pressure and Tachometer ....................................................................... 26-25

Tachometer............................................................................................................... 26-25

G. Fuel Systems ........................................................................................................ 26-26

H. Oil Systems .......................................................................................................... 26-33

Oil Temperature Sensor ........................................................................................... 26-33

Oil Pressure Sensor .................................................................................................. 26-33

I. Vacuum System Installation (Optional) ................................................................... 26-35

Chapter 27: General Wiring .................................................. 27-1

1. INTRODUCTION .................................................................................... 27-1

2. PARTS LIST ............................................................................................. 27-2

3. CONSTRUCTION PROCEDURES ........................................................ 27-3

A. Basic Wiring Techniques ......................................................................................... 27-3

B. Legacy General Wiring ............................................................................................ 27-4

C. Basic Aircraft Wiring ............................................................................................... 27-6

D. Landing Gear Wiring ............................................................................................... 27-7

E. Lights Wiring .......................................................................................................... 27-8

F. Electric Fuel Pump ................................................................................................ 27-10

G. Trim System Wiring ............................................................................................... 27-11

H. Flap Wiring ........................................................................................................... 27-13

Setting the Flap Limit Stops ...................................................................................... 27-15

I. Pitot Tube Heat Wiring .......................................................................................... 27-16

J. Electric Door Seal Wiring ...................................................................................... 27-16

K. Antenna Placement ............................................................................................... 27-17

Chapter 28: Finishing Techniques ......................................... 28-1

1. INTRODUCTION .................................................................................... 28-1

Painting and Interiors .............................................................................................. 28-1

2. PARTS LIST ............................................................................................. 28-1

3. CONSTRUCTION PROCEDURES ........................................................ 28-2

A. Bid Tapes ............................................................................................................... 28-2

B. Mixing Micro .......................................................................................................... 28-2

C. General Surface Preparation ................................................................................... 28-2

D. Priming Materials .................................................................................................... 28-3

E. Paint Preparations ................................................................................................... 28-4

F. Painting .................................................................................................................. 28-4

G. Base Colors ........................................................................................................... 28-4

H. Trim Colors ............................................................................................................ 28-5

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