Lancair Legacy User manual

Chapter 1 REV. 0/02-15-02
INTRODUCTION
1-1
Lancair International Inc., Represented by Neico Aviation Inc., Copyright © 2000 , Redmond, OR 97756
ASSEMBLY MANUAL
FOR THE LANCAIR LEGACY

Chapter 1 REV. 0/02-15-02
INTRODUCTION
1-2
Lancair International Inc., Represented by Neico Aviation Inc., Copyright © 2000 , Redmond, OR 97756

REV. 3/12-15-04
Table of Contents
Lancair International Inc., Represented by Neico Aviation Inc., Copyright © 2000 , Redmond, OR 97756
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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Lancair International Inc., Represented by Neico Aviation Inc., Copyright © 2000 , Redmond, OR 97756
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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Lancair International Inc., Represented by Neico Aviation Inc., Copyright © 2000 , Redmond, OR 97756
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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Lancair International Inc., Represented by Neico Aviation Inc., Copyright © 2000 , Redmond, OR 97756
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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Lancair International Inc., Represented by Neico Aviation Inc., Copyright © 2000 , Redmond, OR 97756
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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Lancair International Inc., Represented by Neico Aviation Inc., Copyright © 2000 , Redmond, OR 97756
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