Quicksilver MAX Sprint User manual

•ASSEMBLY MANUAL
  
 


_
  

WARNING !!
YOU HAVE JUST WASTED A LOT OF MONEY,
UNLESS YOU FIRST FOLLOW THESE INSTRUCTIONS.
CLAIMS FOR DAMAGED OR MISSING PARTS
1. Inventory the kit completely using the supplied packing list. Do not remove any parts
from the blister-packed boards until you have finished counting everything. The only
exception is parts such as nuts, washers, and pop rivets which you may have to
remove for accurate counting.
2. If you believe you are missing any parts or have damaged parts, inspect the boxes for
holes or damage. Actually, you should have inspected the boxes prior to opening.
For lost or damaged parts, you must file a claim with the freight carrier.
3. Your kit was quality control inspected by two separate inspectors at the factory to
ensure the accuracy of its contents. However, if you believe some parts were omitted
at our factory, you need to do the following:
(a) Itemize the part number, quantity, and description of each part.
(b) Note the aircraft model, serial number, and date received.
(c) Report the claim to your QS rep. All claims must be processed through your
QS rep. OR Air-Tech, Inc.
Upon receipt of the claim, we will compare it to our original packaging records
and determine if the claim is valid. Air-Tech, Inc reserves the right to accept or
reject any claim.
4. NOTE: Only ONE claim per kit will be reviewed. DO NOT begin assembly until, you have
completed your inventory. The packing list is the most accurate representation of the
parts required. Making a list of suspected missing parts during assembly will not work:
and will NOT be accepted. For example builders have been known to use the wrong
size bolt as compared to what is called for by the assembly instructions. Later on
during assembly this can lead you to believe parts are missing. As you only have an
exact number of bolts for each application as called for by the assembly instructions.
Also, small parts may roll under work benches, are borrowed by friends with good
intentions of replacing them, or inadvertently disappear for unexplained reasons
(airplane parts gremlins). Your best protection to build a complete aircraft is to ensure
you have ALL the required parts BEFORE you start.
YOU HAVE 30 DAYS FROM RECEIPT OF THE KIT
TO FILE A CLAIM.
If you do not adhere to the above procedures, Air-Tech, Inc reserves the right to reject
any claim. Replacement parts would then be treated as a normal spare parts order. We
hope you enjoy building your kit and thank you for your patronage. If you have any
questions, please contact your dealer or Air-Tech, Inc. customer service department for
assistance.

NOTE: This aircraft MAY NOT be an ultralight in the United States
and MAY NOT conform to the definitions of the Federal Aviation
Regulation (FAR) Part 103. Contact the Experimental Aircraft
Association (EAA) DIRECTLY in Oshkosh, Wisconsin on how to
obtain a copy of the 'EAA Custom-Built Sport Aircraft Handbook'
for information on aircraft inspection and registration procedures
under (FAR) Part 21, Part 47 and Part 91. Outside the U.S., refer
to local aviation authorities.

1
SECTION 4
WING ASSEMBLY
GENERAL NOTES ...............................................1
BELLCRANK & COMPRESSION STRUTS .................4
GENERAL ARRANGEMENT.................................... 7
ROOT TUBE / SPARS ..........................................8
WING COVER LOCATION / FABRIC TENSION .........9
FABRIC INSTALL ............................................... 10
RIB END CUT OUT............................................. 11
COMPRESSION STRUT INSTALL .......................... 14
DIAGONAL STRUT INSTALL ................................ 15
RIB INSERT...................................................... 18
UPPER WIRES................................................... 19
LEADING EDGE OUTBOARD WIRE CUTOUT........... 20
WIRES INSTALL ................................................ 21
AILERON HINGES.............................................. 24
WING TIP STRUT .............................................. 25
Section 4
1
Air-Tech, Inc

WING ASSEMBLY NOTES
READ AND UNDERSTAND THE ENTIRE PROCESS BEFORE STARTING !!!
ALL CUT OUT TEMPLATES ARE LOCATED IN SECTION 12
These notes are to “assist” the information contained on the assembly pages.
ASSEMBLE COMPRESSION STRUTS First part of the Wing Assembly is to assemble the
compression struts. All Compression Struts require Tube Connectors on both ends.
Two of the struts also have Aileron Bellcranks on them. These will have a Left and Right and
should be marked. They also have a FWD and AFT as indicated. Fittings 20441 and 20442 are
installed into the Compression Struts. Run a 1/4”-20 bolt (10423) into the Threads to assure
thread condition. During final assembly of all Grade 5 bolts use Loctite as thread adhesive.
Anytime these bolts are loosened or removed you must re-apply the Loctite
P-4 Use Vise Grips to hold the 10702 Bearing in place for drilling and riveting. The 1/16” drilled
holes must be deburred before installing the rivets.
P-7 General Arrangement of the Wing Assembly. Follow the lettered details starting with “A”.
P-3 On the SPRINT wing the bolt threads can point down. The SPORT wing requires the threads
point up. The 20310 Safety Rings MUST be oriented as per the drawing. A 3/16” washer can be
added between the Safety Ring and the Bellcrank.
WING COVERS (Fabric) INSTALLATION The assembly instructions jump around on this
procedure. It’s IMPORTANT to read and completely understand the tasks for this step.
Basically, two Root ribs and one Tip ribs are installed so that the orientation of the fabric is
established on the Spars. The Root end of the fabric is secured. Only then can tension be pulled
towards the tip. We use a cheap Wal-Mart type fish scale to pull tension.
The illustrations on these pages show both wings being installed at once. This will require four (4)
wood saw horses or supports. It is also feasible and doable to assemble one wing at a time. The
IMPORTANT factor here is the location of ROOT END of the wing fabric. When completed, the
CENTER GAP COVER must overlap the 2” wide Velcro sewn on the ROOT END of the wing fabric.
Once the fabric is on the spars, the next step is to heat cut the slits in the Trailing Edge
Pockets to allow the Rib Ends to set against the trailing Edge spar.
Installing the three ribs mentioned and also the (temporary) Compression Strut at the extreme
Outboard end helps position the fabric location. Once tension is pulled, install the Large head
Rivets (20164) thru the grommets into the spars. BE VERY CONFIDENT IN THIS STEP !!!
COMPRESSION STRUT HOLES IN FABRIC These are the large holes that allow the compression
struts to pass thru the fabric onto their respective spars. Using the “hidden” bolt holes as a guide,
make a mark to be used with the Compression Strut Template. This one Template is used for both
the Leading Edge holes and the Trailing Edge holes.
DO NOT heat cut the Compression Strut Bolt Holes at this time. That is done during the Wires /
Cables install.
This Template is NOT Full LENGTH. The Finish dimension of this template is indicated on the Side
of the Template. You should make this template out of a durable material.
Section 4
2
Air-Tech, Inc

INSTALL RIBS
Install the balance of the ribs. Help is almost mandatory. You can spray the rib
tubing with a Dry Silicon Lubricant. This will aid the insertion process. The helper should be
pushing down on the Front Tip while it’s sliding inside the rib pocket while you are pushing from
the rear. ALSO… it is important that while the rib is being pushed into the rib pocket that you keep
the rib close to the trailing edge spar. This will reduce the event of tearing the rib pocket at the
entry point. Read the instructions on that page.
WIRES / CABLES Once you begin to install the Wires its best to uncoil the Upper Set
and lay them on the floor under the wing.
NOTE there is a Right and Left set of upper cables. Spread them out so they are in their relative
location. Once the single wires are bolted to the wing they can be uncoiled and the open loop end
can be attached to the Cable Shackle (20331).
Once all wires are attached to the cable shackle, the Upper Wire Set 5 Hole Tang can be ty-rapped
at the Root End of the wing. This will keep wires organized.
All LOWER (flying) WIRES must be the wire closest to the Wing Spar.
The LEADING EDGE OUTBOARD WIRE (Vertical) hole is located 2” Outboard of the Compression
Strut hole. This wire will pass thru the wing fabric to attach to the Wing Spar. Template is
provided for the SLOT cut out. Use the Stand-Off method on page 9 of Section 1 to keep this wire
from Chaffing the Diagonal Strut (40420)
Page-15 You will see an additional Cut Out Template at the location of the Leading Edge Outboard
wires. This cut out will allow the access you need to install the Upper Cable, Saddle and lock nut.
If after the Locknut is “snug” and the head of the bolt easily turns, you will need to a washer.
THE ANTI-DRAG WIRE (71032) attaches to the trailing edge spar near the root tube. You mat
need to cut a slit in the fabric “pocket” to allow the Tang to set flat on the spar.
AILERON HINGES Installation of the 1/4”-20 Locknuts will require a “X” be heat cut in the
fabric to install the washer and locknut. Push the Fork bolt threads against the fabric to mark the
location. You will need to cut away the Velcro gap seal at the hinge locations. BE CAREFULL not
to cut the straight stitch on the wing fabric.
Section 4
3
Air-Tech, Inc

Assemble Compression Struts (BELOW) and Aileron Compression Stut (ABOVE).
VERY IMPORTANT!! Each Tube should be marked FWD and AFT in respect to the Tube Connector Fitting.
AFT END of the Bellcrank Strut has the shorter length AFT of the SLEEVE.
Section 4
4
Air-Tech, Inc

AN4-26a
(10240)
LEFT SIDE ASSEMBLY SHOWN. REPEAT FOR RIGHT SIDE
1-1/2”

BLANK PAGE
6-3b
Section 4
6
Air-Tech, Inc

WING FABRIC
ROOT END OF WING
WING ASSEMBLY
RIB (40196)
9 PER WING
TIP STRUT (40410)
1 PER WING
COMPRESSION STRUT
(40283)
COMPRESSION STRUT
BOLT HOLE IN WING COVERING
RIB POCKET
BELLCRANK COMPRESSION STRUT
(71020) 1 PER WING
TRAILING EDGE
OF WING
DIAGONAL STRUT
(40420)
1 PER WING
WING IS SHOWN UPSIDE DOWN .
DO NOT CONFUSE THE COMPRESSION STRUT “HOLE” WITH THE COMPRESSION STRUT “BOLT HOLE”
HEAT CUTTING THE “BOLT HOLES” IS AFTER THE COMPRESSION STRUTS AND RIBES ARE INSTALLED
GENERAL ARRANGEMENT
COMPRESSION STRUT
HOLE IN EACH WING COVERING
(8 PLACES EACH WING)
LEADING EDGE
OF WING
Section 4
7
Air-Tech, Inc

WING ASSEMBLY
ROOT TUBE ATTACH
T.E. SPAR CHANNEL
IMPORTANT: IN SOME APPLICATIONS
THE ENGINE MOUNT COMPONENTS
ARE LOCATED UNDER THE T.E. SPAR
CHANNELS. IF SO, A SPACER THE
THICKNESS OF THE MOUNT MAY BE
NEEDED AT THIS TIME TO ALLOW FOR
THE MOUN
THE MOUNT AT FINAL ASSEMBLY
1/4” LOCKNUT
(10510)
1/4” LOCKNUT
(10510)
INSTALL SPARS TO ROOT TUBE AS SHOWN
1/4” WASHER
(10560)
AN4-17a
(10150)
AN4-25a
(10235)
Section 4
8
Air-Tech, Inc

OUTBOARD
DOWN
XX X
WING FABRIC
WING COVER LOCATION & FABRIC TENSION
X
2“
8“ (20.23cm)
Above illustration shows both Wings atached to the Root Tube w/ Channels (Section 3)
Assembly is Upside Down as the wings are assembled in the upside down position.
Cord is thru the Black Webbing Loops sewn onto each wing. A Knot suggestion is shown.
Location of the Loops in the illustration is not correct. Actual loaction is indicated with “X”
The objective here is to locate the Root End of the fabric at a specific location on the Wing
Spars. In the Final Assembly steps of the Kit, you will be attaching a GAP COVER that will
V
Velcro to the wing surface.
The Gap Cover MUST Overlap and Cover the mating Velcro. This step assures that overlap.
The 2” dimenstion is from the End of the Wing Spar (L.E. & T.E.) to the edge of the fabric.
Mark the Spars at the 2” location. Secure the LOOPs so that the Fabric is securely fixed.
Another OPTION is to tie the Loops to the bolts going thru the Channels. Either method is
fine so long as the end result securs the fabric in place for the next step.
SPANWISE TENSION On the Outboard Tip of the Wing you will need to pull the fabric taught.
A fish scale can be used and the pull should be appr
A fish scale can be used and the pull should be approx 35 pounds.
This will locate the Outboard Tip of the fabric close to 3/4” from Tip End of the Spars.
The previously installed (3) Ribs helps shape the Fabric Location on the Spars.
AT THE OUTBOARD ENDS OF THE WING FABRIC ARE STAINLESS STEEL GROMMETS.
ONCE YOU ARE ABSOLUTLY SURE OF THE WING FABRIC LOCATION, YOU WILL USE THESE
GROMMETS AS A GUIDE TO DRILL 3/16“ HOLE AND INSTALL A 20194 RIVET IN EACH LOCATION.

RIBS (40169)
WITH VELCRO
IN SECTION 12
WING TIP
NOTICE

Trace the lines onto the Trailing Edge pocket for each Rib. See NOTE for Tip Rib.
Carefull not to cut into the main (TOP) surface fabric. For all 9 Rib locations
12
Section 4
11
Air-Tech, Inc

TRAILING EDGE
LEADING EDGE
CENTER THE LOCATOR HOLE OVER THE SCRIBES LINE. ALIGN THE ZIG-ZAG LINES
ON THE TEMPLATE OVER THE ZIG-ZAG SEWING ON THE COVER
MARK THE HOLE WITH A PENCIL
SCRIBE LINE
Locator Hole in Template
COMPRESSION STRUT
CUT OUT TEMPLATE
Hidden hole under
fabric. Do Not cut
out at this time !!
Compression Strut holes are located at 62”(157.48cm) 130” (330.2cm) 159” (403.86cm) from Root End
of the spars.
Locate the Hidden holes under fabric and mark with pencil as shown. This is the “Center Line” for the
Compression Strut Cut Outs.
.
WING COVER ATTACHMENT CONT.
Section 4
12
Air-Tech, Inc

Cut all the Entry Points for all the Compression
Struts and the Diagonal Strut.
Whatever Method you choose be
carefull to only cut the intended surface.
The Preferred method is to use a Hot Knife
A dedicated tool that is used for Wood Carving.
A modified Soldering Iron is the most common
tool. Simply shape the soldering tip into a
Blade Shape.
SEE COMPRESSION STRUT CUT OUT TEMPLATE SECTION 12
WING COVER ATTACHMENT (CONT’D)
One method of Cutting the holes in the
fabric is to use a Razor Knife and then
heat seal the fabric edges with a Soldering
Iron.
USE SOLDERING IRON
TO HEAT SEAL THE
CUT EDGE
CUT OUT HOLE IN
WING COVER
Section 4
13
Air-Tech, Inc

3“
COMPRESSION STRUTS
(40283)
TRAILING EDGE
WING TIP
ADDITIONAL CUT OUT
FOR THIS HOLE TO AID IN ASSEMBLY
OF LEADING EDGE OUTBOARD WIRES
CUT WITH
TEMPLATE
POP ALL 3 STRUTS INTO PLACE. DO NOT CUT FABRIC FOR BOLT HOLES
LEADING EDGE
COMPRESSION STRUT
BOLT HOLE IN FABRIC
CUT DURING CABLE INSTALL
COMPRESSION STRUT HOLE
IN WING FABRIC
BELLCRANK COMP. STRUT
(71020)
COMPRESSION STRUT ATTACHMENT
Section 4
14
Air-Tech, Inc

Section 4
15
Air-Tech, Inc

Aircraft using the EXTRUDED Channels
DO NOT need this washer
Aircraft using the EXTRUDED Channels
DO NOT need this washer
D
DETAIL B
8
8
DIAGONAL STRUT ATTACH Cont’d
DETAIL A