Veloce 400 User manual

VELOCE
Manufacturing
Manual –400

Summary
1General Information 1
2Getting Started 3
3Wing 4
3.1 Wing mounting template 4
3.2 Wing top coating preparation 5
3.3 Rear spar preparation 7
3.4 Experimental Fit 7
3.5 Main spar 8
3.6 Fuel Tank Preparation 8
3.6.1 Fuel output 10
3.6.2 Fuel vent lines 11
3.6.3 Tank breather 11
3.6.4 Anti-slosh valve 12
3.6.5 Fuel sensor 12
3.7 Fuel cap 13
3.8 Tank bridge 14
3.9 Rigid point for aileron horn 15
3.10 Bonding of the top coat 15
3.11 Tank closing lamination 16
3.12 Fuel Test 18
3.13 Static pitot lines18
3.14 Electrical conduit 18
3.15 Undercoating preparation 19
3.15.1 Fuel drain valve19
3.15.2 Aileron horn inspection panel 20
3.15.3 Suggested pitot tube fabrication 20
3.15.4 Undercoating lamination 21
3.15.5 Aileron's inspection panel cover fixation 21

3.16 Trailing edge strengthening 22
3.17 Hinges Installation 23
3.18 Aileron horn 23
3.19 Wing tips Installation 24
4Horizontal empennage 25
4.1 Assembly Preparation 26
4.1.1 Horizontal stabilizer spar 28
4.1.2 Elevator spar 20
4.1.3 Ribs preparation and positioning 30
4.1.4 trim-tab hinge region preparation 32
4.2 Component lamination 33
4.2.1.1 Spars lamination 33
4.2.1.2 Elevator Spar 33
4.2.1.3 Stabilizer spar 33
4.2.2 Ribs Lamination 33
4.2.3 Trim-trab hinge preparation 35
4.3 Top coating mounting and installation 35
4.4 Elevator and stabilizer cutting sections 37
4.5 Trim Tab 37
4.6 Trim tab hinge 37
4.7 Surfaces closing lamination 38
4.8 Elevators hinge 39
4.9 Assembly of the elevator control horn 40
4.10 Closing of edges 40
4.11 Mass balance 41
4.12 Trim-tab actuation servo 42
5Fuselage 44
5.1 Preparation of components 44
5.2 Leveling and fixing 45
5.2.1 Wedge Rods 46

5.3 Temporary fit of the fuselage top 47
5.4 Firewall 48
5.4.1 Front face of the firewall 49
5.4.2 Engine mount reinforcements 50
5.4.2.1 Lamination of the firewall lower reinforcements 51
5.4.2.2 Lamination of the firewall's top reinforcements 52
5.5 Front seat reinforcement 53
5.6 Installation of the rear seat backrest 56
5.7 126 Station cave 57
5.8 185 Station Cave 58
5.9 Front floor mounting 58
5.10 Reinforcement of the main train box 63
5.11 Reinforcement of the nose gear assembly 65
5.12 Vertical and horizontal stabilizers 66
5.12.1 Installation of the right rear fuselage 66
5.12.2 Installation of the horizontal stabilizer 69
5.12.3 Bonding of the station cave 70
5.12.4 Gluing of the vertical stabilizer's rib and spar 71
5.12.5 Installation of the left rear fuselage 72
5.12.6 Bonding of the 126 station cave 74
5.13 Wing attachment reinforcements 76
5.13.1 Rear spar 76
5.13.1.1 Placement and installation of the rear spar 77
5.14 Control Console 79
5.15 Assembly of the front seat back section 81
5.16 Assembly of the seat bottom 82
5.16.1 Front seats 82
5.16.2 Rear seats 83
5.17 Assembly of the upper fuselage 83
5.17.1 NACA input 83
5.17.2 Door buffer reinforcerment 84
5.17.3 Alignment 85

5.17.4 Gluing -86
5.18 Luggage compartment cover 86
5.19 Elevator scale 88
5.20 Installation of the wing attachment eyelets 89
5.21 Wing-fuselage junction 90
5.22 EngineCowl 91
5.23 Internal finishes 91
6Fuselage - Translations (includes mechanics)............................................. 92
6.1 Mounting the stick linkage 92
6.2 Flap mountingBracket 93
6.3 Rudder cable route 94
6.4 Installation of the aileron horn 95
6.5 Installation of the Elevator Push/Pull Polen 97
6.6 Installation of the Rudder Horn 97
6.7 FLAP TORQUE TUBE INSTALLATION ACTUATION 99
6.8 CRUISER FLAP PIVOT HANGERS ACTUATION 100
6.9 ROUTING RUDDER CABLE AND INSTALLATION 102
6.10 INSTALLATION main gear 107
6.11 LINE INSTALLATION BRAKE 109
6.12 Rudder Pedals 110
6.13 Extras 113
7Flap 136
7.1 Assembly of the bottom undecoating 136
7.1.1 Spar 137
7.1.2 Bottom Assembly 137
7.2 Flap actuation rail 139
7.3 Preparation and gluing of the top coating 139
7.4 Assembly of the Flap Actuator Rail 139

7.5 Mounting the hinges 141
8Aileron142
8.1 Preparation for Spar assembly142
8.2 Initial assembly of the lower half 143
8.3 Gluing Preparation 143
8.4 Preparation for the aileron control arm 144
8.5 Installation of top coating 145
8.5.1 Gluing the top coating 145
8.6 Closing of the external face 146
8.7 Assembly of the Aileron Components 147
8.8 Balance 147
9Rudder 148
9.1 Rigid point on spar 148
9.2 Assembly of the right side 149
9.3 Final gluing of half of the right side150
9.4 Fitting Test 151
9.5 Rudder actuation arm 151
9.6 Final closing –Gluing 152
9.6.1 Front lamination of the spar 152
9.7 Balancing 154

Page 1
1General Information
Congratulations on selecting the Veloce 400 as your personal aircraft build kit. If
you've built any other composite aircraft before, you'll be pleasantly surprised at the
simplicity and ease with which this project will progress. If this is your first build on a
project, please pay particular attention to all phases of instruction and you will also be
guided to a satisfactory completion of this excellent aircraft. The theme under the entire
project development line is focused on the simplicity in the construction and operation of
the complete aircraft. This manual provides detailed step-by-step instructions for
assembling the Veloce 400 aircraft kit. However, the basic instructions in each section
assume a certain degree of familiarity and experience in building with composite material.
The introductory chapters will define several terms and provide detailed assistance on
many of the repeated operations, but if you do not have any experience, it is recommended
to look at other reference texts and possibly some test projects with composite
construction. Working with some practice in using composite material is strongly
recommended.
If during construction you have any questions or concerns about the construction
procedure, do not continue until you obtain the required information or skill to complete
the procedure correctly. If you are not knowledgeable about fiberglass construction
techniques, please consult some of the referenced sources for such knowledge before
starting construction. It is also important to have someone with previous experience help
you and provide training in these procedures. Changes to the aircraft design or specified
construction procedures must not be made without the prior approval of VOLATO.
Unauthorized changes can create hazardous conditions impacting aircraft safety and/or
structural integrity. Failure to comply with these warnings and/or other instructions and
precautions contained in the manual coan result in an unsafe aircraft with the potential for
increased injury or possible fatality.

Chapter 2 - Getting Started
3.1 - Wing assembly template
Page 3
2INITIAL INSTRUCTIONS
IT IS OF VITAL IMPORTANCE TO READ THIS CHAPTER BEFORE
BEGINNING CONSTRUCTION.
All references relating to BID tape laminations refer to bidirectional glass
fabric laminations. This fabric is cut and laminated at +/- 45º if not specified.
The small radii on the edges using MICRO (micro glass spheres) or FLOX
pastes are approximately 1/8 inches which can be made by sliding the
indicator over the joints.
Don't do anything without full knowledge of how to complete the step in
question.
It is extremely advisable to read the entire section before carrying out any
operation.

Chapter 3 -
Wing
3.1 - Wing assembly template
Page 4
3Wing
3.1 Wing Assembling Template
The first step in assembling the wing is to fabricate an assembly template similar to
the photo shown below. The upper contour of the airfoil should be traced from the full-
size template provided and carefully cut into the plywood or MDF (you will build the
wing sections from top to bottom on this frame).
Cut perpendicularly around the leading edge contour (as shown in the template) to
provide a positive reference for positioning the leading edge of the top coating. Some of
the materials can be retrieved from the shipping crate , but most will need to be sourced
locally. Make sure the beams between the contours are straight and not curved
(reinforcing the beams with plywood fillets or cutting them from a ¾'' board can help
them stay straight). The beams must be placed so that the center beam is aligned with the
main spar, and the rear is centered below the rear spar. It is recommended that the beams
be approximately 130 inches long and the edges of the frame airfoil should be 127.5
inches apart. The frame's assembly must be securely fastened to a table or brackets at a
convenient height for working on them. Leveling is an acceptable way to assemble the
template, but straightness and lack of twist are really important parameters. When
positioned, secure in place so that the template does not move and twist during
manufacturing (use epoxy to glue the supports to the floor or secure through

Chapter 3 -
Wing
Preparation of the top wing coating
Page 5
pipes, foundation shoes and holes in the ground). Make a mirror template on the newly
constructed one and attach this to the side so that the wing is constructed in one piece.
It is recommended that the wing template be made stronger than suggested in the
basic instructions. More rib outline sections are desirable (as shown in the photos above).
Wing coatings have a tendency to twist during cure to a tighter radius than the initial
airfoil contour, so significant weight is required to fit the rib contour. Keep this in mind
when making the template for assembling these items. Elongated sandbags (such as those
made from old trouser legs) are ideal for securing the coating to all surfaces, a total of
500 kg for gluing the bottom coating to each wing.
3.2 Preparation of the top wing coating
Select the proper wing coating for each side of the wing you are planning to
assemble (the inner section of the wing's top coating can be identified by the extra layer
of glass in the area intended for stepping on top). Remove all peel ply and any residual
molding material, especially in the areas where the spar and ribs will be glued. Finishing
on the edges. The inner edge of the coating will be on the BL 23 ¾. Position the upper
wing coating on the frame by pulling the front outline into place in the mold. Secure in
place with a few superb screws threads.

Chapter 3 -
Wing
3.3 - Preparation of the rear stringer
Page 6
3.3 Rear spar preparation
The rear spars are identical and interchangeable, however note that there are hard
points on the edges which will be located in the center of the wing. Select a rear spar for
the wing section you are building. Cut any extra corner material and remove all peel ply
and other non-structural manufacturing materials. Sand the corners of the fiberglass parts
to make them safe to handle (potential splinters and cuts from these sharp corners can be
very unpleasant –perform this operation when selecting the pre-molded parts for
assembly).
Locate the inner end of the selected rear spar. This is completed by identifying the
end of the spar where the spar core material is made with a 4-inch long phenolic section
(hold the spar against a bright light to identify the corners of this solid block and mark
the center). The center of this block must be positioned on the BL 24 where it will be
drilled for the rear spar pin. Position the rear spar in place along the rear section of the
wing casing with the open face pointing forward. Locate the rear spar carefully with the
rear face 1 ¾'' in front of the rear edge of the coating. Establish the relationship between
the reference lines between the spar and the coating by aligning the inner edge of the
coating with the BL 24 mark previously made on the spar.
Secure the spar in place with several clecos or small superbly threaded screws.
Position the rear rib sections on the rear spar at the appropriate reference stations and
mark the places where gluing will be performed as a reference for further surface
preparation. The rear rib flange must fit the rear spar without slack for proper placement
of the wing assembly components along the rope.

Chapter 3 -
Wing
3.4 - Experimental Fit
Page 7
3.4 Experimental fit
Select the ribs for the assembly (there are no ribs on the right or left side, so just
select the required number of parts). Again, remove all peel ply and sand the corners for
personal safety when handling. Prepare the rib gluing areas in the same way as the other
gluing areas –roughen the surfaces with sandpaper and clean. Experimentally assemble
the spars and ribs to ensure they will interfere with each other, mark the areas of the
placement for later reference. The lines of placement of the ribs are measured at the
centerline of the sandwich panel of each rib. Their positions are BL –27.5; BL –52; BL
–85; BL - 118; BL
–125; BL –157.5 (right and left). Remembering that for BL 125 there is only the front
rib.
Pay particular attention to the orientation of the ribs. The top and bottom parts of
some rib sections are easily confused, also remember that we are building the wing from
top to bottom. Note again that there are no left and right side rib sections. The rib flanges
will point outward from the fuselage on the right wing and toward the fuselage on the left
wing (pictures and sketches show the right side of the wing). Clean and scratch the areas
of the top cladding (based on these marks) which will be glued together with an 80
sandpaper similar to how you prepared the spar flanges and ribs.

Chapter 3 -
Wing
3.5 - Main stringer
Page 8
Clecos or small metal screws can be used to correctly position the parts before and
during gluing and will be useful for re-installing the parts precisely in place with the
gluing materials for final assembly.
3.5 Main spar
Select the main spar, remove the peel ply etc, prepare in the same way as for the
rear spar. Place in position on top cladding (center of top liner coincides with BL 0), locate
and mark all bonding surfaces including rib positions. Make sure all surfaces are free of
any peel ply and other particles. Leave rough surfaces for gluing with 50 sandpaper.
3.6 Fuel Tank Preparation
Position the front ribs of the tank as mentioned above. In this step you should have
already completed the positioning of the rear ribs and the main and secondary spars.
Secure the ribs with clecos or superbly threaded screws.

Chapter 3 -
Wing
3.6 - Fuel tank preparation
Page 9
With the help of the leading edge of the front ribs, position and mark the location
of the tank closing spar, fasten it with clecos or screws with superb thread.
Note that there is an extra front rib added to support the aileron drive arm mounting
point and that the front channel inner closure ends at the end of the tank bay. The open
area in the nose of the wing is for the aileron control rod coming out of the fuselage and
the crank will be mounted in this small bay to transfer its movement to the aileron.
The center front rib (BL 85) of the fuel tank must have its corners chamfered as in
the figure below to allow the passage of fuel between the sections and to avoid any gluing
conflict with the perimeter of the tank area.
While assembly is at the experimental stage, it might be a good time to review the
assembly of vent lines, fuel level sensors and

Chapter 3 -
Wing
3.6 - Fuel tank preparation
Page 10
anti-slosh valve. Drilling holes and other preparations are most successfully done on local
components prior to gluing.
3.6.1 fuel output
The fuel outlet uses a “finger” filter located in the lower back corner of the first rib.
It may be easier to install this filter on the loose rib before sticking it in place. Refer to
figure for location and procedure to install fuel outlet. If an injection mechanism is used,
check where a fuel return line is to be equipped. If so, this rib is also the appropriate place
for this line.
The innermost rib requires arigid point for fuel outlet and other surface penetrations
as a measure of fuel level. The suggested material to be inserted into these parts is a ¼
inch aluminum sheet to provide a rigid, non-porous material for screws and fittings. Cut
out a 4 x 2,5 rectangle from the aluminum. De-shave all sharp corners, clean and rough
all surfaces thoroughly. Cut the rib side near the fuselage and clean the core material in
the hard spot area. Glue in place and fill final gaps with wet MICRO paste and cover with
2 layers of BID.
Any other penetration of fuel into the tank area through this rib or other locations
must perform similar techniques with enough aluminum insert to withstand the locking
forces. The phenolic or plywood inserts used at other mounting points would likely let a
small amount of fuel leak due to their porosity.
The fuel outlet hole must be drilled by piercing the casing and rigid point on the rib
5/8; from the top of the rib and 7/8; from the trailing edge of the rib. Drill and tap the tap
to thread as needed for the equipment.

Chapter 3 -
Wing
3.6 - Fuel tank preparation
Page 11
3.6.2 Fuel Vent Lines
Fuel tanks must be vented, allowing the entry or exit of air equivalent to the fuel
flow. The upper rear corner of the outermost rib of the tank bays is the preferred location
for locating this vent. The lines are made of aluminum tube ¼ inch provided in the kit.
Direct this vent line to the wing tip and away from it where the underside of the wing will
be as shown in the figure. Secure this line with the temporarily assembled structural
members of the wing, cut any required location for line placement before gluing.
Once the ribs have been definitively glued, glue this to the tank with a paste of
FLOX.
3.6.3 tank breather
take the tube from ½’’ of the breather, make a hole in the upper posterior corner of
the rib so that it can be glued. Make a dry MICRO paste, place the tube in place flush
with the liner and glue it in place with the paste on both sides of the rib.

Chapter 3 -
Wing
3.6 - Fuel tank preparation
Page 12
3.6.4 Anti-slosh valve
The anti-slosh valve system is installed in the lower section of the second outer rib.
This rudimentary check valve will keep the internal tank relatively full during agitation
due to inclement weather or maneuvering. This valve is a flap configuration which is
attached to the second rib. Drill a 1 ½” hole centered 1 ¾”from the back edge of the rib
and 1 ¼” from the bottom edge of the rib. Take the tube with the anti slosh valve (see
figure) and sand it to make it rough where it will be glued. Moisten the hoving with resin
and 3 to 4 turns on each side of the rib to secure the valve in place. Keep this parallel to
the sides of the spar (horizontal and vertical) until it heals.
3.6.5 Fuel sensor
The first rib is the logical place for positioning the fuel level sensor device
installation. No system is provided in the kit. fuel level measurement , however the tubular
capacitive fuel metering sensor is one of the best known devices. For this type and/or
several other sensors, the most logical installation is next to the fuel outlet. The hole can
be drilled 5/8”from the top of the rib and 2 ½”from the trailing edge of the rib. Drill and
tap the tap to thread as needed for the equipment.
Also locate the path for the entire length of the sensor, mark any rib sections that
need to be penetrated, remove and modify these ribs. Any holes through these ribs that
will be exposed to the fuel liquid must have the core forced down at the corners and filled
with an MICRO folder . Carefully follow the manufacturer’s instructions for any bending
that needs to be performed to make the desired level measurement.

Chapter 3 -
Wing
3.7 - Fuel cap
Page 13
3.7 fuel cap
The fuel cap will be installed in the highest corner of the fuel tank area. Locate the
desired position and hold the cap against the inside surface of the liner and draw around
the perimeter. Cut the inner liner to the edges of the mark, clean the core material without
damaging the outer liner.
Rough the coating areas around this cut and the metal surfaces of the fuel cap in the
glued areas, clean the debris from the area. Cover with FLOX around the cut area,
working it into the core material and seat the cap in place. Cut a three-ply “washer” from
wet BID and laminate around neck (3 inches beyond lid surface). Work with this BID on
all joint areas and remove any bubbles from the lamination.

Chapter 3 -
Wing
3.8 - Tank bridge
Page 14
After curing remove the outer coating from inside the cap and finish.
3.8 tank bridge
Take the pipe sections for the bridge and laminate them with two BID layers. Allow
healing. Drill 2 holes of 1 ½” with center to 7/8” the top and bottom edges and the 1”
from the trailing edge of the ribs of the BL 118 and BL 125 . Pass the PVC pipe sections
through these holes. Moisten the hoving with resin and 3 to 4 turns on the non-flange side
of the ribs, on the flanged side stick in place with a FLOX paste. Remember to keep
sections apart 7 inches. Allow healing.

Chapter 3 -
Wing
3.9 - Rigid point for the aileron horn
Page 15
3.9 Rigid point for aileron horn
The BL 125 rib is where the aileron horn will be mounted. The rigid point for this
mount can be installed more easily before gluing the ribs to the wing. Take the aluminum
rigid points provided, demarcate their position on the outer shell of the tank (this rigid
point is centered on the rib and with the front face aligned with its internal flange, see
figure). Cut the casing and dig the core in these positions. Prepare a FLOX paste and glue
this hard spot in place. Roll in place with 3 layers 1-inch BID overlay.
3.10 Top coat bonding
Replace all rib and spar sections following the modifications and ensure that no
modifications made previously created any problems with the fit. When the placement is
satisfactory, gluing can be started. Again, this is accomplished by working from the rear
spar to the front. Prepare the top coat and face bonding areas of the sections to be bonded.