Wills Wing Fusion 141 Application guide

Fusion 141 and 150
Owner / Service Manual
October 15, 1998 - Third Edition

500 West Blueridge Ave • Orange, CA • 92865 • Phone [phone] • FAX [phone]
Internet Web address: http://www.willswing.com • E-mail: [email protected]
October 15, 1998 - Third Edition
Copyright © 1994, 1995, 1996, 1997, 1998 by Sport Kites, Inc. dba Wills Wing, Inc. All rights reserved.
No part of this manual may be reproduced in any form without the express written permission of
Sport Kites, Inc., dba Wills Wing, Inc.
Fusion 141 and 150
Owner / Service Manual

Contents
Glider Delivery Check List .................................................................................... i
Introduction...................................................................................................... 1
Disclaimer and Warning...................................................................................... 2
Technical Information and Placarded Operating Limitations ...................................... 3
FUSION MANUAL ADDENDUM ........................................................................... 6
Leading Edge Pocket / Mylar Insert ................................................................................... 6
Nosecone Installation ......................................................................................................... 6
Transverse Batten Installation ............................................................................................ 6
Button Lock Apex Slider .................................................................................................... 6
Fusion Breakdown Procedure for Shipping, and Reassembly Procedure ..................... 7
To break down the leading edges follow these steps .......................................................... 7
Remounting the rear leading edges..................................................................................... 8
Fusion Set-Up Procedure .................................................................................... 9
Preflight Procedure .......................................................................................... 15
Along the left leading edge............................................................................................... 15
At the left wingtip ............................................................................................................. 15
Along the trailing edge, left wing ..................................................................................... 15
From the rear keel ............................................................................................................. 16
Along the trailing edge, right wing ................................................................................... 16
At the right tip................................................................................................................... 16
Along the right leading edge............................................................................................. 16
Under the glider at the control bar .................................................................................... 16
Laying the Glider Down Flat .............................................................................. 18
Setting the Glider Up Flat on the Ground ............................................................ 18
Launching and Flying the Fusion........................................................................ 19
Minimum controllable airspeed and minimum sink airspeed .......................................... 19
Using wing tufts to find the minimum sink speed of your glider ..................................... 20
Towing .............................................................................................................................. 22
Trimming Your Glider in Pitch ............................................................................ 23
Speeds to Fly and Using Your Airspeed Indicator ................................................. 24
Using the VG System ...................................................................................... 25
Landing the Fusion .......................................................................................... 26
Fusion Breakdown ........................................................................................... 29
Fusion Stability Systems .................................................................................. 30
Fusion Sprog Adjustment and Flight Testing ........................................................ 31
Sprog measurement .......................................................................................................... 31
Alternate sprog measurement ........................................................................................... 31
Method of adjustment ....................................................................................................... 31
Test flight .......................................................................................................................... 32

Maintenance................................................................................................... 33
Every month...................................................................................................................... 33
Every six months .............................................................................................................. 33
Every year ......................................................................................................................... 34
Special circumstances....................................................................................................... 34
A note about cables and cable maintenance ..................................................................... 35
Removing the Sail from the Airframe and Re-Installing.......................................... 36
Sail removal ...................................................................................................................... 36
Re-installing the sail on the frame .................................................................................... 37
Replacing the Perlon hang loop ........................................................................................ 38
Glider Tuning .................................................................................................. 39
Dismounting and remounting the sail at the tip................................................................ 39
CG adjustment .................................................................................................................. 39
Turn trim ........................................................................................................................... 39
Airframe............................................................................................................................ 39
Battens .............................................................................................................................. 39
Sail mount plugs - adjusting sail tension and rotational alignment .................................. 39
Sail tension ....................................................................................................................... 40
Twisting a tip .................................................................................................................... 40
Batten tension ................................................................................................................... 40
Leading edge sail tension.................................................................................................. 41
Car Top Mounting and Transport ........................................................................ 41
In Closing....................................................................................................... 41
HGMA Fusion 150 COMPLIANCE VERIFICATION SPECIFICATION SHEET ...............................42
HGMA Fusion 141 COMPLIANCE VERIFICATION SPECIFICATION SHEET ...............................43
Assembly Diagrams
83E01.1 Fusion Crossbar Center ....................................................................... 2
83E02.2 Fusion Front Leading Edge and Cam VG ................................................ 3
83E03.2 Fusion Sprog Wire and Bracket (Carbon Sprog) ...................................... 4
83E07.0 Fusion Sprog (Carbon) ........................................................................ 5
83E04.1 Fusion Noseplate ............................................................................... 6
83E05.1 Fusion Rear Leading Edge.................................................................... 7
83E06.1 Fusion Keel ....................................................................................... 8
83E10.0 Fusion Aluminum Sprog and hardware Assembly.................................... 9
83E09 VG Folding Base Tube ....................................................................... 10
80E08 VG Control Bar ................................................................................ 11
Fusion 150 Frame Plans ................................................................................... 12
Fusion 141 Frame Plans ................................................................................... 13
Button Lock Apex Slider Assembly .................................................................... 14
Fusion Control Bar........................................................................................... 15

World Record Hang Gliders Since 1973 • Orange, California USA
Glider Delivery Check List
PO # Model / Size Serial # Date
Customer Name Phone #
Address City State Zip
Dealership Name Order Date Date Delivered
Dealer Test Flight Results
Pilot Site Date Tested Airtime
Test Flight Comments
Dealer/ Customer Checklist Customer Dealer
Reviewed glider owner’s manual with customer
Reviewed set-up, break-down, and pre-flight procedures
Reviewed maintenance and service procedures
Reviewed car top mounting (HG), Trunk heat cautions (PG)
Delivered customer response form
Delivered glider parts kit
Delivered owner’s manual
READ BEFORE FLIGHT
CAUTION: Use of this equipment may result in INJURY OR DEATH. Please be sure
you are qualified to fly this product, are thoroughly familiar with and follow all
proper procedures as explained in the owner’s manual. You are reminded that YOU
FLY AT YOUR OWN RISK.
I have read and understood all of the above and hereby release Wills Wing Inc., its
employees, and dealers acting in association with or on behalf of Wills Wing Inc.
from all liability in connection with my use of this glider.
Customer Signature Dealer Signature
Wills Wing Inc. • 500 West Blueridge • Orange, California USA • 92865 • Ph(714) 998-6359

 1 
Introduction
Thank you for purchasing a Wills Wing glider, and welcome to the world wide family of Wills Wing
pilots. We are a company of pilots and aviation enthusiasts, and our goal is to serve your flying needs
now and in the future, as we have done for pilots throughout the world since 1973.
We encourage you to read this manual thoroughly for information on the proper use and maintenance
of your Wills Wing glider. If at any time you have questions about your glider, or about any aspect of
hang gliding that your Wills Wing dealer cannot answer, please feel free to give us a call.
If you have access to the Internet, please visit us regularly at http://www.willswing.com. The site
features extensive information about Wills Wing gliders and products, a Wills Wing Dealer directory, a
comprehensive list of service and technical bulletins, the latest editions of owners manuals, our com-
plete retail price list, a search engine, e-mail and more.
The most important contents of our internet site are the service and technical bulletins, and the latest
editions of owners manuals. This is your single best source for safety and airworthiness advisories on
Wills Wing products. Many of the documents are published in Adobe Acrobat format. A free viewer for
Acrobat files is available at http://www.adobe.com.
We wish you a safe and enjoyable flying career, and, once again, welcome aboard!
Rob Kells, Mike Meier, Linda Meier, and Steve Pearson
Wills Wing, Inc.

 2 
Disclaimer and Warning
Hang gliding is a form of aviation. Like any form of aviation, its safe practice demands the consistent
exercise of pilot skill, knowledge of airmanship and weather, judgment and attention at a level which is
appropriate to the demands of each individual situation. Pilots who do not possess or exercise the
required knowledge, skills and judgment are frequently injured and killed. The statistical rate at which
fatalities occur in hang gliding is approximately one per thousand participants per year.
The Federal Aviation Administration does not require a pilots license to operate a hang glider. Hang
gliders and hang gliding equipment are not designed, manufactured, tested or certified to any state or
federal government airworthiness standards or requirements. Federal Aviation Regulation Part 103
states in part, "ultralight vehicles are not required meet the airworthiness certification standards
specified for aircraft or to have certificates of airworthiness" and "operators of ultralight vehicles are
not required to meet any aeronautical knowledge, age, or experience requirements to operate those
vehicles or to have airman or medical certificates." Wills Wing hang gliding products are not covered
by product liability insurance. As a hang glider pilot, you are entirely responsible for your own safety.
You should never attempt to fly a hang glider without having received competent instruction. We
strongly recommend that you not participate in hang gliding unless you recognize fully and wish to
personally assume all of the associated risks.
Please fly safely.