Section 20, Turtle Deck Final Assembly, SeaRey, LSA

Progressive Aerodyne, Inc.

3801 State Rd 19
Tavares, FL 32778

Document Number
Revision Description Remarks Date
03282012 Initial Creation 03/28/2012
02072013 Update Pg 7, 8, 9, 10 - Reversed Tie Rod Tube 10 ¾” with 11 ¾” 02/07/2013

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 Section 20, Turtle Deck Final Assembly SeaRey, LSA

1.0 Scope
This document will detail the steps necessary to perform final assembly of the Turtle Deck area.

2.0 Applicable Documents

N/A

3.0 Requirements
3.1 Equipment
3.1.1 The following tools will be necessary to perform this procedure:
 Awl
 Allen Wrench, 5/32”
 Allen Wrench, 3/16”
 Center Punch
 Deburring Tool
 Drill Bits, Jobber Length, 1/4”
 Drill Bits, Jobber Length, 1/8”
 Drill Bits, Jobber Length, 3/16”
 Drill, Electric, or Cordless
 Hammer, Plastic Tip
 Marker
 Open End Wrench, 3/8”
 Open End Wrench, 7/16”
 Open End Wrench, 1/2”
 Pop Rivet Gun, Manual or Pneumatic
 Ruler
 Socket Set, SAE, 3/8”, 7/16”, 1/2” sockets
3.2 Materials
The following general supplies will be necessary to perform this procedure:

 Grease, Wheel Bearing or equivalent

 Lacquer thinner (Cleaning labels off of parts)
 Teflon Tape

3.3 Procedure

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 Section 20, Turtle Deck Final Assembly SeaRey, LSA

Cabin
Window

Inner
Tracing

Figure 1. Making a Cabin Window Tracing

1.1 Place the Cabin Window (#5610-015) on a piece of light cardboard. Trace the Cabin Window onto the cardboard and then
remove the window from the cardboard.
1.2 Trace another line to the inside of the overall window size that is 3/4” to 1” less than the overall size of the actual Cabin Window
(#5610-015). Cut out the cardboard on the inner window tracing. This is your cabin window template.

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 Section 20, Turtle Deck Final Assembly SeaRey, LSA

Window
Cutout

Cabin
Window
Template

Figure 2. Locating the Cabin Window Tracing on the Turtle Deck

2.1 Tape the Cabin Window Template onto Turtle Deck (#5340-009). Locate the front side of the Template 3” from the forward arch of
the Turtle Deck and 4” from the bottom edge of the template to the bottom lip of the Turtle Deck.
2.2 Use a grease pencil to trace the outer edge of the template onto the Turtle Deck and then remove the template.

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 Section 20, Turtle Deck Final Assembly SeaRey, LSA

Cabin
Window
Opening

Figure 3. Cutting Out the Cabin Window on the Turtle Deck

3.1 Using a Jigsaw, Cutoff Wheel or Nibbler, cut out the window opening in the Turtle Deck.

Note: Remember, there is carpet glued to the inside wall of the Turtle Deck. Do not catch the carpet and snag.

3.2 Remove the carpet from the opening with a hot knife. File the edges of the window opening.

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 Section 20, Turtle Deck Final Assembly SeaRey, LSA

Spacer, Flap
Retainer 5/8 x 2”

Slave Arm

Slave Arm
Flap Slave Horn

Forward

Figure 4. Installation of the Flap Slave Arm

4.1 Install the Slave Arm, 1/2” x 5” (#5750-002) by sliding the Slave Arm through the 1/2” hole in the end of the Flap Slave Horn
(#5750-001) and center the Slave Arm in the Flap Slave Horn.
4.2 Slide a Spacer, Flap Retainer, 5/8” x 2” (#5750-004) over each end of the Slave Arm, 1/2” x 5” (#5750-002).

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 Section 20, Turtle Deck Final Assembly SeaRey, LSA

Rod End
Jam Nut

Tie Rod Tube

Tie Rod Assembly

Rivet SB6-8

Figure 5. Assembly of the Tie Rod Tube, 11-3/4”

5.1 Place a Threaded Insert 7/16” Aluminum (#AL-23DC) into end of Tie Rod Tube, 11-3/4” (#2750-010). Place a mark at 1-3/16” from
edge of the Tie Rod Tube and drill a 3/16” hole completely through the centerline of the tube.
5.2 Secure the Threaded Insert 7/16” Aluminum (#AL-23DC) inside Tie Rod Tube, 11-3/4” (#2750-010) with a Rivet, SB6-8 (#SP-66).
5.3 Place (1) Nut, 1/4-28 Jam, Stainless (N1428J) on the end of a Rod End, 1/4-28 Male (#3230-027), threading the nut completely
down. Thread the Rod End, 1/4-28 Male (#3230-027) half way into Threaded Insert 7/16” Aluminum (AL-23DC).
5.4 Repeat Steps 5.1 – 5.3 on the other end of the Tie Rod Tube, 11-3/4”.
5.5 Repeat Steps 5.1 – 5.4 to construct the second Tie Rod Tube, 11-3/4”.

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 Section 20, Turtle Deck Final Assembly SeaRey, LSA

Flap Slave Arm

Fender
Washer
Bolt AN4-07A Flap Tie Rod Tube
Forward

Flap Tie Rod Tube

Forward

Figure 6. Installation of the Flap Slave Arm with Tie Rod Tube, 11-3/4”

6.1 Install a Tie Rod Tube Assembly built in Figure 5 to the Slave Arm, 1/2” x 5” (#5750-002): Install Bolt, AN4-07A (#N407A) through
a Washer, 1/4 x 1 SS Fender (#FW100-14), through Rod End, 1/4-28 Male (#3230-027), add another Washer, 1/4 x 1 SS Fender
(#FW100-14) into the Slave Arm, 1/2” x 5” and tighten.
6.2 Repeat above Step to the other side of the Slave Arm, 1/2” x 5”.

Note: Torque Value on the AN4 bolts in this section should be between 60 inch lbs and 70 inch lbs of torque.

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 Section 20, Turtle Deck Final Assembly SeaRey, LSA

Rod End
Jam Nut

Rivet SB6-8

Tie Rod Assembly

Tie Rod Tube

Figure 7. Assembly of the Tie Rod Tube, 10-3/4”

7.1 Place a Threaded Insert 7/16” Aluminum (#AL-23DC) into end of Tie Rod Tube, 10-3/4” (#2750-002). Place a mark at 1-3/16” from
edge of the Tie Rod Tube and drill a 3/16” hole completely through the centerline of the tube.
7.2 Secure the Threaded Insert 7/16” Aluminum (#AL-23DC) inside Tie Rod Tube, 10-3/4” with a Rivet, SB6-8 (#SP-66).
7.3 Place (1) Nut, 1/4-28 Jam, Stainless (N1428J) on the end of a Rod End, 1/4-28 Male (#3230-027), threading the nut completely
down. Thread the Rod End, 1/4-28 Male (#3230-027) half way into Threaded Insert 7/16” Aluminum.
7.4 Repeat Steps 7.1 – 7.3 on the other end of the Tie Rod Tube, 10-3/4”.
7.5 Repeat Steps 7.1 – 7.4 to construct a second Tie Rod Tube, 10-3/4”.

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 Section 20, Turtle Deck Final Assembly SeaRey, LSA

Bell
Crank,
Upper
Aileron Tie
Rod Tube

Flap Tie Rod Tube Bolt AN4-14A

Forward

Figure 8. Installation of the Aileron Tie Rod Tube, 10-3/4”.

8.1 Install the Tie Rod Tube Assembly built in Figure 7 to the Bell Crank, Upper (#2710-008): Install Bolt AN4-14A (#N414A) through
Washer AN4 (#N4W) and through Rod End, 1/4-28 Male (#3230-027), add Washer AN4 (#N4W) and install the Bolt AN4-15A
through the Bell Crank, Upper (#2710-008) from the top side followed by a Washer AN4 (#N4W) and Nut AN4 (#N4LN) and
tighten.
8.2 Repeat above Step to the other side of the Bell Crank, Upper.

Note: Torque Value on the AN4 bolts in this section should be between 60 inch lbs and 70 inch lbs of torque.

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 Section 20, Turtle Deck Final Assembly SeaRey, LSA

Bow Eye Inside forward

Backing Plate end of hull

Battery Box

Bow Eye Bolt

Figure 9. Installation of the Bow Eye

9.1 At the center point of the nose of the Hull, measure from the top edge down the center ridge approximately 8”. The exact location
of where the Bow Eye Bolt, 3/8” x 3” (#BE3-38) is located is up to the discretion of the builder.
9.2 Drill a 1/2” hole at the 8” location. Install the Bow Eye Bolt, 3/8” x 3” (#BE3-38) into the hole. Mark the location of the two anti-
spin pins on the Bow Eye Bolt where they touch the hull. Remove the Bow Eye Bolt and drill (2) 3/16” holes to allow the anti-spin
pins to set into.
9.3 Cut off some of the threaded rod on the Bow Eye Bolt, 3/8” x 3” so it extends approximately 1” through the hull.
9.4 Apply some silicone caulk in the (3) drilled holes. Also put some caulk on the back side of the Bow Eye Backing Plate (#1020-
001).
9.5 Push the Bow Eye Bolt, 3/8” x 3” into the 1/2” hole from the outside. On the inside of the hull slide the Bow Eye Backing Plate
(#1020-001) over the threaded rod, setting the “V” of the Plate into the “V”-Notch of the hull. Install the washer supplied with the
Bow Eye Bolt, 3/8” x 3” and then the nut and tighten.

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 Section 20, Turtle Deck Final Assembly SeaRey, LSA

Root Support
Drill 1/4” Hole Mounting
Angle

Root Support
Mounting
Bolt AN4-27A Angle

Root Support,
Forward

Figure 10. Installation of the Root Support Mounting Angle

10.1 Hold a Root Support Mounting Angle (#5320-011) to the Root Support, Forward (#5320-002) so the angle sits flush to the bottom
of the Turtle Deck arch and is spaced approximately 1/16” away from the fiberglass arch on the Turtle Deck. Clamp the Root
Support Mounting Angle to the Root Support, Forward.
10.2 Drill through the 1/4” hole in the Root Support Mounting Angle (#5320-011) and into the Root Support, Forward (#5320-002).
Repeat the above procedure for the other side and drill into the Root Support, Forward, maintaining a level straight hole through
both sides of the Root Support, Forward.
10.3 Install the Root Support Mounting Angles into the 1/4” holes just drilled in the Root Support, Forward: Install Bolt AN4-27A
(#N427A) with a Washer AN4 (#N4W) through the Root Support Mounting Angle (#5320-011), Root Support, Forward (#5320-
002), Root Support Mounting Angle (#5320-011), Washer AN4 (#N4W) and Nut AN4 (#N4LN) and tighten.

Note: Torque Value on the AN4 bolts in this section should be between 60 inch lbs and 70 inch lbs of torque.

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 Section 20, Turtle Deck Final Assembly SeaRey, LSA

Root Support
Mounting
Angle Turtle Deck
Bulkhead
Aluminum

Turtle Deck
Root Support, Bulkhead Bulkhead
Forward Aluminum Angle, 3-3/8”

Figure 10. Installation of the Bulkhead Support

10.1 Hold a Turtle Deck Bulkhead Aluminum (#5340-010) up against the back side of the Turtle Deck Bulkhead fiberglass arch. Be
sure to have the Aluminum match the Turtle Deck Bulkhead fiberglass arch. The first piece of Turtle Deck Bulkhead Aluminum
will sit between the Root Support Mounting Angle (#5320-011) and the Turtle Deck Bulkhead fiberglass arch, and the Bulkhead
Angle, 3-3/8” (#5420-003) and Turtle Deck Bulkhead fiberglass arch. Cut off the ends if necessary to fit end to end from the Root
Support, Forward (#5320-002) to the Bulkhead Cross Tube, Upper (#5310-002).
10.2 Hold a Turtle Deck Bulkhead Aluminum (#5340-010) up against the back side of the Turtle Deck Bulkhead fiberglass arch. Be
sure to have the aluminum match the Turtle Deck Bulkhead fiberglass arch. This second piece of Turtle Deck Bulkhead
Aluminum will sit on the aft side of the Root Support Mounting Angle. Cut off the ends to fit end to end from the Root Support,
Forward to the Bulkhead Cross Tube, Upper, but be able to sit on the aft side of the Root Support Mounting Angle and the
Bulkhead Angle, 3-3/8”.

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 Section 20, Turtle Deck Final Assembly SeaRey, LSA

Root Support
Mounting Turtle Deck
Angle Bulkhead Core,
Wood

Turtle Deck
Root Support, Bulkhead Core, Bulkhead
Forward Wood Angle, 3-3/8”

Figure 11. Installation of the Bulkhead Support

11.1 Hold a Turtle Deck Bulkhead Core, Wood (#5340-025) up against the back side of the Turtle Deck Bulkhead fiberglass arch. Be
sure to have the Wood match the Turtle Deck Bulkhead fiberglass arch. The Turtle Deck Bulkhead Core, Wood will sit against the
edge of the Root Support Mounting Angle (#5320-011) and the Turtle Deck Bulkhead fiberglass arch and the edge of the
Bulkhead Angle, 3-3/8” (#5420-003) and Turtle Deck Bulkhead fiberglass arch. Cut off the ends if necessary to fit end to end from
the Root Support, Forward (#5320-002) edge to the Bulkhead Angle, 3-3/8” (#5420-003) edge.

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 Section 20, Turtle Deck Final Assembly SeaRey, LSA

Turtle Deck
Fiberglass
Arch

Root Support
Mounting
Drill 1/4” Hole Angle
through here

1/4” Hole 1/4” Hole

Figure 12. Installation of the Bulkhead Support

12.1 Locate the 1/4” holes in the Root Support Mounting Angle (#5320-011) that face against the Turtle Deck Bulkhead fiberglass arch.
From the aft side drill through the 1/4” holes in the Root Support Mounting Angle (#5320-011) and through the Turtle Deck
Bulkhead fiberglass arch.

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 Section 20, Turtle Deck Final Assembly SeaRey, LSA

Turtle Deck
Bulkhead
Aluminum

Turtle Deck
Bulkhead Core,
Wood

Turtle Deck
Bulkhead
Aluminum

Figure 13. Installation of the Bulkhead Support

13.1 Assemble all of the Turtle Deck Bulkhead Aluminum (#5340-010) pieces and the Turtle Deck Bulkhead Core, Wood (#5340-025)
like a sandwich. First install the Turtle Deck Bulkhead Core, Wood, then from the front side install the Turtle Deck Bulkhead
Aluminum and on the aft side the remaining Turtle Deck Bulkhead Aluminum. Clamp all the pieces together to the Turtle Deck
Bulkhead fiberglass arch.

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 Section 20, Turtle Deck Final Assembly SeaRey, LSA

Root Support
Mounting Bolt AN4-07A
Angle
Drill 1/4” Hole Turtle Deck
through all the Bulkhead
Bolt AN4-07A materials Aluminum

Figure 14. Securing the Turtle Deck to the Root Support Mounting Angle

14.1 Using the 1/4” hole drilled in the Turtle Deck Bulkhead fiberglass arch, drill from the forward side all the way through all of the
materials sandwiched together and out the 1/4” hole in the Root Support Mounting Angle (#5320-011).
14.2 Install Bolt AN4-07A (#N407A) with a Washer AN4 (#N4W), Turtle Deck Bulkhead fiberglass arch, Turtle Deck Bulkhead
Aluminum (#5340-010), Root Support Mounting Angle (#5320-011), Turtle Deck Bulkhead Aluminum (#5340-010), Washer AN4
(#N4W) and Nut AN4 (#N4LN) and tighten.

Note: Torque Value on the AN4 bolts in this section should be between 60 inch lbs and 70 inch lbs of torque.

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 Section 20, Turtle Deck Final Assembly SeaRey, LSA

Drill 3/16” Hole Bulkhead

through all the Angle 3-3/8”
materials

Bolt AN3-06A
Bolt AN3-06A
Bolt AN3-06A

Bolt AN3-06A

Figure 15. Securing the Turtle Deck to the Bulkhead Angle

15.1 Locate the Bulkhead Angle, 3-3/8” (#5420-003) on each end of the Upper Bulkhead Cross Tube behind the fiberglass arch of the
Turtle Deck. Drill from the front side of the Turtle Deck, spacing (2) 3/16” holes in the lower edge of the Turtle Deck fiberglass and
centered on the Bulkhead Angle, 3-3/8”.
15.2 Install Bolt AN3-06A (#N306A) with a Washer AN3 (#N3W), Turtle Deck Bulkhead fiberglass arch, Turtle Deck Bulkhead
Aluminum (#5340-010), Bulkhead Angle, 3-3/8” (#5420-003), Turtle Deck Bulkhead Aluminum (#5340-010), Washer AN3 (#N3W)
and Nut AN3 (#N3LN) and tighten.
15.3 Repeat above installation to the other side.

Note: Torque Value on the AN3 bolts in this section should be between 20 inch lbs and 25 inch lbs of torque.

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 Section 20, Turtle Deck Final Assembly SeaRey, LSA

Pilot Side Co-Pilot Side Turtle Deck

Bulkhead
Aluminum
Bulkhead
Angle 3-3/8
Bulkhead
Angle 3-3/8

Drill 1/4” hole

Bolt AN4-07A

Figure 16. Securing the Bulkhead Angle to the Upper Bulkhead Cross Tube

Note: The Bulkhead Angle may not be perfectly perpendicular with the Bulkhead Upper Cross Tube.

16.1 Adjust the Bulkhead Angle, 3-3/8” (#5420-003) so it rests firmly against the Turtle Deck fiberglass arch.
16.2 Using the 1/4” hole pre-drilled in the Bulkhead Angle, 3-3/8” (#5420-003) drill through with a 1/4” drill bit into the Bulkhead Cross
Tube, Upper (#5310-002). Only drill through the upper side of the 2” square tube.
16.3 Install Bolt AN4-07A (#N407A) with a Washer AN4 (#N4W), Bulkhead Angle, 3-3/8” (#5420-003), Bulkhead Cross Tube, Upper
(#5310-002). Reaching through the end of the Bulkhead Cross Tube, Upper, install a Washer AN4 (#N4W) and Nut AN4 (#N4LN)
and tighten.
16.4 Repeat above installation to the other side.

Note: Torque Value on the AN4 bolts in this section should be between 60 inch lbs and 70 inch lbs of torque.

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 Section 20, Turtle Deck Final Assembly SeaRey, LSA

Pilot Side Pilot Side

Root
Support
Rivet SB6-8
Mounting
Angle

Turtle Deck
fiberglass arch Rivet SB6-8
Root Support
Mounting
Turtle Deck Angle
Bulkhead
Aluminum
Bulkhead
Angle

Figure 17. Riveting the Bulkhead Angle to the Turtle Deck

17.1 Along Turtle Deck fiberglass arch measure and mark for rivet holes to the inside of the bolts that were installed at the Bulkhead Angle,
3-3/8” (#5420-003) and the Root Support Mounting Angle (#5320-011). Space the rivets every 2-1/2” – 3” and double them up on
the width of the arch.
17.2 Drill a 3/16” hole at all of the marked locations all the way through all the sandwiched Turtle Deck Bulkhead Aluminum (#5340-
010) pieces and the Turtle Deck Bulkhead Core, Wood (#5340-025).
17.3 Install Rivet(s) SB6-8 (#SP-66).
17.4 Repeat above installation to the other side.

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 Section 20, Turtle Deck Final Assembly SeaRey, LSA

3/16” Hole

Boom
Tube Screw, #10
Cover x 3/4” Sheet
Boom Vertical Fin Metal
Tube Trailing Edge

Figure 18. Installing the Aft Boom Tube Cover

18.1 Locate the center of the Boom Tube Cover, Aft (#5310-025). Drill a 3/16” hole at the center through the Boom Tube Cover, Aft.
18.2 Hold the Boom Tube Cover, Aft up to the aft end of the Boom Tube (#5310-012). Locate the center mark through the Boom Tube
Cover, Aft and transfer a mark onto the Vertical Fin Trailing Edge (#5530-010). Drill a 9/64” hole into the Vertical Fin Trailing Edge at the
mark, through one side only.
18.3 Apply a bead of silicone caulk on the perimeter edge of the Boom Tube Cover, Aft (#5310-025). Insert a Screw, #10 x 3/4” Sheet
Metal (#S75-10) into the center hole of the Boom Tube Cover, Aft (#5310-025). Leave a ¼” open spot at the bottom without silicone so
water can drain out or put a small hole in the Cover for water to escape.
18.4 Place the Boom Tube Cover, Aft with the Screw onto the end of the Boom Tube and run the screw into the hole drilled into the Vertical
Fin Trailing Edge. Tighten the screw only to the point where the Boom Tube Cover, Aft (#5310-025) is firmly up against the Boom Tube
(#5310-012).

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