1 - Installation of The Lower Backrest Adjustment

SCHEMPP-HIRTH Appendix to Page: 01
Flugzeugbau GmbH. Technical Note

Kirchheim/Teck No. 265-13 No of pages.:07
Working Instructions
1. Installation of the lower backrest
adjustment
◦ Manufacture GFRP-adjustment part according
drawing.
◦ Take in mind that the right hand part is

manufactured homologous but only with 3 mm
bores!
Position of the left hand GFRP-part
◦ The GFRP-adjustment parts have to be placed 33
mm above the old lap belt fitting at the steel frame
work see drawing HS02-10.001/1. For the position
in the seat pan see drawing HS02-10.131.
Attention:
For a precise positioning of the GFRP-adjustment
parts use a gage placed on the cockpit rim and
measure the equal distance on both sides. This
will avoid a non-symmetric installation of the
backrest. The GFRP-adjustment parts are not
positioned symmetric in regard to the seat pan!
◦ After the positioning of the GFRP-parts, drill the GFRP-part is positioned and bored
holes for the rivets. These holes are needed to fix
the GFRP-parts.
◦ Sand down the gelcoat 50 mm around the GFRP-

parts until the glasfibre cloth.
◦ Then glue the GFRP-parts to the seat pan with

resin (thickened with cotton flocks) and fix them
with rivets.
◦ Round corners with thickened resin and cover

GFRP-parts with 1x 92125 und 2x 92110
diagonal, at least 30 mm on the seat pan.
Left hand GFRP-part laminated
◦ Cover all with peelply.
◦ After hardening transfer the holes from the left

hand GFRP-parts to the right hand part. Take in
mind that the backrest is symmetric to the
fuselage cockpit.
◦ Then bore the holes with 10 mm diameter until the

seat pan (not deeper!) and trim the holes.
Right hand GFRP-part laminated

t
2. Installation of the fitting for the steel cable on the left hand side of the cockpit
cockpit::
◦ Remove airbrake control rod
◦ Install the backrest in the aftmost position
◦ Mark the approximate area of the adjustment

fitting, see photo.
◦ Sand this area (approx. 340 mm x 100 mm) down

until the glasfibre cloth.
Positioning of the fitting
◦ Reinstall airbrake control rod
◦ Mark the exact position for the fitting, see photos.

Take care that it does not interfere with the canopy
closing mechanism. Take care that the steel cable
streaks the airbrake control rod as less as possible.
Check this with different positions of the backrest.
◦ Remove fitting of the canopy closing mechanism.
◦ Glue the fitting in place with cotton filled resin, fill

Distance bulhead – rear bore: 415mm
the edges. Cover it with 3 x 92125 and 1 x 92110
diagonal, 5mm graded from layer to layer.
◦ Cover with peelply
◦ After hardening, trim the borders, reinstall fitting of

the canopy closing mechanism
Distance top edge of fitting – cockpit rim

20mm
3. Installation of the adjustment on the

right hand side of the cockpit:
◦ Install the backrest in the rearmost position
◦ Mark the approximate area of the adjustment

fitting see photo.
◦ Sand this area (approx. 450 mm x 150 mm) down

until the glasfibre cloth.
Positioning of the anchor part for the
adjustment
◦ Then position the anchor part of the right hand
adjustment very precise. Take in mind that the
function of the landing gear operation is not
hindered by the knob of the backrest adjustment.
It is advantageous to position the anchor part as
high as possible!
◦ Tape the holes of the nuts from the backside.
◦ Glue in place the anchor part with thickened resin

and round the corners (position see photos).
Distance bulkhead to aft screw is
◦ Cover the anchor part with 3x92 125 und 1x92 110
390mm
diagonal, (400 mm x 110 mm, 5 mm from layer to
layer.
◦ Cover all with peelply.
◦ After hardening clear the cut out.
◦ Install the fitting and tighten screws.
Distance screw to cockpit rim is 75mm
Anchor part must be clear to the

landing gear operation!
4. Adjustment und cutting of the steel cable:
◦ Mount the backrest in the rearmost position.
◦ Connect the cable on the right hand side with the shackle in the adjustment
fitting.
◦ Adjustment in the rearmost position!
◦ Slide on the cable on the left hand side approx. 50 mm shrinkable tube and the
clamp.
◦ Connect the shackle in the rear eye of the fitting on the left hand side and
insert the thimble.
◦ Then hold the backrest against the steel tube frame work, tighten the cable
and fix it.(i.e.. with a holding tongs)
◦ Press the clamp, cut off the exceeding cable and slide over the shrinkable
tube.
◦ Heat the shrinkable tube.

5. Modification of the lap belt position:
◦ Mark the position on both sides of the seat pan

460 mm from the bulkhead.
◦ With the aid of an appropriate rule check the

symmetric position of the markers and change if
necessary.
◦ Apply on the rule a marker 42 mm from the edge

of the seat pan on both sides.
◦ From these marker measure 125 mm

rectangular down see photos.
◦ This is middle of the new lap belt fittings.
◦ From the middle draw the size of the cut out for
the fitting. The fitting is parallel to the edge of
the seat pan.
The size of the cut out is approx. 80 mm x 20
mm, corners rounded.
The fitting will later protrude over the seat pan.
The lap belt could then engage easily.
◦ Mark the size (approx. 120 mm x 200 mm) for

the cut out which is required for the glasfibre
cloth over the fitting to the fuselage shell.
◦ With aid of a thin diamant disc saw the cut out.

Attention:
Take in mind that below the seat pan cables
and Tecalan tubes may be routed.
Be careful when cutting that these may not
be damaged!
◦ Roughen very carefully the fuselage shell.
◦ Mark the position of the lap belt fitting.

◦ Glue in the lap belt fitting with thickened resin

(with cotton flocks) that no dents are below the
fitting!
◦ Apply the resin for all the glasfibre layers on a

plastic sheet and position it over the fitting.
Layers:
6x 92125, 1x 92110 diagonal, 180 mm x 100 mm
◦ Cover all with peeply
◦ Hardening of the laminate.
◦ Post curing 15 hours at 55°C.
◦ Smooth the glasfibre around the fittings that no

roughness is present which can later damage the
lap belt.
◦ Apply at the edge of the cut out some GFRP-
dopplers.
Then the original cap of the seat pan can be
installed in
two ways:
a) Glue in the cap on the dopplers, scarf it out and
and apply 4x92140
Or
b) Install 8 locknuts M 4 and screw the cap with M 4
countersunk screws.
6. Trimming the optional GFRP-cover to the fuselage ssteel

teel tube frame wor
workk
◦ Cut the GFRP-cover parallel to the front wing

attachment tube. In a width of approx. 30 mm sand
down the gelcoat of the GFRP-cover down to the
glasfibre for the later extending of the GFRP-cover.
◦ Trim the front part of the GFRP-cover to the steel

tube frame und fix it provisionally.
◦ Assemble the wing
◦ Slab the area between the gear box und the spar with
styropor or similar material. Cover the front part of the
spar with approx. 10 mm styropor for enough
clearance to the spar. Tape over the upper side of the
spar. Prepare the styropor surface for the laminating
of the glasfibre.
◦ Cover the pin on the upper spar side with plasticine

and avoid an undercut.
◦ On the front side of the GFRP-cover scarf the outside

margin approx. 30 mm to extend the GFRP-cover
and the openings.
◦ Laminate the prepared area with glasfibere cloth 3x

92125 (45°-90°-45°) and overlap it at least 30 mm to
the GRP-cover and at least 20 mm on the upper spar
side with the pin.
◦ Remark: The GFRP-cover on the spar and the pin

secure the GFRP-cover later against a downwards
pressure.
◦ After hardening and trimming paint the GFRP-cover

with grey gelcoat.
◦ Fix the front part of the GFRP-cover with a 4 mm

screw to the front steel frame work.

1 - Installation of The Lower Backrest Adjustment

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SCHEMPP-HIRTH Appendix to Page: 01

Flugzeugbau GmbH. Technical Note

◦ Take in mind that the right hand part is

◦ Sand down the gelcoat 50 mm around the GFRP-

◦ Then glue the GFRP-parts to the seat pan with

◦ Round corners with thickened resin and cover

◦ After hardening transfer the holes from the left

◦ Then bore the holes with 10 mm diameter until the

Right hand GFRP-part laminated

◦ Remove airbrake control rod

◦ Install the backrest in the aftmost position

◦ Mark the approximate area of the adjustment

◦ Sand this area (approx. 340 mm x 100 mm) down

◦ Mark the exact position for the fitting, see photos.

◦ Remove fitting of the canopy closing mechanism.

◦ Glue the fitting in place with cotton filled resin, fill

◦ Cover with peelply

◦ After hardening, trim the borders, reinstall fitting of

Distance top edge of fitting – cockpit rim

3. Installation of the adjustment on the

◦ Install the backrest in the rearmost position

◦ Mark the approximate area of the adjustment

◦ Sand this area (approx. 450 mm x 150 mm) down

◦ Tape the holes of the nuts from the backside.

◦ Glue in place the anchor part with thickened resin

◦ Cover all with peelply.

◦ After hardening clear the cut out.

◦ Install the fitting and tighten screws.

Distance screw to cockpit rim is 75mm

Anchor part must be clear to the

4. Adjustment und cutting of the steel cable:

◦ Mount the backrest in the rearmost position.

◦ Adjustment in the rearmost position!

◦ Heat the shrinkable tube.

5. Modification of the lap belt position:

◦ Mark the position on both sides of the seat pan

◦ With the aid of an appropriate rule check the

◦ Apply on the rule a marker 42 mm from the edge

◦ From these marker measure 125 mm

◦ This is middle of the new lap belt fittings.

◦ Mark the size (approx. 120 mm x 200 mm) for

◦ With aid of a thin diamant disc saw the cut out.

◦ Roughen very carefully the fuselage shell.

◦ Mark the position of the lap belt fitting.

◦ Glue in the lap belt fitting with thickened resin

◦ Apply the resin for all the glasfibre layers on a

◦ Cover all with peeply

◦ Hardening of the laminate.

◦ Post curing 15 hours at 55°C.

◦ Smooth the glasfibre around the fittings that no

6. Trimming the optional GFRP-cover to the fuselage ssteel

◦ Cut the GFRP-cover parallel to the front wing

◦ Trim the front part of the GFRP-cover to the steel

◦ Assemble the wing

◦ Cover the pin on the upper spar side with plasticine

◦ On the front side of the GFRP-cover scarf the outside

◦ Laminate the prepared area with glasfibere cloth 3x

◦ Remark: The GFRP-cover on the spar and the pin

◦ After hardening and trimming paint the GFRP-cover

◦ Fix the front part of the GFRP-cover with a 4 mm

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