CHAPTER 2 REVISION LIST ‘The following list ofrevisions will alow you to update the Lancair IV construction ‘manual chapter listed above. Under the "Action" column, "R&R" directs you to remove and replace the pages affected by the revision. "Add” directs you to insort the pages shown and "R" to remove the pages. Pagots) affected Description 21822 None Bither Rev. # is correct 22 thru 215 R&R Revised Spood Brakes Section 2168, Add Rovised Speed Brakes Section 2.16 thru end None 5 5 [Coane 2 [anaes RR WEB |[2 ESCHAPTER 2 SUPPLEMENTS REVISIONS irom time fotime, revisions tothisassombly manual may be dened necorsry. Whe such revsns ato ‘made, you eld mmeditaly replseallouteed po Diese: jagewrilatsa issued, Thiepage tadehaptar Ane able sored infront ofthe opening pags Ghis pags il esonpany any revision madetenchaper ARROWS Most drawing wil hove stro sto show which diresionthopartzarefacng uniessthedowingitslf males thor veryaiinus "AROUPrafers sete davon tht uldbep te par wereinealiadn splene ng {nthe upeigt positon Inmustonssthe part shows lbeoricledia eam peconoeshopne tefl ould teplontddaringthat camp sop However fn gasonndchangecae made socaraelate Uepail tochoorionttin arrows. CONTENTS 1. SPEED BRAKE 2, DOORSEAL. 3. WINGLETS 4, DOOR LATCH. STDIV 5. FUEL DRAIN 6. SA.008 ANTENNA, 7. INTERIOR CABIN HEAT- NON PRESSURIZED 8. INTERIOR CABIN HEAT- PRESSURIZED 9. SUN VISOR. 10, GASCOLATOR 11. LANDING LIGHT 12, FAST BUILD FUSELAGE 13, ALIGNING THE CRADLES 14. ONE PIECE "B" KIT FB 15, BELLCRANK BEARINGS AAR TY =& ==FINGER IV Manual supplement Precise Flight Speed Brakes PF2000 ls1 SPEED BRAKE INSTALLATION ‘The Precise Flight Model 125 speed brakes are specially designed for the Lancair IV wing, Precise Flightspeed brakes have proven reliable in hundreds of aircraft ‘and will add anew safety dimension to your fast, high altitude flying. High rate of descents, whether voluntazy or involuntary, ean be made without risking engine ‘damage by shock cooling. The throttle can still be left open, although a partial power reduction is highly recommended for maximum sink rate. Installationis very straight forward, but please locate the speed brake units where we instruct you to, Mounting the units further inboard would give you more room towork, but the turbulence ofthe deployed brakes would cause turbulence over the horizontal stabilizer. ‘Note: In the following assembly steps and figures, the term "Speed Brake" has been abbreviated to "S/B*. Precise Flight speed brakes ‘SB NCAR TV 5 [= eee applementCONTENTS A. MOUNTING S/B TO TOP WING SKIN B, CABLE INSTALLATION ©. BOTTOM WING SKIN SUPPORT Overview of S/B location FiguresB:2 etre! Lit EEE Spoedbrake NOTE: Be sure to orient yourself with the arrows. inthe drawings. Some drawings are oriented right- side up and some upside-down as the wing sits in the jig. So whether your wings are sillin the jig oF ‘not, pay attention to the arrows, Ace TV | 7A, MOUNTING S/B TO TOP WING SKIN “The S/B is mounted to the top wing skin with countersunk screws and nutplates. ‘A flange must be formed in the tap wing skin 0 that the S/B will be lush when serowed in position, AL. FigureSB:A:1 and SB:2show the location ofthe cutoutin the top wingskin. Notice thatthe rear wing spar is notched slightly. This notch isto provide more clearance between the S/B and the long aileron pushrod, Draw the 11.5" x 1.8" rectangular shape on the inside ofthe top wing skin. Drill four #50 holes through the top wing. ‘skin, one through each corner of the rectangle.’These holes will help you locate the rectangle from the outer side ofthe top wing skin. Do not cut into the top rearspar ceap more than 25", Speed brake location PigureSB:1 44.8" ‘SB cutoutin a top wing skin 3p wing = Right rear wing spar (top spar cap) Wate: De ot uti th top er Le) Spar cap more han 25" Top wing skin 026-99, IRCA TV SaAD. Ag. AA. AB. Carefully cut the rectangular section out of the top wing skin as shown. Use the four small holes you drilled in Step A1 to locate the rectangle from outside the top ‘wingskin. Cutting from outsides much easier than from theinside. Don'tout more than U/4" into the rear spar. From outside the wing, insert the $/B cartridge into the rectangular hole and centerit, It will be necessary to grind a small notch in one side to allow the cable tofit. Notice that the $/B connector and cable are on the right side facing forward for both wings and the opening in the Speed Brake Curtridge for Blade Passage is biased toward the forward side (thin forward, thick aft). When the blades are deployed the cupped-machined blade surfaces will be forward, This allows for a slightly greater air spill for the blades and inerementally increases theireffective: When the S/B is properly centered, mark the outline of the large S/B mounting flange onto the outer surface ofthe top wing skin, Anawl type scribe workswell for this step. Removethe S/B, Carefully trim back the OUTER laminate and core ofthe top wing. skin to the outline you drew in Step A4. Don'ttrim back the inner laminate of the ‘wing skin, Also recess the core material around the cutout 1/4" between the inner and outer laminates. Core removal for S/B FigureSBA2 ‘S/B housing AIC up FF Sy [cate Te aro ANGRY |= a|AG, Mark (with a folt pen) the orientation of the large aluminum S/B flange. (i.e. = forward, outer surface, etc.) Remove this lange from the S/B and coveritwith thin release tape. Apply a light coat of wax to the S/B housing and let it diy prior to putting on the release tape. Thisis to keop the adhesive backingof the tape from permanently sticking to the aluminum. AT. Use instant glue to temporarily bond straight wood pioees to the outer surface of the aluminum S/B lange, These wood pieces will hold the flange flush with the wing skin, See Figure SB:A:3. AS. Use 40 grit to sand the inner surface of the top wing skin in the area around the SJB cutout. Clean this area with MC. A9, Place the aluminum S/B flange into positionin the top wing skin. The wood pieces: ‘should hold the flange flush with the top surface, Use instant glue to hold the wood. ppioeos and flange in position, SB mounting flange FigureSBAS ‘Wood pieces hold S/B flange flush with the top wing skin. ‘S16 flange Top wingA10. Fillthearea between the aluminum S/B flange and the inner wingsskin laminate with a thick epoxy/flox mixture, Be sure to push the fox back into the wing skin ‘where the core has boon removed, ALL, When the flox has cured, carefully use the countersunk mounting holes in the aluminum flange as guides to drill #28 holes through the flox and wing skin, A12, Remove the aluminum mountingplate from the wingskin and romove the release tape from the flange, |A18. Attach MS21069 nutplates to the inside ofthe top wing skin at each $/B mounting hole. Use either of the methods shown in Figuro SB:A:4 to mount the nutplates. Securing S/B mounting nutplates FigureSB:Ast Now met ‘S18 housing jaa aT nese aa} ‘ot Te wae ee Fe Co 7 nga pce 821069 nage oee Nine tate td ged ce some Sas hermes Bake ecietetiaom — [Eee im YOAIR TV | SipplemansAld, Reattach the aluminum S/B flange to the SIB. A15. You should now be able to mount the entire S/B to the top wing skin using ‘MS24698-S30countersunkescrews, Axe |= aeB. CONDUIT INSTALLATION ‘The $/B electrical wiring isrouted into the fuselage througha plasticeonduit. The same typeofblackplasticelectricconduit that you used for routing electrical wires ‘through the wing will work well for the $/B cable. BI. Place the S/B unit in position and markon the BL 76 rib where the aft edge ofthe ‘S)Bis located. The conduit should be centered top to bottom ineach ofthe fourribs. Note that the Speed Brake electrical wires exit out the right side of the S/B cartridges. This makes it necessary to extend the conduit in the right wing toapoint 1" past the outboard edge ofthe S/B, Run thisconduit through the BL Gon the aftside ofthe S/B, The leftwingconduit should also exit the BL “6 rib slightly aft of the $/B cartridge. Remove the S/B unit from the wing, IB cond slots in the wing ribs igureSBB:1 x J Lo AIC up 3/4" dia. en B2. Grind 9/4" dia, holes in the BL 76, 52, 38, and 25.6 ribs as shown in Figure SB:B:1. "These holes will properly route the cable conduit to the inboard edge of the wing. 1B3. _ Insert the plastic conduit into the ribs. The conduit should end 15" inboard of the BL 25.5 rib and may be trimmed later as necessary. Bd. Use a thick epoxy/flox mixture to pot the conduit into the BL, 76, 52, 98, and 26.5, ribs (rar Ty | aPotting conduit into ribs FigureSB.B2. Conduit is potted into ribs with ‘epoxyifiox | eA WW eer©. BOTTOM WING SKIN SUPPORT A fiberglass pocket must be secured to the bottom wing skin to brace the $/B assembly. The pocket is molded around your S/B housing to assuse a close tolerance fit, CL Temporarily ndd.25" offoam tothe outboard side ofthe S/B unit. This will giveyou some free room, sided to side, in the Ghorglass pocket, easing alignment in the future. C2. Apply one layer of release tape to the bottom and sides of the S/B housing. The fiberglass pocket will only extend up 1.25" socover the S/B housing at least 2" up from the bottom, Duct tape is a good release material for this step. Fiberglass pocket ‘igure SB:C1 310 iborglass Apply olease tape tothe bottom ‘ofthe SIB housing and form the {3 BID pockst over this ares | RiCAIR TV Sy ee ar SupplementsC3. Buildup BID fiberglass pocket around the bottom ofthe S/B housing. One piece Jaminates would be too difficult so just overlap piocesin the comers by 1°. Extend, the 3 BID up the SIB housing 1 1/2 C4. When the $ BID has cured, remove it from the S/B housing. Trim the pocket to 1 Ud" in height. C5. Remove the release tape and the 1/4" foam piece. C6. _ Install the S/B into the top wing skin. Lacate the four bottom corners of the S/B housingon the inside ofthe bottom wing skin. Mark the outline of the housing on this surface. C7. Remove the inner laminate and core of the hottom wing skin only in the rectangu- lar area of the $/B housing, DO NOT cut into the outer skin. Also remove 1/4" of core from around the perimeter of the cutout area. 8. Use 40 grit tosand and clean the areas 2" around the recesses area of the bottom, wingskin, C9, Apply a 8 BID reinforcement to the coreloss area extending 1 1/4" forward and outboard of the recessed area in the bottom wing skin. (Applying BID to the inboard and aft sides would interfere with the aft spar cap and BL 76 capstrip.) Chapter! ma Supplements 28Reinforcing bottom wing skin recess FigweSB:C2. Dashed lines indicate location of BL 76 capstrip = Inner laminate and core Fd where have been removed pent the 3 BID pocket is Igcated i _| eee ac V LL Tm Tore Cnt C10, Install the S/B into the top wing skin. Place the fiberglass pocket onto the S/B. For clearance purposes, place @ couple tongue deprossors between the bottom ofthe Si Bhousing and the fiberglass pocket. The pocket should be centered spanwise on the S/B, leaving about a 1/8" gap inboard and outboard. C1 Place the bottom wing skin in position and check that the fiberglass pocket is not interfering withthe proper fit. Therecessed (coreless) aren ofthe bottom wing skin will have to be expanded slightly to fit the fiberglass pocket. ays Sy Gia _ [a ( Piheoaee WV | |eC12. When satisfied with the fit ofthe fiberglass pocket, remove the bottom wing skin and prepare both it and the fiberglass pocket for bonding. Sand and clean all bonding areas. C13, Fillthe recessed area ofthe bottom wingskin withanepoxyifloxmixtuze. Withthe ‘Sberglass pocket in position on the S/B housing. Lower the bottom wing skin into position so the flox will ond tothe fiberglass pocket. Be sure the bottom wingskin isreatingon the aft spar cap, BL 76 capstrip, and wing contor spar cap. A limited inspection can be made through the aileron bellerank inspection hole. Note: Inwarmer climates, the flox buildup under the pocket could exotherm while curing. Use afan to reduce this possibility or keep your shop cool while bonding Bonding pocket to bottom wing skin FiguresB:C:3 ‘818 housing, tongue dopressor between SIB and pocket ensures ‘skin Chapters [a AOD ‘Supplements |_Feaez tv |C14, After the flox hascured, remove the $/B from the top wing and remove the bottom wingskin, C15, Apply a3 BIDreinforcomenteovering the forward face ofthe fiberglass pocket and overlappingonto the 3 BID previously applied. Besure tosandandcleanall areas where the BID is applied. Reinforcing the fiberglass S/B pocket FiguesB:C4 AIC up Fwd jap 3810 Bottom wing reinforcement ae pgcket J skin Drain hole (inbd, aft comer) C16, Drill a 18" dia, drain hole in the inboard, aft comer of the fiberglass pocket and though the bottom wing skin. Also drill a 1/8" drain hole in the forward, inboard comer of the rib bay, where the BL 76 rib meots the fuel bay web. See Figure SBC, ‘This completes the Precise Flight Speed brake installation in the wings of your Laneair IV. This isall that ean be done on the speed brake until after the wing is finally closed. For final installation, the electrical cable must be pulled through the conduit and routed appropriately through the cockpit, Attach the eable connector at the S/B and lower the unit into the wing. Install the MS24693-S30 countersunk screws. 7A || Pevsice ight Rev. T2609 2 ae2. OPTIONAL LECTRIC DOOR SEAL PUMP ‘The optional door seal pump for the standard Lancair IV and Lancair BS is the same as used on the Lancair IVP. The seal is automatically inflated and kept at 20psi. The electricdoor seal pump comesin 12or24voltsversion, Read the pump abel to determine if you have the proper voltage. ‘Mounting Pump to Left Fuselage Side Fig. 22.41 (pit Phenol Bo & nus2tst0-0686 Clamp. (Open nae to 36" ae inthe pump body (ysa4s04-ss4 Sorows ‘nth ats groune nto toad. Potted ite Phentle wats Hysol Mounting Plate rr) (1702) " Al, Use the317-02nutplatetomount the pump to the 317-04plate. The 817-04plate is countersunk to accommodate the MS24694 screws. See Figure 1. A2, The 317-04 pump mountingplateis secured to theleft side of the fuselage behind the shearpanel supports. Aphenolic block with studs isbonded to the side of the fuselage as amountingbasefor the317-04plate. Grindflatson the headsofthree ‘MS24694-S54 screws, then pot them into the phenolic base with Hysol. At the same time, use Hysol to hond the phenolic base to the fuselage side. Chapter? [REN OF O01 eae WV ||A3, When the studded phenolic base has cured, secure the 317-04 plate to the base with AN965-1032A locknuts. Notice that the forward, upper stud is also used to secure the pressure switch with aMS21919-DG16 clamp. Ad, Mount the MJTV-3 contzol valve switch to the instrument panel in a location of your choice. Door Seal Hookup Fig 2242. = a ‘check vee_prevnts bres te Boeing Sttiough re pare. upaerooy sa pume Grom Girt pir [Game __ Deora ‘SupplementsUse 3814-6 flexible plastichose ta connect the electric inflation system as shown. in the figure above. Note there is a check valve installed between the pump and thepressure switch to prevent air from leaking back through thepump when itis notranning. When the pump is turned off, the pressure in the door seal will vent ‘out through the panel mounted on/off switeh, Door Seat Pump Fig22A3 Sean te sev cont CO ‘connect a fines | ae tor st pang 6, Wire the door seal pump as shown in Figure 3.3. WINGLETS 1. INTRODUCTION ‘The winglets for the Lancair1V are optional. The optional kit, paxt# 1048/1049, includes the winglet skins, carbon graphite cloth, NACA scoops, and all the necessary hardware. ‘The winglets can citherbe installed with the wings still n the cradles or with the swings mounted on the aircraft. Since the winglets are a "retrofit' option andsince you may not still have the wing cradles, this supplementis written assuming you fare installing the winglets with the wings installed on the aircraft. You can also install the winglets with your wings still in the cradles, although ehis will take ‘some creative thinking on your part, ‘The alignment of the aircraft is critical for installing the winglets! Before beginning, position the aiveraft in such a manner that it is possible to leave it exactly whereitisforseveral days. Chalk the wheels and support the wings with saw horses and foam blocks or whatever is necessary to stabilize the aircraft. 2, CONSTRUCTION PROCEDURE A. WINGTIP FLANGE REINFORCEMENT ‘Al, Remove the old wing tips. Remove the nutplates from the wing tip joggle. ‘Suggestion: Use a sharp chisel between thenutplates and the wing tip. Wehave found this to be easier than drilling outall the rivets. m ‘Chapter? [Rev 0702-01-98 AMCAR TY |= =is Reinforcing the Joggle Fig. 28:A:1 UT Revel piis BL 171 Ri Jem] Ag. Install the 10 BID carbon graphite reinforcement as shown in Figure Al. First, using 40 grit sandpaper, sand the bonding surfacesin preparation for the 10 BID. Clean the bonding surfaces with MC. The graphite should runall the way to the edge of the joggle and 1” onto the rib. 3. After the 10 BID has cured sand the 10 BID flush with the old wing tip flange. Ad. Wipe the outside, orexterior, ofthe winglets with a degreaserlike Dupont ®Prep- sol, PPD© DX330, MC ar acetone and then followed up with a dry rag. While the parts ave still wet, wipe with a dry cloth to remove the wax, | [Giana [nev 07 03-01-98 ‘Supplements ANGAR WV‘Trimming the Inboard Edge of the Winglet Fig.23:A:2 Lower inglat Skin 1 4 iT ‘Trim th winglet ein soit ft into the Joga. Aileron Straight Edge Nota: ttmay be necessary to sightly trim the LE ofthe jose ofthe wing in otder to accept the winglet. ‘The existing BL171 edge of the winglet should be very close to the net size. This ‘edge should only need a small amount of sanding to bring the leading edge into a straightcondition, Again, carefully check the dimension "12.5" tomakesure that, they are built to the same size, The wing tip joggle shouldbe parallel with theline [ear ipplements offen Nee WV |= = a EES =]INSERT PAPER TEMPLATE HERE ev OF 00-01-98 ham Wo = SupplementsB. MOUNTING ANTENNA ‘There isan B-glass window’ for mountingthe NAV antennain thewinglets. The recommended antennas the SA.004, one for the left wingletand one forthe right ‘winglet. These antennas were specially built for the Lancair IV and are available through Lancair. Positioning the NAV Antenna Fig. 2:3:B:1 ‘Tn screws scutng steough ve nena a msstenmees Tt sttaalong tenia’ e65e. py anfona into he corte ar. NOTE: Apart oft antenna must stayin the E las window: BI. The NAV antenna is mounted on the lower winglet mounting flange. Positioning the antenna: 1. Refer to Figure B1 to position the antenna spanwise (1" from edge) 2. Position the antenna far/aft such that the antenna fitsinthecoreless area ofthe wingtip, 3, None of the antenna should extend onto the carbon portion of the winglet. [ LR TV = == ‘SupplementsSecuring the NAV Antenna Fig. 23:32 Rivets, ae SS SS ee Wingle Note: Install the 3 rivets as far outboard as B2, Secure the antenna as shown in Figure B2. Secure the outboard members with 1 BID and theinboard member using3 AN3-5Arivets. Some of the screws securing the winglets will pass through theantenna,sandwichingtheantennabetween the swinglet and the wing tp joggle. The reason forthisisthatthe wing’scarbon bottom, isbeing used as a ground plane. B3. With an ohmmeter, you can test the continuity between thenav antenna and the bottom wing skin. There must be contactor the antenna to workproperly. The bottom wing skin is used as the ground plane BA, Follow the manufacturers instructions for wiring the nav antenna, ‘This is a process of stringing the RG-58 coaxial cable through the electrical tube you have previously installed, then wiring theconnectorson theinboard and outboard ends ofthe wing, o . apier2*( ‘0/ 02-01-98C. FUEL VENT LINE COMPLETION -y ‘The fuel vent line runs from the fuel tank out to the wing tip. From there it connects tothe aluminum ventline thatruns up tothe NACA scoop in the winglet. ‘Trimming the NACA Scoop Fig. 2:3:C:1 | [\ _ C1. Trim the flanges of the NACA scoop to a 3/8" as shown in Figure C1 | FINCAR TVPositioning the NACA Scoops Fig. 23:02 Upper Edge <—4- ” 212" Passe eoagls, MEE fea are _— C2, Install the NACA scoops. Itis easier to install the NACA scoops before you start, ‘mounting thewinglets, The NACA scoop should beapproximately centered in the coreless area on the outhoard end of the lower winglet skin. The NACA scoop shouldbe pointing’ straightforward. Use the upper/outboard edge ofthe winglet as reference to level the NACA scoop, 3. Using 40 grit sandpaper, sand all bonding surfaces of the winglet and the NACA scoop. Clean the winglet bonding area with MC. Wipe off the NACA scoop with ‘acetone (MC will melt the NACA scoop). C4. Bond the NACA scoop into position with epoxy/flox. . Te |[Gaee Der oior98 [_ Bee yy = SimaTrimming around the NACA Scoop Inlet Fig. 2:3:C:3 | ‘Smooth out scoop entry flush with inside ‘ef NACA scoop. Pwd (5. After the scoop has cured into position, trim around the NACA seoop to get ashaxp edge. Asharp edge helps theairflow and adds efficiency to the NACA scoop. Fair in the narrow inlet at the LB, of the NACA scoop to allow a smooth airflow. a WS SupplementsBonding Vent Tube to NACA Scoop Fig. 28:04 Bysot Alumingm Tube} NACA scoop a ‘Winglet ———> ew C6. Cuba 40” piece of 14” dia, aluminum tube (Part # 5052-250x085) and flare one end, Bend the tube as shown in Fig, C5. The exact routing is not critical as long asyoustay clear ofthe antenna. Itmustalsobein aconvenient location toconnect, the plastic hose to the vent line in the wing. C7. Drill a 1/4" hole through the aft face of the small NACA scoop. Sand the area around the 1/4" dia. hole, Rough up the surface ofthe aluminum tube whereit will, be bonded to the NACA scoop. Clean all the areas with MC. C8, _ Use Hysol (with a little flox added) to pot the non flared end of the 30" long tube into the aft face of the NACA scoop. Install the vent line approx. 0.1" above the carbon fiber winglet skin to avoid contact problems between the carbon fiber and ‘the aluminum. Install with Hysol and secure with 1 BID as shown in Figure C5. C9, Thefinal ink will beinstalled when the wingletis completed. Itconsists ofa B44- 8 plastic tube that secures with a hose clamp in each end. f OMe TT |] pierRouting Aluminum Tube Fig. 23:05 8 Hrsomoe tet SC ‘The oxaet eaton a the alumipun vont, aot ries! Run ler ofthe Newer BLATI Rib, Aluminum Vent ine ingle <= ow NOTE: Inlalte be so tl not nk and choke tthe aie | Axe iy | edD. INSTALLING WINGLET INTERNAL STRUCTURE. D1, Establish acenterlineon the loor underneath the aireraft from the tail tothe nose, Alsorun a line at 90° from the centerline out tothe winglets. This will serve asthe reference line for aligning the winglets, D2, Make acradle to support the end of the wing, Plywood bondoed to the floor works good. Keep thisinposition until the winglet iscompletely built. Steady the aircraft withjacks, Steadying the Wings Fig. 2:3:D3 Plumb bobs must ‘match the exact width Install a eradie to steady the wing. Bondo in place. Aligns with end of wing N and is parallel to aircraft NS centerline. REMEMBER. the incidence is set by subtracting 316" from the "x" NOTE: Keop the cradies in postion unt measurement here! the winglets completely installed.Aligning the Winglet Fig. 28:2 allel with ‘he line of ght, edge may require i saoua of ending Uso straightedge to align tho winglet LE. Ree cteac ss! owe el bus pur tet tape ‘ike protest th paint ~ | right edge te slign the lower winglet into thetower renface ofthe wing [Gian [aor oor — fe ‘Sapplements CART |Da ‘Align the lower wingletskin. ‘The alignment criteria are: 1. The LE. of the winglets must align with the L.B, of the wing, 2. The lower skin of the winglet must align to the lower skin of the wing. Clamp the lower winglet skin into place. ‘Note: The thickness of the wingletin the area where it fits into the joggle of the ‘wingtip isthicker than what thejoggle llowsfor. Thisisfairedin with epoxyimicro later, Make another wooden jig for the winglot tip (se Figure D1). Hot stuff or Bondo into place. ‘The purpose of this is to stabilize the tip of the winglot. This fg is also sets the incidence of the winglt. (The incidence must be set prior to installing the ribs and the spar), ‘To sot: the winglet incidence: 1. Drop a plumb bob straight down from the L.E. of the winglet at the ‘approximata loestion shown in Figure DL. 2. Drop a plumb bob straight down from the T.B, of the winglet at the ‘approximated location shown. 3, Sot the incidence such that the I. is 8/16" closor to the fuselage centerline than the T.B, of the winglet, is sets tho incidence. Poriobcally cheek the incidence through the construction Securing the Winglet to Wingtip Fig. 23:80 [|| Ghee Tue 07 02-01-98 ‘SupplementsSecuring the Winglet | Fig.2:3:D:8: (MS24504-$51) Machine Screws (K1000-3) Nutplates (NAS390BLOP) Tinnerman Washers (AN426A3-5) Rivets L D5. Following the bolt pattern of Figure D3, install (12) MS24694-851 screws, (12) 1000-3 nutplates, (12) NAS390B 10P tinnerman washers, and (24) AN426A3.5 rivets in the lower winglet skin, The screws should becentered on the lange and evenly spaced apart. Scuff up the tinnerman washers and Hysol in place. DG. Drill holes along joggle of winglet and wing, nutplate, and serew into position. ‘You'll need to remove the winglet from the fixture for this step. After you have installed the nutplates, einstall the winglets with the screwssupport the winglets atthe tip AGAR TVInstalling the Winglet Rib Fig.2:3:D:4 y° ply per side prepfeg D7. Fit the winglet sib pattern (blueprint #2-111801). Refer to Figure D5 for the location. Make a notch in the rib for the fuel line. The winglet rib is made from 2ply per side prepreg. DS, Remove 1/4" ofcore along the bottom edge of the rib. Sandall bonding surfaces of the prepreg rib and the winglet in the area where therib bonds. Brush a thin coat of epoxy in the trough of the rib you just formed and the lower winglet skin. Fill the trough with a thick epoxy/micromixture. Position therib atthe location shown, in Dd. The rib should install vertically. Secure the rib with 2” wide 2 BID.Installing the Winglet Spar Fig. 2805 Winglot Rib ‘The ventline ‘Must not touch the ‘antenna. NOTE: The purpose of running the aluminum tube up is to prevent water from entering the fuel tanks. And, it also keeps fuel from running out when parking on uneven surfaces. D9. Fitthewinglet spars, Thereis an inboard section and an outboard section of the spar. Both pieces are made from 2 ply per side prepreg. 10. Remove 1/4" of core along the bottom edge of the spar. Sand all bonding surfaces of the prepreg spar and the wingletin the area where thesparbonds. Brush athin ‘oat of epoxy in the trough of the spar you just formed and the winglet. Fill the trough with a thick epoxy/micromixture, Position the spar at the location shown inD5. Secure thespar with 2" wide 2 BID to thelower winglet skin andin the area where it meets the rib. Chap [net area 98 Sapplemants 235 | FRARTVDIL, Fitthe upper wingletskin. When you ted thelower wingskin youhad cradles [7] twaccurately determine thesize ofthe ribs. ry ise the wingskins to align the winglet ‘The wingletshould match the wingsat the BL 17 location, Using straight edges, adjust the height of the winglet by trimming the ribs and spar of the winglets. Winglet Capstrips Fig. 23D:6:0 2S: cape “duct tepe Fil with mlcro © eave one ayer deat tape ve" netWinglet Capstrips Fig.23:D:6b 12, Fitting the upper winglet skin is done ina similar manner to the way the wing skins ate Sted, Ifyou have uot dane this before, xefer to Lancair TV manual Chapter 6, section D. In summary: 1. Apply 3 layers of duct tape on the bon ding sutface of the lower winglet skin, 2, Fit the ribs and spar by performing trimming and performing a micro release. 3, Remove two ofthe three layers of duct tape. 4, Lay the eapstrips onthe duct tape ofthe upper winglet skin and apply peel ply on top of the BID. Let cure then remove the peel ply. 5, Using 40 grit, sand the capstrips. 6, Install the capstrips using a wet epoxy/micro mixture on the ribs 13. Form an epoxy/micro radius between the capstrips and the rib. Reinforce with 2 BID as shown in Figure Da. Hom Ve == == ws SupplementsBE, CLOSING THE WINGLETS ‘The wingletsareclosedin asimilar manner tothe wings. Itis especially important that the winglets are properly aligned and supported during the closing. Thisis your last chance to adjust the incidence! Do a practice ran before closing the ‘winglet. Epoxy mixed with flox or Hysol mixed with flox may be used for closing the winglets. Applying Adhesive to Bonding Surfaces Fig. 2318.1 Epoxy er otto ibispar ‘quired fo ateh alerons parlor or ipso! Moe Hey P= z Hike TepplementeEL Ee. Bs, BA, Es. Sand all the capstrips, the joggles, and the bonding surfaces of the inside af the [7] ‘upper winglet skin, Clean with MC, (Did you drill your vent holes?) Apply a pure coatofepoxy ox Hysolto all bonding surfaces, Mixfloxinto the Hysol or the epoxy (1 thsp. per 2 oz.) Build this mix up as shown in Fig. E. Lower the upper winglet skin into place. Clamp and weight down as required. Check the winglat incidence. Closing the Winglets Fig. 28082 Weight the winglet down fon the spar and ribs. ‘aileron aero (1 "21 12 angle Winglet outbd. Support After the winglet has cured, install (8) MS24594-51 screwsand (6) K1000-3 and (16) AN426A3-5 rivets, Fill as requixed to form a smooth transition from the wingskins to the winglets. [Grape [wer 07 20 SupplementsWINGLET LIGHTING ‘The Lancair IV wingletismolded to accept a Whelen AG50-PG/PR position/strobe light Gedlight onleft tip, green on right). Fiberglass tip light mounts areprovided for easy mounting of the position/strobe light assembliesand lenses, A tail strobe light (Whelen A500) is mounted on theruddertoconform to AA regulations, The power supply (Whelen A413A) for all lighting is located in the fuselage, Winglet Light Assembly Fig 28F-1 a Winget View a" ight moont rag sos ‘ion A030 SS. Lens Wingtip Nutplate—“ [S~ wiontip tight mount 7 AFi, Locate the position light/strobe assembly on the winglet light mount as shown in Figure F2. There are scribemarks on the vertical face of the lightmount. Use the scribe marks as a guide to grind out the fiberglass so the position light/strobe assembly can rest flat on the light mount. Some additional trimming may be necessary, but keep the grinding to a minimum. Locating Position Light/Strobe Assembly Fig. 23.72 Prelocated scribe line = [nai Aeon [Fixer IV ESF2, Use the position light's mounting holes as guides to drill #29 holes through the winglet light mount 3, Use AN426A3-5 rivets to secure an MS21069 nutplate to the inboard face of the ‘wingtip light mount at each mounting bolt hole, 4, Secure the position light assembly to the winglet light mount with MS24694-S26 countersunk screws, Securing Light Assembly to Winglet Light Mount Fig. 20F berate ty Ligh mount oro (comes with he Hight» Aon, washate SSateee28 wate gots S28 aunchine orews (2) F5, Trim the wingletlight mount so itwill tin the wingtip joggle. The surface ofthe light mount should be about 0.090” below the surface of the winglet around the perimeter of thejoggle. This wil allow the clearlens tot Qush with the wingtip. » Chapter 2 [rev__0/ 02-01-98 7. SapplosaatFitting Winglet Light Mount to Winglet Pig. 244 Po, When you are satisfied with the fit ofthe wingletlight mount, use afew drops of instant glue to temporarily secure the mount to the wingtip joggle. FT. ‘Trim the clear lens to fit into the winglet joggle, flush with the suxface of the wingtip Fitting Clear Lens to Winglet Fig. 2325 Lens Fiberglass tip light mount F8. When satisfied with thefit ofthe lens, temporarily secure thelens to the wingtip swith masking tape, Don’tuse instant glue to securethelens asthe glue will fos up the clear plastic. ean [pene IV SaarF9, Drillsix#29holes through thelens, light mount and wingletjoggle. Thelocations for these holes are given in Figure 10:B:6, Be extremely careful when drilling ‘through the clear plastic lens, ‘There are drills made especially for plexiglass available (Aircraft Spruce has them) that make the drilling process safer. Ifyou | | mustuse normal dvllsitisa good:dea to apply masking tape to thelens irs, then tightly centerpunch (no, not with abighammer) whereyou are about todrill. Drill | a very small, #50 hole fist, then drill progressively larger ones until you reach, #29. Ifyou don't drill very slowly, the plastic could shatter. Mounting Lens and Light Mount to the Wingtip Pig, 2F0 — MS24694-526 serew AN426A3-5 “Sy OSS SS io Wingtip Mount — MS21069 nutplate Supplements10. When you've finished drilling, remove the lens and winglet light mount from the winglet, Use AN426A3-5 rivets to secure MS21069 nutplates tothe joggle ateach ‘mounting hole location. FI. Carefully countersink the clear plastic lens for MS24694-S26 screws. F12. Thatwaseasy, wasn'tit? Now assemble the position light assembly, ightmount, andclearlens nto the winglet. Ifthe lens still doesn't est lush with the winglet surface, you can insert a thin cork washer between the lens and the light mount, to bring the lens surface up flush with the winglet surface, Adjusting Height of Lens Fig. 237 Cork. Wingtip. Wingtip light mount- 7 Chapter 2 [Rev 0702-01-98 LT Eero4, DOOR LATCH, L-IV (in Chapter 28 follow pages 28-1 through 28-15 then follow this supplement.) A, DOOR STIFFENER Inthissection you will cut out the 2latch aecesspanels. You will then makeflanges andinstall the nutplates, The door stiffener will then be bonded to the door skin. Latch Access Panels ig. 24411 Sy ean SS eusavarnanas oe N 47 Fxtend a straight edge off the side t fe measurements of Al. Cutthelatch accesspanelsin the doorstiffenerusing thedimensionsonblueprint 28-316, Thecut along the sides should be 0.7" (18mm) from the top of the radius. Use arotary type cutter. 4 f a _ Sam (AMAR IV acneAccess Panel Nutplate Locations Pig. 2442 ‘The $ RID lunge iy 1/2" ut aut- ‘plate Incations und 1/2" elsewhere ‘the lower aft left access poe requires «thi ont Pinte in this corner ro mame ware to leave enough Range. This putplate ie installed later. 2. 1D 8 ner, (See blueprint #B- 316.) a) Cover the panels with release tape. 'b) Tape the panels back into position in the door stiffener. c) Lay a3 BID flange ontotheinside ofthe stiffener extending about 1/2" (15mm) ‘onto the piece that was eut out, This forms the joggled flange to hold the access panels, 2) After care, remove the panels, trim the 3BID flange down to about 1/4" (6mm) except where nut plates are to beinstalled. Atthe nutplate locations leave 1/2” (5mm). (Continue with nutplate installation in Chapter 28-18 and follow to page 28-82) Aka WV | eeB. DOORLATCHES ‘The latches will surely he alot of fun, they always are with any door! ‘The latch. system developed by Lancair was designed, by the motion of the Latch itself, to reach out and pull down thus helping to achieve a better fit. ‘Typical Door Latch System Figure28B:1 ‘Torque Tube (CD 316-15) ele 5 Holler and roller pin i yg Anchor (218.02) 7? Anchor adjuster plate (315-03) ~ <— Anchor adjustor bolt (ANS-4A) BL Assemblethelatches. These assembliesswing the hookthrough a90°plane, draw ‘down and achieve an "over-contey" selflocking condition. They should besmooth operating with very little drag when properly assembled. Look for any burrs etc. in the laser cut pieces, Hand file and smooth as necessary. The latches are very similar, The differences will be explained in the assembly instructions. NCAR WT Te [Game ores pplementsAttaching the Clevis to the Links yy Figure28B2 D+ —ommesn CES coeipte 500 BE? cee ep q =) 1) Press the small pins into the ends of the clevis, they must be centered on the levis tab end. The vise is handy for this purpose. Inserta link on each side as shown, Insert the Assembly in the Hook Figure2823 a Unkiclavie into the book, Invert the hook into the latch housing ‘The holee throvgeh the atch houeing, howl aod Cinetip the elevis must ali ) Insertlink/elevis assembly into the hook. Then insert this assembly into the latch housing. You willneed oalignthe hole that goes through thehoak andclevis with the slotin thelatch housing. We find the easiest way to accomplish thisis to lay the assembly on its side, Then take a wire and align all the holes. Next insert the clevis pin. You will nead a cir-clip washer on each side of the latch housing. Notice that the bevelled edge of the washer faces the latch housing. Attach ac clip oneach side, | B Ted [nora 38 he TupptenoatsDrive Pin Installation (Fwd. Latch) Figaro 8B Dril for and install the spiral pin (RP-O1} here ‘Add washors (ANSEO-516L) between the letch housing fend the hook as necassary ) Both latches use AN5-33A bolts for the drive pins. Assemble the latches as follows: 1. Ifnocessary, insert AN9G0-5IGL washerson each side in between the latch housing tnd the hook an each side 2, Insert abolt from theside shown. You will need a 1/32" (Imm) gap between the bolt head and the latch house. 3. Using the holo in the elevis a a guido, drill a #41 sizo hol the drive pin (CD315-11). Insert the RP-O1 spiral pin hough the center of Drive Pin Installation (Aft Lateh) FigurezeB5 ‘ANS-33A bolt 1132" gap 2 ° mA Drive Pin 4, Make sure both of the latches operate smoothly and lock in place. Fionn WT | TEE >SeeAnchor Assembly Pigure2sB:6 315-16 roller pin 415-02 anchor 815-09 roll ANBBD-10L washer $b eg 906314011 roller pin nut 915-08 anchor adjustor plate eth 3 HD B2, Assembl shor: 28:B:6 The purpose ofthe adjustor plate isto allow for minor final adjustments. Install the adjustor bolt (AN4-44) so that you arein the middle ofthe adjustment range. In other words so that the holes in ‘the adjustor plate arecentered in the oval shaped holesin theanchor. Apply adab of bearing grease in the roller prior to installing it, NCR IV Dar |[ onic [Rv oF 92-01-98 ‘Supplements,©. MOUNTING PADS Latch Mounting Pads Figure28:C:1 Bpoxyffox mounting pads Epoxyiflox, mounting pad in the FUSELAGE (The ariehors will mount to these) Inorderforthe latches tofunction smoothly itisnecessary tohavelevel mounting pads. Thelatches must be mountedin the same plane as they are connected with ‘a solid drive shaft. You will first build a simple fixture that will establish the correct alignment. Cl. Makethe latch pad fixtures, This is a simple fixture that will help you properly ‘make the epoxy/flox mounting pads. Follow the figure below for assembly. INGUR TT Sa [Gre ORT iplementsLatch Pad Fixtures igure2802 ‘Cut ewe gieos of 8/4" 25" plywnnd, Thess pecan fre ned forthe fixcore fr the lower bu loses. FL thew pices a pach of tha Biagelocstins sx hewn ia Prgure 28044 (Ite easier La tat the aot out Vetere falling the die bettonn pieced Clue 2 2s pases of masonite or equrvalene (euch of te §° 8° piss of freed, Dat tothe geomatry afte Itches, the isteho fn the fuselage side urd th ltehes on te dour side st be roomed ata beighe ditecone of 0.04". The {neha line eypresebts a 6.14" pce tha mil be ule Tater tune waters) vou have Haat 980.17 thick a 22021 8! pees of masonite ‘.14!x 28" 2 12" pives v0 be added Inter Cue Blt" ¥ 1 UR" 29° prince Uplyurod. Place ehe ewe Shiegt pleeus un Bet curface Aa hewn, Pasian Ube as abate {pd seeure the 28" plywood piece ‘sing wrod sores Glog the OTE" aturon ta Bath oF AT, hes r 3" mares on the DOOR SEDI Hever tothe CO figure Chapter [Rav 07 02-01-98 Ane | ‘SupplementsLatch Pad Locations Pigueo28C3 ‘Tey to install Che, Iniohes perpendicular tathe dace openinit. Note: The dimensions given are tthe center of each ofthe latches. C2. Markthelocation of thefloxpads on the doorstiffenerwhere theycan beseen when the door is shut, You will use these marks for fitting the fixtures. SINGER TV Tar [Gane __ Reo SupplementsFitting the Latch Pad | Figure2&C4 Lateh Mounting Pad Fixture Drywall Serews 4 — Muke the pads | | av cluse as possible to the doar stiffener] AC Up and the door frame, eee Cut a nateh ag requiced to clenr the doar frame and the door stiffener. C3. With thedoor closed, fitthe fixture asshown. You will need tocut anotch in each of the fixtures in order to fit over the armrest, door stiffener and the door frame. ‘The flox pads on the door side neod to extend up to the door stiffener. The pads on the fuselage side should extend up to the door frame. Note that the anchor pads areinstalled on top of the corein the fuselage. This will require afairly thick flox buildup. A 1/4" thick padis also xequired on the door side for the torque tube actuator arm to work, These pads may taper on the sides (see blueprint #B-316.) While you are fitting the fixtures, note how much flox you will need underneath thepads. Onceyouarehappy with the fit ofthe fixtures, drill holes for the dry wall screws as shown, ‘The screws will hold the fixtures in place while curing, Note: Make sure you have the fixtures oriented correctly with the 0.14" (4mm) shim on the door side. C4. Prep all the suxfaces that will receive the mounting pads. C5. Cover the fixture hottoms with plastic release tape | C6. Make the latch mounting pads, You will need to plan this step asit requires the door to be shut, We suggest the following procedure using a helper: en Ee1, Bolt the door shut using the existing holes along the perimeter of the door skin. Itis important that the door is properly closed as the mounting pads will dictate the final fit of your door. 2. Have your helper mix up a bunch of resin to hand to you inside the fuselage. Apply a thin coat to the latch mounting pad areas. 3, Mix lox in with the remaining resin. Apply a generous mound at each of the 2 mountingpadlocations. You should have a good idea of how much flox you will need from the gap under the fixture bases. You will at some pads requie up toa 1/4" (Gmm) thick pad. 4, Set the fixtures in place and have your helper install the screws from the outside, Make sure the fixture is installed with the 0.14" (4mm) shim on the door side, Wipe up all the excess squeezed out flox thatean bereached. This saves having to grind it later. NOTE: Itisimportant to keep the micro/flox pad relatively thin inside the door. the pad were allowed to gettoo thick, then thelatch body might not fit inside the stiffener, Tosee this, simply place the latch inside thestiffenerin the approximate position, trial fittheinspection cover aver it, and observe how much oom youhave available. Use this as a reference when setting the fixture with micro/flox. If pressed firmly in place during cure, the pad height should be OK, C7. After the pad cures, remove the fistuxe and clean up thepad areas. You will not ‘need thesefixtures again sodon't worry about wrecking them. There willbeplenty ‘of squeezed out flox soit's worth a litte time cleaning this up with a rotary tool. 7 yp | Ghia ANCA TV aoeDoor Latch Installation Figure 28:D:1 For the installation of the latches the doorneeds to be tightly shut with the bolts in place. Note in Figure 28:D:1 the location and type of latches. If you find it difficult entering and exiting through the wheel well, get some wing nuts. These ‘will make it considerably faster to bolt the door in place. Aiea WVNotehes for the Hooks Pigare25D:2 Bring the letch hous asclose as possible to the dooe stitfener ws Cut notches us required for adequate clearance or the Iutches' Poll eange of travel D1. Grindnotchesin the doorstiffener forthe hook tofitthrough, Thelatehes will be centeredon thelatch pads, Thenotches musthe large enough to accommodatethe hook through its full 90° ar. D2, Cutthe tube shaft tolength out of the tube shaft supplied (315-6), Cutthelength ‘such that thereisa 1/16- 1/32" gap between the tubeshaft and the latch housings. = ew [Geer oro AAR Ty | aaaD3. Installthelatches. The door mustbe bolted in place when installing thelatches [7] and the actuator arm(816-51) should be installed but not drilled. (The door [~~ hinges should already be bolted on). In summary the alignment criteria are 1, The latches should be centered an the latch pads, 2, The latches should be as close as possible to the lower side ofthe stiffener. 3. The latches must be in parallel alignment with each other, the fixture has already assured that the pads are in plane with one another. The tubular connecting shaft will assure this parallel latch alignment. ‘When satisfied with the alignment, superglue the latches in place, | Lateb/anchor Installation X-section Figure 28:D:3 H— Door skin 1 Door Iateh Make sure the hook is in full contact with the roller! D4. Position the anchors, Itisimportant that the anchors are positioned correctly on the adjustor plate as previously described. When satisfied with the aligament, superglue the anchors in place, RL IV RN OO ipplements‘NOTE: Phe xeceiveris slightly wider than the hook. Ttis generally best to orient ‘the hook soit s slightly aftof center in the receiver. ‘Thisisbecause, the gas strut ‘on the door will tend to drive the door forward and this hook / receiver orientation vill then hest accommodate any variations due to the gas strut’s influence. D5, Duill the 3/16" dia, holes for the doorlatches, Countersink the holes. Find the correctscrewsfor thelatches. Tt wouldbe wise to getsomecastlenutsorequivalent for easy removal (you'l need to remove the latches a few times). You have been supplied with a variety of MS24694 bolts, Note: Screw lengths vary depending ‘on the thickness of your lox pad. Ifyou need a different length screw(s), please contact one of our service representatives. D6. Drill the 8/16" dia, holes for the lower two anchors, Make sure that the anchoris ‘still positioned correctly on the adjustor plate. Notch the serew head. This will keep the head from turning, should you ever have to undo the lock nuts securing the anchors. Countersink & flox them in, DT. Removetheholts securing thedoor. ‘The latches should now hold the door tightly shut. You can make minor adjustments Gifnecessary) with the adjustor bolt. ‘D8. Install the actuator arm on the tube shaft, Do not drill forthe rol pin. See step B7-4for adjustment. D9. Drillandpin thotubeshafi, Usea 1/8" drill andinstal the spiral vollpins ORP-02), ‘Make sure that bath latches are in the same position. kar Vv = eeDoor Centering Guide Block Figure 2804 Inbward end of sot with the door closed Jobd_ D8. Install the door centering pin guide block. This is a simple alignment device for ‘the door when it closes, Lacate the position for the nylon Guide Block and install it approximately in the center (fore and aft) on the door frame. + Fwd/aft location: Not critical at all. * Inbdioutbd location: It should be installed such that the inbd edge of the block lange is approximately aligned with the inbd most surface of the door stiffener. Cut asquare hole which makes asnugiit. Alight dab of epoxy orpaste adhesive can be used to secure the Guide Block in position butif the itis snug enough, that alone can be sufficient to hold itin place. ANCE Ta [Games eT IV SupplementsA few words on door movement/pin alignment: The Centering Pin will engage ina sliding motion, sweeping into the Guide Block slot asthe dooris closing. Thus thepin will sweep from outboard sideoftheblockandmoveinboard. Andtypically, the pin will engage along the outhd, aft edge of the slot so as the door closes, it will beshifted forward slightly intoits proper closedposition due tothe pin. Thisslight xearward door shift is typically due to the forces exerted onto the door by the gas strat. ‘To install the Centering Pin: 1a) Close the door and note the distance between your nylon block and the door stiffener. Place 5/16" washers over the pin to equal this distance (minus the thickness of the pin bonding flange). },) Place the pin (with the 5/16" temporary spacing washers)into the Guide Block, locating the pin toward the inboard end of the block's slot. ) Place a dab of bondo ox equiv. on the top of the bonding flange of the pin and then close the door. Allow the bonde to set up against the door stiffener, then try. ‘opening the doorbeing careful to notbreak thebondo andpin offthe doorstiffener. ‘This will verify thatyou'velocated the pinin an acceptablemanner. Ifyoucan not. ‘open the door without breaking the pin off, then it wasnot properly orientatedin_ thenylon slot. Thisisall pretty simple, but adjustasnecessary and when finished, note the pin position (with the door closed) which works correctly. 4) Clean off the bondo and set the pin back in the noted position in the Guide Block, Itis a goodidea tocovertheblock andlocal area with somerelease tapejust incase some epoxyiflox were to drop off the pin's bonding flange. ) Apply amoundof Hysol tothe top of the pin'shonding flange and simply clase the door onto it ‘Secure the doorin the closed position until the Hysol cures. Then open the door andclean up the area as desired. £) We recommend applying a small 1 BID tape over the pin to assure that it remains in place (and this can help dress up the installation as well) ee Gam rE IV SapplemenesGusset Installation pare 28D 2 _--— Nalom guideblock 2PPS, 1/4 thick prepreg. \ ge wide, 9 BID rein. forvemeuts on each side NOTE: You ate lonking nt the undewide of the arm rest ‘D9. Installlagusseton each side-ofthe door centeringpin, ‘Make the gusset as shown in Figure 28:D:5. The gussets provide xeinforcement at the door pin location and strengthen the arm rest area NOTE: We recommend that you fit the door handlecover at this time (see section, J. You can wait with fitting the cover but it will be more difficult as the door handles will bein your way. DL. Billallthealignmentholesarqundthedoorwith an epoxy-micro(floxmix, You will not need these holes any more. Chapiees ma 02 ‘SupplementsDOOR HANDLE ‘The doorhandleismountedin the aft section ofthe door. The latches are activated byapushipull rod. When the door handle is in the shut position, the over center spring helps lock the mechanism in place Bond the phenolic block with flox and 2 BID, and secure the spring tab #CD316-06 by bonding an AN3-7A screw into the phenolic block. Door Handle iguee282-1 1 Spring #00316-15 Spring tab #CD316-06 Sim Screw #ANS-7A Phenolic Block — #CD-316-08 Note: You mnay ft the handle cover ay deccribed in section "J" prior to installing the door handle. Note: You may fit the handle cover as described in section "J" prior to installing the door handle. Ta [Geant _ Teor oTDoor Handle Exploded View Figare282 ena Fe an anos Iter Handte | Stewie hice | aNBee0L) om est8'e0, SN ger SP fate. Burton Head Screw: 1 am \3 feenaey ° le Dru ere (918514158) wy ae ‘Gaps acto Head {ielorias Dove Bale ‘aie El, Tofamiliarize yourself with the door handle assembly we suggest that you fit the pieces on the table. ‘The Basic door handle components are: 1, The exterior door handle (816-05) 2. Theinterior handle and drum, (316-044) 3. The collet (316-01) 4. The spindle (316-02) 5, The knob (CR-20) 6, The hoop (316-09) = Fee || Seamer __ [nev 0702-01-98Installing the Collet Figure28P:3 Cc “the door handle should he parallel ta the lower edge of the window. GMOT w the lower edge of the door). 2, Install the collet, To position the collet, see blueprint #B-316. 1, Drill a1 1/2" hole at this location. A circle saw works well, 2. Thenotch in the collet (thenotch that theexterior doorhandle dropsinto) must be positioned such that the handleis pointed aft and parallel to the lower edge of thewindow. NOTE: DO NOT USE THE DOOR SKIN BOTTOM AS A LEVEL REFER- ENCE SINCE THAT DOES NOT FORM A HORIZONTAL LINE, ‘Thoroughly sand the bonding area on the collet. The anodize should be com- pletely removed for a good bonding surface, When satisfied with the alignment, pot the collet in place with Hysol™ or epoxyiflox. ANG TV 2.66 Chapters [e721 ‘SupplementsSpring Tab Mounting Block a ao vot Spring ab =—= lewe Deill x 216" diameter ble for fhe ANG? bol Using thedimensions given, makethespringtab mounting block outafa 1/2" thick orkot block (916.06), Drill 3/16" diameterholeforthe AN3-7Abolt. Roughen the bolt with sandpaper or the equivalent. Slide the bolt through the spring tab and bond in place with Fiysol"™ Es. Spring Tab Mounting Block Location Figured om Fed nS, Bewens a Phocolo bck ot ANAR TT |EA. Bs. Be. ET. (oxterns Firstinstall thespring and then use the roll pin to lock them together. Refer to the exploded view, Figure 28:E:2 Install the screw into thespindle untilit bottoms out. Cut off the exposed threads and remove the screw. Grind some more off sothat the screw will bottom outon its shank when installed. Install the two O-rings on the spindle. Put alight lubrication film over the pieces before assembly (bearing grease works wel). Slidethespindleintothecollet mountedin the door, Insert the screw through the door handle drum, collet, and spindle. You may as well wait with installing the ddoor knobs as it will give you a Little more room to install the push/pull rod with them off. This s also a good timeto test ft the averconter hoop and spring. Use caution as the spring ia very snug fit. Soe blueprint #B-816 smble 16. wn, - ‘Extra threads have beea provided so that itcan be shortened. Cutor grind aslot in the stiffener for the push/pull rod to get past, Other helpful hints 1 Install the clevis pin for the over center hoop and tapein place. Thisis difficult ‘toinstall after the pushpull rod isin place. 2, Latch “open” stop is achieved by clevis #6D-330-12 and actuator arm #316-51 hitting the inner surface ofthe door stiffener. Make sure that the end of theclevis isround to prevent damage to thestiffener and allow maximum travel ofthelatch, 3, Use sufficient washers to shim the rod end (HIFC-3) away from the doorhandle ‘ab to prevent it from rubbing in the closed position. 4, Adjustment - Wait until the door is installed to drill the hole through the torque tube, for the spiral roll pin (RP-02) in the actuator arm, With the door installed, open the bottom latches until the door can just barely be opened. ALlow 44/- 1/4" clearance between the latch and door frame. Move the actuator arm toit's ‘open stop position (gee hint #2). Drill the hole and install the spiral roll pinin the actuatorarm, Readjustthepush/pull rod until theinteriorhandleisin thecovrect position when the door is closed. See Figure 28:B:1. The exterior handle should bein aneutval position with no force on the handle drum screw (91251A155). It should rest freely and not be bound to the collet 5 Sat 7. earDOORLOCK ‘To keep all the crooks out of your Lancair we supply a lock that locks the door handlein place, To install the door lock we recommend that you remove the door from the aircraft (it is easier toinstall the door handle cover with the door off t00) © Nu @ Star washer Door lock tab Brass bushing {If required) © inant Zt & Door lock (Part# DL-O1} ee “Supplements ie WIDoor Lock Location Piguro28P2 Location of tab with door FL FS, FA, Door handle drum location LL. rd ‘Drill e V4" diametor pilot hole mt this Tocation Using the dimensions in blueprint #B-316. mark the door lock Jocation, Most likely your hole will be at the edge of the doorstiffenerflange. Drilla 1/4*diameter pilot hole at this location, 8" hole from th shown in Figure 28:78, Itisideal ‘you can make it 8/8" deep, ut you must not drial the way through the doos! Every door will vary in thickness a this location socheck you door. You can simply hock the depth of your U4" hole thatyou drilled. You shouldleave atleast 3/16" of material beyond the 78" diametarhole. Itis OKifthe face af yourlockssticks out alitile Drill through the remainder of the hole using a 5/8" diameter drill. Enlarge the holes the rest of the lock will it. First place the aft door handle in. thelocked position. Ttis somewhat difficult to determine exactly on which sides to enlarge the hole. Ideally the lock will drop intoits hole with a snug fiton all sides to preventit from rotating. Here is our suggested mothod: 1, Turn the lock over so you are looking at the front of it. With the key, turn the lock all the way clockwise. Thisis the locked position. Put the lock tab on the assembly. Point the lock tab directly at the tab on the door handle drum. Grind the hole so the door lock will ft snugly in this orientation. Should you remove ‘to much material you can fill with epoxyitlox. 2 3. ANCUR TV Tio | Giese oT SupplementsRecessing the Door Lock Figure 283 rr 8 —— e + ouTBD fave Door Lock Tab Figure28 7:4 Shape and bend the lock tab so that it Its the tab on. the door handle drum end first, then shape| because the heading shortens the tab. Bend the lock tab to get the right height ToL se pplementsF5, Shape and bend the doorlack tab, Slide the door lock through and tighten down the lock with theving mut. Bend and shape the lock tab so thatit hits the tab on ‘the door handle drum as shown. Operate the door lock. Itis possible you'll need, to make a notch in the door stiffener for the lock tab to fit through in the open position, G HANDLE COVER In this section you'll over up the work you've spent so much time on with the handle cover. The handle cover can he removed with the handles in the open position, Handle Cover Pigure28G:1 Gl. Hitthehandle cover, You may find it easiest to remove the door handle for this step. The cover fits into the flange on the door stiffener and covers the latch mechanism, G2. Drill.a 11/4" diameter hole for the door handle drum. This will allow room for upholstery. Make sure you are able to install and remove the handle cover with door handle in place. G4. Install the four nut plates and J-nuts, (See blueprint B-316) G5, _ Install thedoor knob, Chances are that you will takeiton and offmany moretimes Dut at least youll know where itis, (Continue in Chapter 28, with page 28-67.) a [Game AINCAR TV =