Sequoia Aircraft Corporation F.8L Falco Construction Manual
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Sequoia Aircraft Corporation F.8L Falco Construction Manual

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Summary of Contents for Sequoia Aircraft Corporation F.8L Falco

  • Page 1 F.8L Falco Construction Manual...
  • Page 2 F.8L Falco Construction Manual Sequoia Aircraft Corporation 2000 Tomlynn Street, P.O. Box 6861 • Richmond, Virginia 23230 • 804/353-1713 • Fax 804/359-2618 • www.SeqAir.com...
  • Page 3 F.8L Falco, Falco, the Falco logo, and the Sequoia Aircraft Corporation logo are trademarks of Sequoia Aircraft Corporation. This document was produced on an Apple Macintosh computer using Microsoft Word, PageMaker,...
  • Page 4 Revision 4 March 1, 2002 The F.8L Falco Construction Manual was originally written in 1984, and since then portions of the manual have been revised in 1986 and 1989 to correct minor deficiencies. At the time of these revisions, a system of tracking revisions had not been fully adopted, and Revision 1 and 2 were identified only by dates on the bottom of each page.
  • Page 5 March 1, 2002 28-1 thru 28-26 March 1, 2002 A-1 thru A-6 March 1, 2002 B-1 thru B-6 March 1, 2002 C-1 thru C-4 March 1, 2002 D-1 thru D-20 March 1, 2002 F.8L Falco Construction Manual Revision 4, March 1, 2002...
  • Page 6 Falco builders. If you have any comments, ideas or new procedures for assembling the Falco, please let us hear from you so that future builders can benefit from the lessons learned by previous builders. Alfred P. Scott President Sequoia Aircraft Corporation F.8L Falco Construction Manual Revision 4, March 1, 2002...
  • Page 7 F.8L Falco Construction Manual Revision 4, March 1, 2002...

  • Page 8: Table Of Contents

    Lighting Temperature Control Humidity Control Getting It In and Out Chapter 4 Tools Introduction Measuring Tools Clamps Drilling Tools Band Saw Table Saw Radial Arm Saw Coping Saw Stationary Belt/Disc Sander F.8L Falco Construction Manual Revision 4, March 1, 2002...
  • Page 9 Corrosion Protection Introduction Alodine Conversion Coating Zinc Chromate Primer Polyurethane Enamels Steel Parts Do Not Paint... Do Not Plate... Chapter 8 Aircraft Woodwork, Materials Spruce Other Woods Birch Plywood Moisture Content Glues F.8L Falco Construction Manual Revision 4, March 1, 2002...
  • Page 10 Plywood Scarf Joints 13-2 Spar Cap Joints 13-2 The Ends of the Spars 13-2 Doubling Up 13-2 The Aileron and Flap Spars 13-2 The Forward Wing Spar 13-2 The Main Wing Spar 13-2 F.8L Falco Construction Manual Revision 4, March 1, 2002...
  • Page 11 Chapter 20 Rudder Assembly Fin and Rudder Assembly Notes 20-1 Rudder Assembly 20-1 Chapter 21 Fin Assembly Chapter 22 Aileron/Flap Assembly Kits on Hand 22-1 Aileron/Flap Hinge Installation 22-2 Aileron/Flap Assembly 22-4 F.8L Falco Construction Manual Revision 4, March 1, 2002...
  • Page 12 Fuselage Assembly 26-2 Chapter 27 Fuselage Assembly, Part 2 Nose Gear Bay Assembly 27-1 Cockpit Flooring 27-6 Battery Box Installation 27-16 Exhaust Port Framing 27-27 Nose Gear Screwjack Support Assembly 27-30 F.8L Falco Construction Manual Revision 4, March 1, 2002...
  • Page 13 Aircraft Covering & Painting, The Best Books Aircraft Engines Aircraft Engineering Publications Appendix C Paint Scheme Colors Appendix D Glue Instruction Sheets Aerolite 306 Penacolite Adhesive G-1131 Weldwood Waterproof Resorcinol Glue D-10 Aerodux 500 D-16 F.8L Falco Construction Manual Revision 4, March 1, 2002...

  • Page 14: Preparing For Construction

    Your family will enjoy having you around and being able to check in on you. Nothing is worse than building an airplane at the airport or some other remote location. Traveling to and F.8L Falco Construction Manual 1–1 Revision 4, March 1, 2002...

  • Page 15: What To Make

    You cannot build a perfect airplane—there are bound to be little errors—but you should set your standards early. We suggest that you set them very high. F.8L Falco Construction Manual 1–2 Revision 4, March 1, 2002...

  • Page 16: Modifications

    There is no way to adequately explain the horrible way this “Swiss watch” syndrome grows as the airplane nears completion. When you have all of the flight controls installed, you will think that F.8L Falco Construction Manual 1–3 Revision 4, March 1, 2002...
  • Page 17 Falco. These improvements are modifications to the original design, but we have done the engineering and spent the time to check out interference F.8L Falco Construction Manual 1–4 Revision 4, March 1, 2002...

  • Page 18: Visit A Falco Builder

    In general, you will find that the aircraft that they are building are not of the same class as the Falco. You will find an occasional expert F.8L Falco Construction Manual 1–5...

  • Page 19: Contacting Sequoia Aircraft Corporation

    Sequoia Aircraft. In addition, all of the Falco drawings contain a notice to this effect. The F.8L Falco aircraft design is the property of Stelio Frati, the designer of the aircraft, and it is available from Sequoia Aircraft Corporation by contract between Mr. Frati and Sequoia Aircraft and this contract prohibits the resale or transfer.
  • Page 20 $100.00 covers the cost of printing the drawings and construction manual, $100.00 goes to Mr. Frati (his only compensation), and $200.00 remains for Sequoia Aircraft Corporation to cover its costs. Thus, for us, the transfer of a set of plans is the same as the sale of a set of plans except that we do not have to print and ship another set of drawings.
  • Page 21 F.8L Falco Construction Manual 1–8 Revision 4, March 1, 2002...

  • Page 22: Reading The Plans

    Many people are initially intimidated by the number of drawings and the amount of detail shown on the Falco drawings. As you begin the construction of the Falco, you will appreciate how F.8L Falco Construction Manual 2–1 Revision 4, March 1, 2002...

  • Page 23: The Basic Views

    Let's look at Drawing No. 605. (We are not going to help you any more with the plans index. You will have to get in the habit of using the index.) In this drawing, the part is shown in only two views. F.8L Falco Construction Manual 2–2 Revision 4, March 1, 2002...

  • Page 24: Sections & Views

    Drawing No. 520-3 is an example. This is a half-section. Above the centerline, the part is shown as a section view, while it is a normal side view below the center line. F.8L Falco Construction Manual 2–3 Revision 4, March 1, 2002...

  • Page 25: Dimensioning

    In all cases the dimensions on the plans take preference to the drawing itself, and you should not scale directly from the drawing unless you are instructed to do so. In some cases, the F.8L Falco Construction Manual 2–4...

  • Page 26: A Few Terms

    On Drawing No. 788A again, the 13.5mm dimensions are all for the distances between centerlines. F.8L Falco Construction Manual 2–5 Revision 4, March 1, 2002...

  • Page 27: A Few Symbols

    So don't let the revisions frighten you. And please, if you find something that doesn't look right or confuses you, let us know so that we can correct the problem. F.8L Falco Construction Manual 2–6 Revision 4, March 1, 2002...

  • Page 28: Need More Help

    There may be times that you will find a contradiction between the plans and the construction manual. Remember this, the Falco is built from the plans. Any changes will be reflected in the plans revisions. The plans always take precedence over everything else. F.8L Falco Construction Manual 2–7 Revision 4, March 1, 2002...
  • Page 29 F.8L Falco Construction Manual 2–8 Revision 4, March 1, 2002...

  • Page 30: Your Shop

    You will also find that you will need some additional portable lights to illuminate your work. Photographic stand lamps work well. Hardware stores sell clamp-on utility lights which are also very nice. F.8L Falco Construction Manual 3–1 Revision 4, March 1, 2002...

  • Page 31: Temperature Control

    One final point. If you build a shop for a Falco, you will probably have an air compressor. These make a lot of noise, and you would be well advised to build a small shelter for it on the outside wall. F.8L Falco Construction Manual 3–2 Revision 4, March 1, 2002...

  • Page 32: Tools

    A drafting pencil will be very handy for marking the wood. These are inexpensive and can be purchased at a drafting supply company. A Pentel drafting pencil with a .5mm lead is recommended. F.8L Falco Construction Manual 4–1 Revision 4, March 1, 2002...
  • Page 33 A combination square is a handy thing to have. These are exceptionally versatile instruments. We like the Starrett squares best. In addition, you will probably also want to buy a carpenters square, a drafting triangle, and a carpenters level. F.8L Falco Construction Manual 4–2 Revision 4, March 1, 2002...

  • Page 34: Clamps

    We know a few people who have them, and they all swear by the thing. F.8L Falco Construction Manual 4–3...

  • Page 35: Band Saw

    This may be purchased from a local machine tool supply company or from Travers Tool Company (see F.8L Falco Kit Price List). You will need a few transfer punchs. A transfer punch is a special type of punch used to locate the center of a hole.

  • Page 36: Stationary Belt/Disc Sander

    Similarly, small aircraft nails take forever. The pneumatic guns will shoot staples as fast as you can pull the F.8L Falco Construction Manual 4–5 Revision 4, March 1, 2002...

  • Page 37: Hand-Operated Stapler

    They are made by a variety of companies. Disston offered a line of "Abraders", but these have since been discontinued. D. G. F.8L Falco Construction Manual 4–6 Revision 4, March 1, 2002...

  • Page 38: Sanding Blocks

    Jackson Wood Technology sells kits, but we've not seen one. Also, the July- August 1985 issue of Fine Woodworking carried an article on making your own moisture meter. The meter costs about $30.00 and features a meter type of indicator. F.8L Falco Construction Manual 4–7 Revision 4, March 1, 2002...

  • Page 39: Torque Wrench

    Fiber Glast Developments. Fiber Glast Developments also carries wax-less paper cups and your local pharmacy supply company will sell 30cc plastic cups with 5cc graduations. These are handy for mixing glue. F.8L Falco Construction Manual 4–8 Revision 4, March 1, 2002...

  • Page 40: Planning Ahead

    Thus, you are eligible to have your aircraft licensed only if you are building the airplane for your own “education and enjoyment.” F.8L Falco Construction Manual 5–1 Revision 4, March 1, 2002...
  • Page 41 The inspector enters the shop and begins quietly to look over the airplane. At some point, you will hear something like “Boy, this is really nice work!”. The next thing you know you have a F.8L Falco Construction Manual 5–2...

  • Page 42: Notifying The Faa

    Your contact with the inspector is not the time to express your rugged individualism or your dislike for government. Take the proper attitude, and you will be able to turn the situation into an enjoyable and informative session. F.8L Falco Construction Manual 5–3 Revision 4, March 1, 2002...
  • Page 43 F.8L Falco Construction Manual 5–4 Revision 4, March 1, 2002...

  • Page 44: Machining, Welding & Fabrication

    Normalized 4130 (“4130N”) is used for most of the parts in the Falco. The steel is available in the normalized condition in both tubing and sheet. When the steel is welded, internal stresses are F.8L Falco Construction Manual 6–1 Revision 4, March 1, 2002...

  • Page 45: Bronze Alloys

    The bushings act as bearings for low friction, and they make the Falco less “jig-critical” since they may be adjusted slightly to make various parts fit together. F.8L Falco Construction Manual 6–2 Revision 4, March 1, 2002...

  • Page 46: Hinge Fabrication

    Before you make P/N 766 and P/N 768, see Chapter 23 for the method of jigging these fittings. The O.D. of P/N 768 should be made so that it exactly fits inside the I.D. of P/N 766. F.8L Falco Construction Manual 6–3...

  • Page 47: Main Landing Gear Legs

    For this reason, it is best to weld the upper tube completely, with the oleo brackets in place, then turn the bearing surfaces. After all of this is done, weld on the lower tube. F.8L Falco Construction Manual 6–4 Revision 4, March 1, 2002...

  • Page 48: Corrosion Protection

    This primer contains sacrificial pigments, which protect the base metal from corrosion. For the interior of the aircraft this is adequate. These primers may also be used on the landing gear and F.8L Falco Construction Manual 7–1 Revision 4, March 1, 2002...

  • Page 49: Polyurethane Enamels

    Then, the acid will eat away the metal—seriously weakening the weld. Don't plate welded parts! F.8L Falco Construction Manual 7–2 Revision 4, March 1, 2002...

  • Page 50: Aircraft Woodwork, Materials

    When wood is subjected to a constant temperature and relative humidity it will in time come to a definite moisture content, which is called the equilibrium moisture content. This relationship between the moisture content of Sitka spruce and the surrounding atmospheric F.8L Falco Construction Manual 8–1 Revision 4, March 1, 2002...
  • Page 51 In addition to variation due to season, there is also a variation in relative humidity in different parts of the country as affected by altitude, proximity to the ocean, precipitation or some comparatively local condition. The table above shows the relative humidity for a number of F.8L Falco Construction Manual 8–2 Revision 4, March 1, 2002...
  • Page 52 Chapter 9 “Moisture Protection of Wood”. When you purchase birch plywood, it is quite likely that the plywood will have a low moisture F.8L Falco Construction Manual 8–3 Revision 4, March 1, 2002...

  • Page 53: Glues

    It sets up quickly, allowing—and requiring—quick assembly. Of all the glues available, this glue is the best choice for most builders. The original F.8L Falco Construction Manual 8–4 Revision 4, March 1, 2002...

  • Page 54: Aerolite

    1131 which is probably the easiest and most forgiving resorcinol to use. Penacolite is a two-part adhesive, and a powdered hardener is mixed with a liquid resin. The mixing ratios are important and require weighing—measuring by volume is not recommended. A minimum temperature of F.8L Falco Construction Manual 8–5 Revision 4, March 1, 2002...

  • Page 55: Plastic Resin Glues

    Penacolite—particularly for things like the spar and fuselage frame laminations. Penacolite must be ordered direct from Koppers Company. See the F.8L Falco Kit Price List for ordering information. Koppers Technical Bulletin on the use of Penacolite G-1131 is reprinted in Appendix D of this manual.
  • Page 56 This usually means a well-ventilated shop, so that you will not breathe the fumes. You should protect your hands with rubber gloves or a barrier creme—PR88 is the best available. F.8L Falco Construction Manual 8–7 Revision 4, March 1, 2002...
  • Page 57 We are very impressed with the professionalism of this company. They maintain a large testing facility and have done pioneering work on fatigue testing of wood and fiberglass—wood wins by a large margin. F.8L Falco Construction Manual 8–8 Revision 4, March 1, 2002...

  • Page 58: Test Blocks

    This technique of using test blocks is an excellent one, and something you should F.8L Falco Construction Manual 8–9...
  • Page 59 The soundness of the glue joints should not be something that depends on luck. With such tests, you will quickly learn how to make glue joints that you can depend on. There is, in our opinion, no other way to go about it. F.8L Falco Construction Manual 8–10 Revision 4, March 1, 2002...

  • Page 60: Moisture Protection Of Wood

    The 1950’s Techniques The techniques and materials included here are a summary of the suggested procedures from ANC-19. F.8L Falco Construction Manual 9–1 Revision 4, March 1, 2002...
  • Page 61 For full effectiveness, however, at least one aluminized coat should be a priming coat or an undercoat, that is, it should be sandwiched between the wood and succeeding coats or between coats. When F.8L Falco Construction Manual 9–2 Revision 4, March 1, 2002...

  • Page 62: Recent Developments

    Epoxy paint (2 part) One coat Two coats Three coats Enamel paint (soya/tung/alkyd) One coat Two coats Three coats Aluminum pigmented varnish One coat Two coats Three coats Paraffin wax dip F.8L Falco Construction Manual 9–3 Revision 4, March 1, 2002...

  • Page 63: Application Procedures

    Bellanca Viking wing was given a single dip in a Glidden sealer. The methods used on production aircraft are normally inspired more by production efficiencies than by a desire to attain the best moisture protection. F.8L Falco Construction Manual 9–4 Revision 4, March 1, 2002...

  • Page 64: Under Metal Fittings

    If the fitting may be removed on very infrequent occasions, then a pliable adhesive may be used. Silicon rubber RTV compound is a good choice. 3M makes a long list of suitable sealers. F.8L Falco Construction Manual 9–5 Revision 4, March 1, 2002...
  • Page 65 F.8L Falco Construction Manual 9–6 Revision 4, March 1, 2002...

  • Page 66: Woodworking Methods

    Since end-grain gluing is more difficult (and results in a weaker joint) than side-grain gluing, it follows that where cross grain within the specified acceptable limits is present, all scarf cuts must F.8L Falco Construction Manual 10–1 Revision 4, March 1, 2002...
  • Page 67 All of these requirements for scarf joints, laminations, and many other important aspects of wood construction (grain deviation, moisture content, grading of wood, etc.) are covered in AC 43.13-1 and ANC-19. F.8L Falco Construction Manual 10–2 Revision 4, March 1, 2002...

  • Page 68: Making A Scarf Joint

    A strip of wood tacked to the plywood is used to guide the plywood. The strip of wood fits in the table guide groove in the table saw top. (See “Shop Notes” in Tony Bingelis’s The Sportplane Builder for such an arrangement.) F.8L Falco Construction Manual 10–3 Revision 4, March 1, 2002...
  • Page 69 The other edge may be determined by measuring. Let’s say, for example that you have a 1mm skin, and you want to make a 12 to 1 scarf. Obviously, the scarf F.8L Falco Construction Manual 10–4...

  • Page 70: Conditioning

    1 to 3 weeks or longer, depending on their thickness and width and the conditions of drying. F.8L Falco Construction Manual 10–5 Revision 4, March 1, 2002...

  • Page 71: Beveling Plywood

    The nails should be long enough to penetrate into the underlying structure to a minimum depth of about 3 times the thickness of the surface plywood, but the nails should not be so long as to pass completely through the underlying structure. F.8L Falco Construction Manual 10–6 Revision 4, March 1, 2002...

  • Page 72: Bending Spruce And Birch Plywood

    If the bend has a large radius in relation to the thickness of the wood, the wood can be easily bent, clamped and glued in place. If the bend has a tight bend radius, then you must soak and pre-bend F.8L Falco Construction Manual 10–7...
  • Page 73 1.0” if bent with the face grain parallel to the axis of the bend. If heated, the breaking radius is reduced to about .03” if bent parallel to the face grain and heated. F.8L Falco Construction Manual 10–8...
  • Page 74 This method of hot-bending plywood should not be overlooked by a Falco builder. You can do truly amazing things with wood once it is heated. Bentwood rockers are made this way, as are the molded plywood chairs you see so frequently in cafeterias. F.8L Falco Construction Manual 10–9 Revision 4, March 1, 2002...
  • Page 75 20x20 pine-with-nails is used as well, and it is clamped to the rib. Cut an automobile inner tube into long strips about 1” wide. If you cut the inner tube with a spiral cut, the rubber band will be F.8L Falco Construction Manual 10–10...

  • Page 76: Clamping Methods

    Figure 12 shows the most common method of clamping a rib to a spar. A block of wood is inserted into the gusset pocket of the rib, then two pieces of wood are screwed together as shown and a clamp is used to hold things in place. F.8L Falco Construction Manual 10–11 Revision 4, March 1, 2002...
  • Page 77 If this type of clamping block is positioned right over the rib, you will end up gluing it as well, so you can use some wax paper to keep this from happening. F.8L Falco Construction Manual 10–12 Revision 4, March 1, 2002...
  • Page 78 For the ailerons you can use a variation shown in Figure 16. In this case a 3/4”Ø dowel is used and a hole drilled in the assembly jig for the dowel. F.8L Falco Construction Manual 10–13 Revision 4, March 1, 2002...

  • Page 79: Drilling Holes

    There will be a few instances when you will find that you have really botched a hole. In this case, you may use a wood dowel to plug the hole. Glue a short dowel in place, and after the glue is dry, drill the hole again. F.8L Falco Construction Manual 10–14 Revision 4, March 1, 2002...

  • Page 80: Bolt Torques

    1/4”Ø holes in the airplane, and you may use any size hole you like. The only important thing is that the holes be open so that water will drain out. This is a maintenance item, and the larger holes are less likely to become clogged with dirt. F.8L Falco Construction Manual 10–15 Revision 4, March 1, 2002...
  • Page 81 F.8L Falco Construction Manual 10–16 Revision 4, March 1, 2002...

  • Page 82: Making Ribs

    Note that the drawings for all of the ribs show the spars for the wing or tail as well as the rib. This is so that you can see how everything will fit together when the rib is installed in the airplane. F.8L Falco Construction Manual 11–1...

  • Page 83: Jigs

    This will permit you to place clamps on each gusset. The glue and clamp method will require that you leave the rib in the jig until the F.8L Falco Construction Manual 11–2...

  • Page 84: Making The Ribs

    MEK or lacquer thinner and set it aside for woodwork only. If you prefer to use sandpaper, be sure to use a sanding block so that you don’t round the areas that should be square. F.8L Falco Construction Manual 11–3...

  • Page 85: Wing Ribs

    This makes for a nice looking job, and it is perfectly acceptable. This technique is very slow, and we doubt that it is needed except to appease a personal sense of perfection. F.8L Falco Construction Manual 11–4 Revision 4, March 1, 2002...

  • Page 86: Making The Fuselage Frames

    The sanding belts for these sanders are very expensive, and most shops are very fussy about what they will let go through their sander. Epoxy F.8L Falco Construction Manual 12–1 Revision 4, March 1, 2002...

  • Page 87: Open Vs Closed Laminations

    You will note on the fuselage assembly drawing that the fuselage stations are located on either the forward surface or the aft surface of the frame. Unfortunately, the dimensions for the frames are F.8L Falco Construction Manual 12–2 Revision 4, March 1, 2002...

  • Page 88: The Fuselage Curve

    To calculate the curve, three variables must be known. These variables are shown in Figure 1. Figure 1 The formula for this curve is: 1 − + 1 − F.8L Falco Construction Manual 12–3 Revision 4, March 1, 2002...
  • Page 89 Stores A Program B: Stores B Program C: Stores X (B.L.), Solves for Y (W.L.) Program D: Stores Y (W.L.), Solves for X (B.L.) Storage registers used: X (B.L.) Y (W.L.) F.8L Falco Construction Manual 12–4 Revision 4, March 1, 2002...

  • Page 90: Making The Spars

    “up and in” in the calculations, and that is the way that the production aircraft were built. For the horizontal stabilizer, the spars take a download, so the grain direction of the spars should be “up and out”. F.8L Falco Construction Manual 13–1 Revision 4, March 1, 2002...

  • Page 91: Plywood Scarf Joints

    This is the big one! The main wing spar can be (and has been) made on a shop floor. Most builders will find the job easier if it is done on a long jig table which places the work at a more comfortable level. F.8L Falco Construction Manual 13–2 Revision 4, March 1, 2002...
  • Page 92 Fit the plywood skins to the spars. Use a couple of small nails as alignment pins. Mark off and apply sealer to the inside surfaces of the plywood and to the inside of the spar. You will also want F.8L Falco Construction Manual 13–3...
  • Page 93 Glue on the plywood. F.8L Falco Construction Manual 13–4 Revision 4, March 1, 2002...

  • Page 94: Antenna Installation

    (or under) the skin, and if the elements are run “up and over” the rib cap strips, the reception of the system will suffer. F.8L Falco Construction Manual 14–1 Revision 4, March 1, 2002...

  • Page 95: No. 2 Communications Antenna Installation

    Materials required. RST Ferrite-Foil Antenna Kit 17’ RG58 Coaxial Cable (includes 3-1/2’ extra) F.8L Falco Construction Manual 14–2 Revision 4, March 1, 2002...

  • Page 96: Vhf Navigation Antenna Installation

    No. 1 COM antenna. The coaxial cable will require one UG88 and one UG89 BNC cable connector at frame No. 8. F.8L Falco Construction Manual 14–3...

  • Page 97: Transponder Antenna Installation

    It may be preferable to install the antenna in the alternate position for a shorter coaxial cable. Note also that the marker beacon receiver cable F.8L Falco Construction Manual 14–4 Revision 4, March 1, 2002...

  • Page 98: Adf Antenna Installation

    Aviation, Jim Weir, March 1984. The notes which follow are taken from that article and from discussions with Jim Weir on the specific Falco installation. This installation is not finalized yet and is subject to change. F.8L Falco Construction Manual 14–5 Revision 4, March 1, 2002...

  • Page 99: Loran Antenna Design Requirements

    It is important that the antenna be as tall as possible, measured from the bottom to the top. The antenna wire may be installed on either the forward face or the aft face of the fin spar. It should extend to the bottom of the tail cone. F.8L Falco Construction Manual 14–6 Revision 4, March 1, 2002...
  • Page 100 To insulate this inner lead, heat shrink tubing or electrical tape may be used. A solderless ring terminal is installed on this lead. This is for the antenna wire. F.8L Falco Construction Manual 14–7 Revision 4, March 1, 2002...
  • Page 101 It might be possible to locate the coupler in the leading edge of the rudder, but we think this would be a difficult installation. Installing the coupler aft of the rudder hinge line would be an invitation to flutter. F.8L Falco Construction Manual 14–8 Revision 4, March 1, 2002...

  • Page 102: The Ground Plane

    The grounding of metal parts is primarily related to the installation of an ADF or Loran, and there is no special need to do this if these systems are not installed. F.8L Falco Construction Manual 14–9 Revision 4, March 1, 2002...

  • Page 103: Noise Suppression

    In the process of installing the antenna system, you will have to assemble a number of BNC connectors. To assemble one of these connectors: Figure 3 ❏ Strip the outer cable insulation for a length of 9/32” (7.1 mm). Figure 4 F.8L Falco Construction Manual 14–10 Revision 4, March 1, 2002...
  • Page 104 Remove excess solder from the outside of the contact. Be sure the inner insulation is not heated excessively and swollen so as to prevent the insulation from entering into the connector body. F.8L Falco Construction Manual 14–11 Revision 4, March 1, 2002...
  • Page 105 ❏ Push the assembly into the body as far as it will go. Slide the nut into the body and screw in place with a wrench until tight. For this operation, hold the cable and shell rigid and rotate the nut. F.8L Falco Construction Manual 14–12 Revision 4, March 1, 2002...

  • Page 106: Electrical System

    Landing light (on the lower cowling) Frame No. 1, aft face: Alternator shunt Fuse holder Alternator analyzer transducer Front Fuel Tank: Fuel quantity sender Glare Shield: Four glare shield lights F.8L Falco Construction Manual 15–1 Revision 4, March 1, 2002...
  • Page 107 Altitude encoder Aft Fuel Tank: Fuel quantity sender Battery Compartment: Battery (Gill PS6-11 or Gel/Cell U-128) Front Fin Spar Loran antenna coupler Terminal block (for tail light wires and Loran antenna) F.8L Falco Construction Manual 15–2 Revision 4, March 1, 2002...

  • Page 108: Wire Bundle Routing

    This routing of the main battery wires will greatly ease the installation. On the original production Falcos, these wires were routed up and over the nose gear bay cover. This greatly complicates the installation. F.8L Falco Construction Manual 15–3 Revision 4, March 1, 2002...
  • Page 109 F.8L Falco Construction Manual 15–4 Revision 4, March 1, 2002...

  • Page 110: Tail Group Assembly Preparations

    First, always install parts at the earliest possible stage of construction. It is very easy to install fittings on the fuselage frames when you can place the parts on a drill press and drill the holes. If you wait F.8L Falco Construction Manual 16–1...

  • Page 111: Background

    See Figure 1. F.8L Falco Construction Manual 16–2...
  • Page 112 If you try to wipe up the varnish, you will find that you will only smear it into the wood. F.8L Falco Construction Manual 16–3 Revision 4, March 1, 2002...

  • Page 113: Drawing Notes

    The rib drawings are drawn very accurately and may be used as patterns for the ribs as long as dimensions are checked to make sure that the paper has not contracted or expanded due to the F.8L Falco Construction Manual 16–4...
  • Page 114 “pigtail” and are connected at a terminal block on the forward face of the forward fin spar. The wires are pushed through a plastic tube which serves as a conduit. F.8L Falco Construction Manual 16–5 Revision 4, March 1, 2002...

  • Page 115: Hinge Installation Notes

    “recessed head” means that it uses a Phillips screwdriver. The “type A” means that the screw has a sharp point. We abbreviate this as “TRA”. For flat head screws, we use the abbreviation of “FRA”. F.8L Falco Construction Manual 16–6 Revision 4, March 1, 2002...

  • Page 116: Preparatory Work

    ❏ Any preliminary work for the installation of a Loran antenna coupler may be done at this time. See Chapter 14 for Loran antenna installation details. ❏ If necessary, trim the end of the spar as shown for P/N 415-1. F.8L Falco Construction Manual 16–7 Revision 4, March 1, 2002...
  • Page 117 Note that there are two pieces of plywood at Sta. 4. Scuff-sand the plywood prior to gluing. ❏ Draw centerline on forward and aft face of the spar. ❏ Draw Sta. 0 on the forward and aft face of the spar. F.8L Falco Construction Manual 16–8 Revision 4, March 1, 2002...
  • Page 118 ❏ Install plywood disk at aircraft centerline and drill 3/8”Ø hole for the elevator control cable. Scuff-sand the plywood prior to gluing. ❏ Drill the .62”Ø hole at Sta. 1 on the right side only. This is for the trim tab cable tube. F.8L Falco Construction Manual 16–9 Revision 4, March 1, 2002...
  • Page 119 ❏ If not already done, cut off all trailing edge ribs for the trailing edge strip. ❏ If not already done, install 20x10 spruce block on R.H. elevator rib Sta. 1. See Drawing No. 403. Scuff-sand the plywood prior to gluing. F.8L Falco Construction Manual 16–10 Revision 4, March 1, 2002...
  • Page 120 1270 1200 Rudder Trailing Edge Skin grain Rudder Trailing Edge Skin grain 1200 Figure 2 ❏ Use one 50”x50”sheet of 1.2mm birch plywood and cut in accordance with Figure 2. F.8L Falco Construction Manual 16–11 Revision 4, March 1, 2002...
  • Page 121 Edge Fairing Skin Bottom Rudder Skin grain Elevator Leading grain Edge Skin grain Figure 4 ❏ Use one 50”x50”sheet of 1.2mm birch plywood and cut in accordance with Figure 4. F.8L Falco Construction Manual 16–12 Revision 4, March 1, 2002...
  • Page 122 1125 Fin Skin Fin Skin grain grain Fin Skin Fin Skin grain grain Figure 6 ❏ Use two 50”x50”sheets of 1.5mm birch plywood and cut in accordance with Figure 6. F.8L Falco Construction Manual 16–13 Revision 4, March 1, 2002...
  • Page 123 ❏ Use one 50”x50”sheet of 1.5mm birch plywood and cut in accordance with Figure 7. Elevator Center Trailing Edge Skin grain Figure 8 ❏ Cut one piece of 2mm plywood for the elevator center trailing edge skin. See Figure 8. F.8L Falco Construction Manual 16–14 Revision 4, March 1, 2002...

  • Page 124: Tail Group Hinge Installation

    ❏ Clamp the stabilizer hinges to the main stabilizer spar. See Figure 1. Make sure the hinges are correctly aligned and that the hinges work smoothly. You must be able to move the elevator spar smoothly on the hinges without binding. F.8L Falco Construction Manual 17–1 Revision 4, March 1, 2002...
  • Page 125 ❏ Install the channel-nuts for P/N 755. To keep from moving anything at this critical stage, the screws for the channel-nuts should not be installed at this time. ❏ Re-assemble the hinges with the hinge bolts. Check the alignment of all of the hinges. F.8L Falco Construction Manual 17–2 Revision 4, March 1, 2002...

  • Page 126: Rudder Hinge Installation

    2mm birch plywood together. Since it is desirable that these pads be installed after the Sta. 0 trailing edge rib, you may use extra washers on the bolts or place a F.8L Falco Construction Manual 17–3...

  • Page 127: Elevator Balance Weight Installation

    If the upper elevator stop, P/N 857-8, is not installed, a stainless steel plate should be glued to the bottom of the slot with epoxy. As an alternative, you may use any hard thin material such as aluminum or Lexan. F.8L Falco Construction Manual 17–4 Revision 4, March 1, 2002...
  • Page 128 ❏ Drill the spacers with a 5/32”Ø drill using the holes in the arms as a guide. Do this on a drill press to make sure that the holes are drilled straight. See Figure 4. F.8L Falco Construction Manual 17–5...
  • Page 129 For this reason, you might want to install the weight with AN525- 832R16 screws and MS21042-08 nuts. If so, the holes for the screws should be reamed with a No. 19 drill (.166”Ø). F.8L Falco Construction Manual 17–6 Revision 4, March 1, 2002...
  • Page 130 ❏ You may need to bend the arms slightly to allow for the slight difference in thickness at each end. F.8L Falco Construction Manual 17–7 Revision 4, March 1, 2002...
  • Page 131 It is normal to have the hole 1/32” undersized before the final reaming operation. Figure 10 F.8L Falco Construction Manual 17–8 Revision 4, March 1, 2002...
  • Page 132 P/N 750. You should also be aware that one or two metal plates, and P/N 857-8 are installed as elevator stops. See Drawing No. 857 for alternative construction of P/N 857-8. F.8L Falco Construction Manual 17–9 Revision 4, March 1, 2002...
  • Page 133 F.8L Falco Construction Manual 17–10 Revision 4, March 1, 2002...

  • Page 134: Elevator Assembly

    3 and use the contours of P/N 403-3 and P/N 403-6. Because this solid spruce construction requires a break in the trailing edge, it is easier (although slightly wasteful) to make the trailing F.8L Falco Construction Manual 18–1 Revision 4, March 1, 2002...
  • Page 135 (If you wish, you may also glue P/N 404-7 ribs in place at the same time, per the following step.) See Figure 4. ❏ Install P/N 404-7 ribs. See Figure 4. Figure 4 F.8L Falco Construction Manual 18–2 Revision 4, March 1, 2002...
  • Page 136 This appears to be impossible to do if the hinges are in place, and the glue could get into the hinges—not an appealing idea if you are using epoxy. F.8L Falco Construction Manual 18–3 Revision 4, March 1, 2002...
  • Page 137 Glue the sandpaper to the board with contact cement. You will be able to purchase a contact cement made for gluing sandpaper discs to disc sanders at the F.8L Falco Construction Manual 18–4 Revision 4, March 1, 2002...
  • Page 138 Sta. 1. and outboard of Sta. 5. Lay a piece of masking tape along the leading edge F.8L Falco Construction Manual 18–5...
  • Page 139 (see Drawing No. 402). The cable should then be removed for the rest of the skinning operation. See Figure 10. F.8L Falco Construction Manual 18–6 Revision 4, March 1, 2002...
  • Page 140 Note: Draw a line to mark the end of the scarf. If you are using a 12/1 scarf, then the scarf will be 18mm wide with 1.5mm plywood (12 x 1.5 = 18) and 14.4mm wide with 1.2mm F.8L Falco Construction Manual 18–7...
  • Page 141 ❏ Use alignment pins for the upper skins and mask the inside for varnishing. Draw the internal structure on the outside of the skin for stapling or nailing during the skinning process. F.8L Falco Construction Manual 18–8 Revision 4, March 1, 2002...
  • Page 142 3/16”Ø or 1/4”Ø. It is only important that they be kept open and drain water. You will also be able to install seaplane grommets later on. These are streamlined covers which keep water from being blown into the holes. F.8L Falco Construction Manual 18–9 Revision 4, March 1, 2002...
  • Page 143 ❏ Scarf these fairing skins to match the scarf at the Sta. 1 rib. ❏ Mark the fairings skins for varnishing. ❏ Drill 1/8”Ø drain holes in the bottom of the fairing skins as shown on Drawing No. 402. F.8L Falco Construction Manual 18–10 Revision 4, March 1, 2002...
  • Page 144 This is best shown on Drawing No. 403. See Drawing No. 402, Detail A, for the location of the screw holes. See Drawing No. 402, Section C-C, for the screws installation. F.8L Falco Construction Manual 18–11 Revision 4, March 1, 2002...
  • Page 145 F.8L Falco Construction Manual 18–12 Revision 4, March 1, 2002...

  • Page 146: Stabilizer Assembly

    These strips are shown on Drawings No. 404 and 405, which are very accurately drawn. Thus, we suggest that you take the necessary measurements from these drawings. See Figure 2. F.8L Falco Construction Manual 19-1 Revision 4, March 1, 2002...
  • Page 147 ❏ Trial fit the forward stabilizer spar. See Figure 4. Check to make sure that the forward face of the forward stabilizer spar is 350mm from the aft face of the main stabilizer spar. F.8L Falco Construction Manual 19-2 Revision 4, March 1, 2002...
  • Page 148 ❏ Fit the leading edge rib for Sta. 1 and 6 (P/N 404-5 and 405-11) in place. These ribs must be placed very accurately, since they will be used to align all of the ribs in between. See Figure 7. F.8L Falco Construction Manual 19-3 Revision 4, March 1, 2002...
  • Page 149 ❏ Fit the leading edge strip to the ribs and clamp in place. See Figure 9. Check the stabilizer for alignment. See Drawing No. 402 for the dimensions for the leading edge strip. F.8L Falco Construction Manual 19-4 Revision 4, March 1, 2002...
  • Page 150 Note: At this time you should review your plans for your Falco. If you plan to install a Loran antenna, you may want to install a ground plane wire in the stabilizer. F.8L Falco Construction Manual 19-5 Revision 4, March 1, 2002...
  • Page 151 Use small nails as alignment pins. ❏ Scarf the skins at Sta. 1 for the inboard stabilizer skin that will be installed after the stabilizer is installed on the fuselage (see Drawing No. 401). F.8L Falco Construction Manual 19-6 Revision 4, March 1, 2002...
  • Page 152 Also, it would be an excellent idea to install the elevator on the hinges at this time so that you will know if you are bowing the stabilizer spar. F.8L Falco Construction Manual 19-7 Revision 4, March 1, 2002...
  • Page 153 ❏ Glue on the top stabilizer skin. This skin will extend from the tip of the stabilizer to Sta. 1. Scuff sand the plywood before gluing. ❏ Feather top skin at leading edge. Sand ends of the stabilizer to a smooth radius. F.8L Falco Construction Manual 19-8 Revision 4, March 1, 2002...

  • Page 154: Rudder Assembly

    You should remember that the fin spars are glued to the stabilizer spars and that gluing strips are installed on the forward and aft faces of the fin and stabilizer spars. The surfaces that are to be glued should not be varnished. F.8L Falco Construction Manual 20–1 Revision 4, March 1, 2002...
  • Page 155 ❏ At the bottom of the rudder, install the diagonal leading edge rib, P/N 414-3, and the piece of spruce along the bottom of the rudder. See Figure 3. Scuff-sand the plywood before gluing. Figure 4 F.8L Falco Construction Manual 20–2 Revision 4, March 1, 2002...
  • Page 156 ❏ Fit the trailing edge ribs for Sta. 1, 2, 3 and 4. Do not fit the Sta. 0 diagonal rib at this time. See Figure 6. Figure 6 ❏ Sand these trailing edge ribs to the angle required for the trailing edge strip. F.8L Falco Construction Manual 20–3 Revision 4, March 1, 2002...
  • Page 157 If you do this, first ream the screw holes for the channel-nuts with a No. 27 (.1440”Ø) drill. Scuff-sand the plywood before gluing. ❏ Glue the trailing edge strip in place. See Figure 8. F.8L Falco Construction Manual 20–4 Revision 4, March 1, 2002...
  • Page 158 ❏ Fit the leading edge skin. This will extend from the very bottom of the rudder to the upper face of the rib at Sta. 4-1/2. Do not bend the plywood at this time. See Figure 10. F.8L Falco Construction Manual 20–5...
  • Page 159 After the glue is dry, the plywood may be sanded to a smooth shape. F.8L Falco Construction Manual 20–6...
  • Page 160 14.4mm wide with 1.2mm plywood (12 x 1.2 = 14.4). This can be sanded with a drum sander in an electric drill (work very carefully!) and finished off with a sanding block. Figure 13 F.8L Falco Construction Manual 20–7 Revision 4, March 1, 2002...
  • Page 161 Scuff-sand the plywood before gluing. ❏ Varnish the inside of the right trailing edge skin, and all other internal surfaces that will not be glued. F.8L Falco Construction Manual 20–8 Revision 4, March 1, 2002...
  • Page 162 ❏ Cut out the opening required for the tail light. See Drawing No. 411, Detail A. ❏ Install the two spruce blocks required for the tail light. Scuff-sand the plywood before gluing. See Figure 17. F.8L Falco Construction Manual 20–9 Revision 4, March 1, 2002...
  • Page 163 F.8L Falco Construction Manual 20–10 Revision 4, March 1, 2002...

  • Page 164: Fin Assembly

    Some builders have gone to great difficulty to taper the triangular strips prior to gluing them in place. We feel that the easiest method is to use 15x15 triangular strips and glue F.8L Falco Construction Manual 21–1 Revision 4, March 1, 2002...
  • Page 165 Loran antenna on the forward face of the main fin spar, you should run this wire now. You may drill some holes in the ribs for this wire, but if the wire is small, a small groove may be cut in the braces of the spar. F.8L Falco Construction Manual 21–2 Revision 4, March 1, 2002...
  • Page 166 The distance from the aft face of the main fin spar to the aft face of the forward fin spar should be 375mm, but with F.8L Falco Construction Manual 21–3...
  • Page 167 ❏ Glue the forward fin spar to these ribs, but do not glue the forward fin spar to the forward stabilizer spar. Clamp to the forward stabilizer spar during this gluing operation. See Figure 6. Scuff-sand the plywood before gluing. F.8L Falco Construction Manual 21–4 Revision 4, March 1, 2002...
  • Page 168 ❏ Glue the leading edge ribs for Sta. 2 and 5 in place. ❏ Stretch a string across the ribs at Sta. 2 and 5. See Figure 7. This is to align the remaining ribs. F.8L Falco Construction Manual 21–5 Revision 4, March 1, 2002...
  • Page 169 See Chapter 19, Figure 10. A small block of wood is inserted into the gusset pocket for clamping. F.8L Falco Construction Manual 21–6 Revision 4, March 1, 2002...
  • Page 170 Do this for both the left and right skins. Note: Remember the importance of the moisture content of the skins. See the note in the section on skinning the stabilizer. F.8L Falco Construction Manual 21–7 Revision 4, March 1, 2002...
  • Page 171 This copper tape is easily broken, so roll the tape into a tight coil and tape to the bottom of rib No. 2 with masking tape. F.8L Falco Construction Manual 21–8 Revision 4, March 1, 2002...
  • Page 172 ❏ Glue on the left skin. This skin will extend from the top of the fin to the rib at Sta. 2. Scuff-sand the plywood before gluing. ❏ Feather the left skin at the leading edge. ❏ Sand a smooth radius on the top of the fin. F.8L Falco Construction Manual 21–9 Revision 4, March 1, 2002...
  • Page 173 F.8L Falco Construction Manual 21–10 Revision 4, March 1, 2002...

  • Page 174: Aileron/Flap Assembly

    Figure 1 shows details for fabric covered ailerons and flaps. The spruce trailing edge strip may not be reduced in dimension since the full width is needed to carry the fabric tension. F.8L Falco Construction Manual 22–1 Revision 4, March 1, 2002...

  • Page 175: Aileron/Flap Hinge Installation

    These will be installed after all of the hinge bolt holes are drilled. ❏ Install the channel-nuts for P/N 748. Do not install the screws for the channel-nuts at this time. F.8L Falco Construction Manual 22–2 Revision 4, March 1, 2002...
  • Page 176 ❏ Mark cutouts in the aft wing spar for the flap pushrod. See Drawing No. 206. ❏ Cut out the holes for the aileron and flap pushrods as noted above. F.8L Falco Construction Manual 22–3 Revision 4, March 1, 2002...

  • Page 177: Aileron/Flap Assembly

    2. These dimensions allow about 25mm of extra material. You may want to increase the widths of the upper leading edge skins by 20mm (to 220 and 200) for extra material required by the 20x20-glued-to-an-overhang method of bending the plywood. F.8L Falco Construction Manual 22–4 Revision 4, March 1, 2002...
  • Page 178 (The bottom of the aileron/flap spar is calculated from 69.0 at station 1—a theoretical point—and 71.0 at station 14.) F.8L Falco Construction Manual 22–5 Revision 4, March 1, 2002...
  • Page 179 The length of the long face not terribly important—150mm will be fine. Cut the corner away so that glue squeeze-out will not glue the angle guide to the ribs and F.8L Falco Construction Manual 22–6 Revision 4, March 1, 2002...
  • Page 180 14 ribs will fit into the notches or the trailing edge strip will not fit into place since one rib can prevent it from mating. F.8L Falco Construction Manual 22–7 Revision 4, March 1, 2002...
  • Page 181 See Figure 10. Check to make sure the leading edge ribs at the hinge openings will clear the hinge bases of the hinges installed on the aft wing spar—see Drawing No. 204. Figure 11 F.8L Falco Construction Manual 22–8 Revision 4, March 1, 2002...
  • Page 182 ❏ Screw blocks to the jig table to keep the assembly from sliding around while you float sand. These should fit against the spars and ribs. ❏ Float sand the top of the ailerons and flaps to prepare for skinning. Figure 13 F.8L Falco Construction Manual 22–9 Revision 4, March 1, 2002...
  • Page 183 ❏ Fit the upper leading edge skins. Soak the plywood in water for 24 hours, clamp in place to bend. See Figure 15. This will be done with 3 pieces of plywood—Sta. 2-6, 6-10 and 10-14. F.8L Falco Construction Manual 22–10 Revision 4, March 1, 2002...
  • Page 184 Before installation, scarf for the joint for the trailing edge skin and the next outboard skin. Figure 18 F.8L Falco Construction Manual 22–11 Revision 4, March 1, 2002...
  • Page 185 At this time, you do not have to do any varnishing of the aft ribs or aft face of the spar. ❏ Mask off the gluing surfaces of the upper leading edge skins and varnish in preparation for skinning. F.8L Falco Construction Manual 22–12 Revision 4, March 1, 2002...
  • Page 186 Figure 23 F.8L Falco Construction Manual 22–13 Revision 4, March 1, 2002...
  • Page 187 ❏ Trace the outline of the spar, ribs and trailing edge strip on the under surface of the upper trailing edge skins in preparation for varnishing. F.8L Falco Construction Manual 22–14 Revision 4, March 1, 2002...
  • Page 188 ❏ Mask off the gluing surfaces of the upper trailing edge skins and varnish in preparation for skinning. F.8L Falco Construction Manual 22–15 Revision 4, March 1, 2002...
  • Page 189 ❏ Sand a small radius on the lower leading edge, where the two leading edge skins meet. ❏ Re-install the aileron and flap hinges. Do not cut aileron/flap assembly in two at this time. The assembly should be in one piece when the wing is assembled. F.8L Falco Construction Manual 22–16 Revision 4, March 1, 2002...

  • Page 190: Wing, Preliminary Assembly

    The tapered reamer may be purchased from a local machine tool supply company or from Travers Tool Company (see F.8L Falco kit price list). The 5.00x5 tires and tubes may be purchased from a local FBO or from one of the many catalogue companies listed in the Appendix A “Sources”.
  • Page 191 Locate and mark the chord line. Also locate and mark the upper and lower final trim lines on the aft face of the spar. F.8L Falco Construction Manual 23–2 Revision 4, March 1, 2002...
  • Page 192 No. 4 is also W.L. –355. Thus the spar and frame No. 4 are glued together so that the top of the spar matches the top of frame No. 4. F.8L Falco Construction Manual 23–3 Revision 4, March 1, 2002...
  • Page 193 This method is based on the happy circumstance that the inside diameter of P/N 766 is the same as the outside diameter of P/N 768—a remarkable bit of serendipity that makes for an easy, precise alignment of the landing gear fittings. Figure 2 F.8L Falco Construction Manual 23–4 Revision 4, March 1, 2002...
  • Page 194 ❏ Use three small dabs of epoxy and glue P/N 766 to the wing spar. This will hold the fitting in place for drilling, and then the fitting can be knocked loose. F.8L Falco Construction Manual 23–5 Revision 4, March 1, 2002...
  • Page 195 In the following steps you will locate and install the landing gear side load fittings. These fittings are located relative to B.L. 927.5 and the landing gear water line. Figure 6 F.8L Falco Construction Manual 23–6 Revision 4, March 1, 2002...
  • Page 196 The Sta. 1 wing rib will be very close to this fitting so you should not varnish under the fitting until the rib is installed. Figure 7 ❏ Install P/N 706 and 773 as shown in Figure 7. See Drawing No. 102. Figure 8 F.8L Falco Construction Manual 23–7 Revision 4, March 1, 2002...

  • Page 197: Main Wing Spar/Fuselage Frame No. 4

    Lay the fuselage frames on this template. When all of your dimensions are taken from the same template you can be assured that they will all be the same. F.8L Falco Construction Manual 23–8 Revision 4, March 1, 2002...
  • Page 198 ❏ Glue frame No. 4 to the main wing spar. Make sure that the frame is correctly positioned on the main wing spar. This is an important glue joint, so you should exercise great care in using the proper gluing technique. F.8L Falco Construction Manual 23–9 Revision 4, March 1, 2002...
  • Page 199 60x30 from solid spruce or 6mm thick plywood and glue several pieces of plywood together to get the desired thickness. Drawing No. 102 also shows a good view of these gussets. F.8L Falco Construction Manual 23–10 Revision 4, March 1, 2002...
  • Page 200 ❏ Install the 20x20 spruce piece on the forward face of frame No. 4 as shown on Drawing No. 315. See Figure 13. This should be notched at four places for the 30x15 flooring F.8L Falco Construction Manual 23–11 Revision 4, March 1, 2002...

  • Page 201: Forward Wing Spar/Fuselage Frame No. 3

    No. 3. Mask off these soon- to-be-interior surfaces and varnish. ❏ Varnish all interior surfaces of frame No. 3 which will not be glued when this frame is glued to the forward wing spar. F.8L Falco Construction Manual 23–12 Revision 4, March 1, 2002...
  • Page 202 ❏ Per Revision A28b, drill the two holes for the battery cables. These holes are on the left side only and should be drilled through the front wing spar and then through frame No. 3. ❏ Ream the bushings of P/N 764 with a 1/4” reamer. F.8L Falco Construction Manual 23–13 Revision 4, March 1, 2002...
  • Page 203 Drawing No. 725-1 has been eliminated. For the installation of the pulley on the bracket, see Detail R Drawing No. 201 Sheet 4. F.8L Falco Construction Manual 23–14 Revision 4, March 1, 2002...
  • Page 204 Some tests might be in order to see if it is as strong as spruce. If the flox has sufficient strength, then the gluing strips may be installed early, and flox used during the skinning. F.8L Falco Construction Manual 23–15 Revision 4, March 1, 2002...
  • Page 205 Sta. 2 and 3. This can be seen on Drawing No. 315. The installation of this lower floor is optional and will put your feet in a more comfortable F.8L Falco Construction Manual 23–16 Revision 4, March 1, 2002...

  • Page 206: Fuselage Frame No. 5

    ❏ Cut the five longeron cutouts in fuselage frame No. 5 as shown in Figure 21. As with all other fuselage frames, a master template should be used to locate the longeron cutouts. See Drawing No. 310. F.8L Falco Construction Manual 23–17 Revision 4, March 1, 2002...
  • Page 207 Figure 23 ❏ Install the fuse holder for F5 and F6 fuses on the aft face of fuselage frame No. 5 as shown in Figure 23. F.8L Falco Construction Manual 23–18 Revision 4, March 1, 2002...
  • Page 208 Figure 24. Because the rings are installed with the center of the axle—and therefore the center of these rings—forward of the frame, the slots for the rings are at an angle. The slots for the upper rings should be 15mm. F.8L Falco Construction Manual 23–19 Revision 4, March 1, 2002...

  • Page 209: Fuselage Frame No. 6

    ❏ Draw the interior structure of the frame on the outside of the plywood. This is particularly important for this frame since many electrical devices will be installed on the aft face. F.8L Falco Construction Manual 23–20 Revision 4, March 1, 2002...
  • Page 210 ❏ Clamp P/N 805 in place and use a 3/16”Ø transfer punch to locate the six 3/16”Ø holes. ❏ Drill the six 3/16”Ø holes in P/N 805 using a drill press. F.8L Falco Construction Manual 23–21 Revision 4, March 1, 2002...
  • Page 211 Drawing No. 117, Detail A. The clamp should be installed in the rectangular opening for the elevator pushrod with the cable as far to the left side of the aircraft as possible. Figure 28 F.8L Falco Construction Manual 23–22 Revision 4, March 1, 2002...
  • Page 212 The gluing strip above the gusset should begin at a point about 10mm above the luggage compartment floor, thus making room for a 10mm strip which will be installed fore-and-aft along the base of the inside side wall. F.8L Falco Construction Manual 23–23 Revision 4, March 1, 2002...

  • Page 213: Control Stick Assembly

    ❏ Drill 5/16”Ø holes in the bottom forward face of the control sticks and install the MS35489-4 grommets for the wiring in these holes. These grommets are supplied as part of the electrical kit. See Figure 31. F.8L Falco Construction Manual 23–24 Revision 4, March 1, 2002...

  • Page 214: Landing Gear Retraction Gearbox Assembly

    ❏ For easier assembly, install P/N 623 bushing in each end of each MS20271-B14 universal joint with Loctite. See Drawing No. 102. Allow it to harden for several hours. F.8L Falco Construction Manual 23–25 Revision 4, March 1, 2002...
  • Page 215 Figure 34. Line up hole in miter gear with the hole in the shaft and drill through with a 11/64”Ø drill, then ream with a 3/16”Ø reamer. Use a drill press, or the drill will “wander”. Install the roll pin. F.8L Falco Construction Manual 23–26 Revision 4, March 1, 2002...
  • Page 216 You may find it hard to believe, but this is the industry- standard method of installing gears. Figure 35 ❏ Align the shaft so that the miter gear runs nicely with P/N 520-4. Use the kraft paper method described above. F.8L Falco Construction Manual 23–27 Revision 4, March 1, 2002...
  • Page 217 ❏ When you have everything firmly in place, drill 11/64” and then ream with a 3/16” reamer for the lower miter gear. Install the roll pin for the miter gear. F.8L Falco Construction Manual 23–28 Revision 4, March 1, 2002...
  • Page 218 The end of the screwjack has a short end to the shaft, shorter than the end of the universal joint. F.8L Falco Construction Manual 23–29 Revision 4, March 1, 2002...
  • Page 219 ❏ Install P/N 603 screwjack ends in P/N 512-1 and 512-2 screwjack sleeves as shown in Detail E of Drawing No. 102. See Figure 39. The nut must be finger tight only. F.8L Falco Construction Manual 23–30 Revision 4, March 1, 2002...
  • Page 220 ❏ You must align the shaft and miter gear so that it runs smoothly with the miter gear on the vertical shaft. Put the two universal joints (with the screwjacks and screwjack sleeves F.8L Falco Construction Manual 23–31 Revision 4, March 1, 2002...
  • Page 221 Figure 43. The shoulder screw should be installed with Loctite, but first check to make sure that the handle will turn freely with the shoulder screw tightened all the way. If F.8L Falco Construction Manual 23–32 Revision 4, March 1, 2002...

  • Page 222: Main Landing Gear Assembly

    ❏ If the oleo strut is not 440mm long, deflate the strut and disassemble the strut. The oleo valve is a high pressure valve and to deflate the strut you must back off the upper (5/8”) F.8L Falco Construction Manual 23–33...
  • Page 223 Do not paint the two bearing surfaces of the landing gear leg, i.e., where the leg pivots in the fittings installed in the wing. F.8L Falco Construction Manual 23–34 Revision 4, March 1, 2002...

  • Page 224: Main Landing Gear Bushings Installation

    To install the grease fitting, the tiny grease fitting must be unscrewed from its F.8L Falco Construction Manual 23–35 Revision 4, March 1, 2002...

  • Page 225: Wing Rib Preparation

    • Corner block for Sta. 1, 2, 3 and 4 at the main wing spar and forward wing spar. • Possible access door installation for autopilot servo on inboard face of Sta. 1. F.8L Falco Construction Manual 23–36 Revision 4, March 1, 2002...

  • Page 226: Wing Skins

    Sta. 1 to Sta. 6 Upper Wing Skin Grain Direction Figure 45 ❏ Use two 50”x50” sheets of 2.5mm birch plywood as shown in Figure 45. Cut to fit the aircraft. F.8L Falco Construction Manual 23–37 Revision 4, March 1, 2002...
  • Page 227 Sta. 1 Inboard Bottom Wing Skin Sta. 1 Inboard Bottom Wing Skin Grain Direction Figure 48 ❏ Use one 50”x50” sheet of 2mm birch plywood and cut in accordance with Figure 48. F.8L Falco Construction Manual 23–38 Revision 4, March 1, 2002...
  • Page 228 ❏ Use two 50”x50” sheets of 1.5mm birch plywood as shown in Figure 50. Cut the wheel well and wing tip skins and then cut the wing skins to fit the aircraft. F.8L Falco Construction Manual 23–39 Revision 4, March 1, 2002...
  • Page 229 F.8L Falco Construction Manual 23–40 Revision 4, March 1, 2002...

  • Page 230: Wing Assembly

    Remove the braces and cut the slots. The two rectangular holes are for the flap torque tube and control stick assembly. Trial fit the fuselage centerboard to each fuselage frame (and each wing spar) that will be installed in the jig. W.L.0 17.4 Figure 1 F.8L Falco Construction Manual 24–1 Revision 4, March 1, 2002...
  • Page 231 The centerboard should be supported in some manner. Some builders support it with diagonal braces from the floor, as shown in Figure 2. Others clamp, screw or nail the top of the board to the ceiling of the shop. F.8L Falco Construction Manual 24–2 Revision 4, March 1, 2002...
  • Page 232 This diagonal brace was screwed to the Sta. 1 template and a support from fuselage frame No. 6 extended out the the wing template. Other builders have F.8L Falco Construction Manual 24–3 Revision 4, March 1, 2002...
  • Page 233 1/8” or so, and the alignment string can be stretched from the Sta. 14 template to the centerboard. When everything is in alignment, the string will be centered in the little “gun sight” provided by the screweye. F.8L Falco Construction Manual 24–4 Revision 4, March 1, 2002...

  • Page 234: Wing Assembly

    ❏ Use a water level to level the main wing spar. Use the aft face of the spar and measure from each wing tip. Also check to make sure that the wing tips are the same level as the F.8L Falco Construction Manual 24–5...
  • Page 235 Remember, the trailing edge string should arrive at a common point at the center of the aircraft. This is an automatic check that both wings are the same. ❏ Install the aileron cable pulleys on the inboard face of the wing rib at Sta. 2.. F.8L Falco Construction Manual 24–6 Revision 4, March 1, 2002...
  • Page 236 ❏ Glue the front wing spar to the intermediate leading edge ribs. The landing gear leg must be in place during this operation. F.8L Falco Construction Manual 24–7 Revision 4, March 1, 2002...
  • Page 237 ❏ Clamp the remaining leading edge ribs in place as shown in Figure 8. Sand the aft faces of the ribs as necessary for alignment with the leading edge alignment string. F.8L Falco Construction Manual 24–8 Revision 4, March 1, 2002...
  • Page 238 ❏ Sand or plane the leading edge strip to the approximate airfoil contour. This will save you a lot of sanding while it is glued in place. ❏ Glue the leading edge strip in place. Figure 10 F.8L Falco Construction Manual 24–9 Revision 4, March 1, 2002...
  • Page 239 ❏ Install a plywood plate over the end of the front wing spar to cover the end grain of the wood since end grain can sometimes cause the finish to crack. F.8L Falco Construction Manual 24–10 Revision 4, March 1, 2002...
  • Page 240 ❏ Install two P/N 765 on each end of the flap torque tube. See Drawing No. 201, Sheet 4. If the AN23-31 bolts are too short (some builders have reported this) the bronze bushings may be shortened on the outboard end by filing. F.8L Falco Construction Manual 24–11 Revision 4, March 1, 2002...
  • Page 241 Note: In the following steps you will sand the ribs to fit the aft wing spar. At the same time you will fit the aft wing spar to the forward face of fuselage frame No. 6. You will F.8L Falco Construction Manual 24–12...
  • Page 242 ❏ Install P/N 713A on the flap torque tube. See Drawing No. 201, Sheet 4. Remove P/N 743 from the flap and install on the support hinges (P/N 742) on the aft wing spar. ❏ Clamp the Sta. 2 wing rib in place. F.8L Falco Construction Manual 24–13 Revision 4, March 1, 2002...
  • Page 243 Check the alignment with the trailing edge string. ❏ Clamp the trailing edge rib for wing Sta. 14 to the aft wing spar. Check the alignment with the trailing edge string. F.8L Falco Construction Manual 24–14 Revision 4, March 1, 2002...
  • Page 244 This is also a convenient time to skip ahead and cut the wing skins. In particular, the skins for Sta. 1 to 6 require that a piece be scarfed and glued on to accommodate the trailing edge between Sta. 1 and 2. F.8L Falco Construction Manual 24–15 Revision 4, March 1, 2002...
  • Page 245 The “open air” wheel well uses four 30x15 seat supports. The wheel well door installation has two 60x15 seat supports inboard and two 30x15 outboard. F.8L Falco Construction Manual 24–16 Revision 4, March 1, 2002...
  • Page 246 4mm above the top of fuselage frame No. 5 at the forward face. This will place the F.8L Falco Construction Manual 24–17...
  • Page 247 See Figure 24. ❏ For wheel well door installation—fit the four seat supports in place. See Figure 25. Remember the inboard supports are 60x15 and the outboard supports are 30x15. F.8L Falco Construction Manual 24–18 Revision 4, March 1, 2002...
  • Page 248 15mm deep, thus the bottom of the ring must be notched as well. See Figure 26. ❏ For wheel well door installation—sand the upper wheel well rings to the approximate contour of the seat supports. F.8L Falco Construction Manual 24–19 Revision 4, March 1, 2002...
  • Page 249 This may be seen on Detail S and Detail T of Drawing No. 201, Sheet 4. This is part of the framing for the access panel for the removal of the landing gear leg. F.8L Falco Construction Manual 24–20 Revision 4, March 1, 2002...
  • Page 250 10x10 spruce strips which follow the lower wing contour and then up on the inboard face of the Sta. 2-1/2 rib and the outboard face of the Sta. 2 rib to the 10x40 F.8L Falco Construction Manual 24–21...
  • Page 251 75x15 piece of spruce between the seat supports. It is also a very good idea to install plywood over these corner blocks on the bottom to reinforce the end grain joints—a 2mm plywood gusset at each end will do. F.8L Falco Construction Manual 24–22 Revision 4, March 1, 2002...
  • Page 252 (With the aileron and flap trailing edge still installed as one piece in the wing, the aileron must be in the neutral position.) F.8L Falco Construction Manual 24–23 Revision 4, March 1, 2002...
  • Page 253 Sheet 1. The reason for this break in the conduit is that the wiring for the heated pitot must be routed to the pitot tube. Note that the 1/4” O.D. pitot line will also be routed with the conduit in the left wing. F.8L Falco Construction Manual 24–24 Revision 4, March 1, 2002...
  • Page 254 The fuel tank vent lines (1/4” O.D. nylon tubing) will be routed from the cockpit to this access area. These vent lines may be F.8L Falco Construction Manual 24–25 Revision 4, March 1, 2002...
  • Page 255 See the instructions in Chapter 14 “Antenna Installation”. See Drawing No. 160 and 162. F.8L Falco Construction Manual 24–26 Revision 4, March 1, 2002...

  • Page 256: Skinning The Wing

    F.8L Falco Construction Manual 24–27 Revision 4, March 1, 2002...
  • Page 257 Note: On the upper wing skin, the landing gear bay and access area between Sta. 2 and 2- 1/2 does not need to be varnished at this time since it will be accessible later. F.8L Falco Construction Manual 24–28 Revision 4, March 1, 2002...
  • Page 258 ❏ As shown in Figure 39, cut the bottom skin for the landing gear nut access panel, for the wheel well and for the access panel between Sta. 2 and 2-1/2. ❏ Locate and drill the hole for the jack pad fitting. F.8L Falco Construction Manual 24–29 Revision 4, March 1, 2002...
  • Page 259 ❏ Trace the outline of the ribs and spars on the inside surface of the upper wing skin for varnishing. ❏ Draw the internal structure of the wing on the outside of the skin to assist in nailing or stapling when the skin is installed. F.8L Falco Construction Manual 24–30 Revision 4, March 1, 2002...
  • Page 260 ❏ At the leading edge, scarf the plywood for the lower wing skin to receive the upper wing skin between Sta. 6 and 10. This scarf is a rounded type of scarf, due to the radius of the leading edge. F.8L Falco Construction Manual 24–31 Revision 4, March 1, 2002...
  • Page 261 ❏ Draw the internal structure of the wing on the outside of the skin to assist in nailing or stapling when the skin is installed. ❏ Mask and varnish the inside surface of the upper wing skin between Sta. 10 and 14. F.8L Falco Construction Manual 24–32 Revision 4, March 1, 2002...
  • Page 262 ❏ Put the aileron and flap back on the wing and check the movement of these control surfaces. You may need to “adjust” the openings in the main and aft spars for the pushrods. ❏ Cut the opening for the aileron bellcrank access panel. F.8L Falco Construction Manual 24–33 Revision 4, March 1, 2002...
  • Page 263 ❏ Glue on the upper wing skin between Sta. 10 and 14. Check the alignment of the wing. After this skin is glued in place, the wing will be torsionally rigid. Use plywood nailing strips over the scarfed plywood. F.8L Falco Construction Manual 24–34 Revision 4, March 1, 2002...
  • Page 264 ❏ Use a back rabbet bit and rout the plywood for the three access panels in each wing. Figure 47 ❏ Make and install the three access panels. See Figure 47. F.8L Falco Construction Manual 24–35 Revision 4, March 1, 2002...
  • Page 265 ❏ As shown in Figure 49, use a small piece of plywood to simulate this skin and drill the holes through fuselage frame No. 6 and the gluing strip on the aft face for the outboard seat belt fittings. See Drawing No. 123. F.8L Falco Construction Manual 24–36 Revision 4, March 1, 2002...
  • Page 266 30x15 seat supports. ❏ Mark offset lines on the already-installed skin so that you can accurately locate the seat supports once the inboard skin is glued in place. Figure 51 F.8L Falco Construction Manual 24–37 Revision 4, March 1, 2002...
  • Page 267 ❏ When dry, cut off the extra inboard material and scarf this skin for the joint at Sta. 14. ❏ Draw the internal structure of the wing on the outside of the skin to assist in nailing or stapling when the skin is installed. F.8L Falco Construction Manual 24–38 Revision 4, March 1, 2002...
  • Page 268 ❏ In preparation for closing, varnish the interior surfaces of the wing tip except for those areas to be glued. Figure 53 ❏ Glue on the upper wing tip skin. ❏ Sand the wing tip to a smooth radius. F.8L Falco Construction Manual 24–39 Revision 4, March 1, 2002...
  • Page 269 ❏ Install the wing tip lens. ❏ Remove the wing from the jig and place in a horizontal position in preparation for the fuselage assembly. F.8L Falco Construction Manual 24–40 Revision 4, March 1, 2002...

  • Page 270: Fuselage, Preliminary Assembly

    We believe that the cowling supports should be installed now for the quickest and easiest construction, but there is really nothing wrong with installing them later. F.8L Falco Construction Manual 25–1 Revision 4, March 1, 2002...

  • Page 271: Nose Gear Assembly

    ❏ Drill completely through P/N 658 and P/N 657 bushings with a #3 (.213”Ø) drill. This is for the two grease fittings shown. ❏ Tap the two holes with a 1/4-28 tap for the two grease fittings. F.8L Falco Construction Manual 25–2 Revision 4, March 1, 2002...
  • Page 272 6 to 8mm above the base and paint with zinc chromate primer. Just before assembly, brush a coat of zinc chromate primer on the mating surfaces and assemble wet. This will prevent moisture from entering and creating corrosion. F.8L Falco Construction Manual 25–3 Revision 4, March 1, 2002...
  • Page 273 For this reason, do not install the locking screws in the upper ring nut, axle and axle nut at this time. F.8L Falco Construction Manual 25–4 Revision 4, March 1, 2002...
  • Page 274 Then replace the valve core and inflate the nose wheel tire to about 30 psi. ❏ Install the nose wheel in the nose gear fork using the axle, axle nut and spacers. Do not install the locking screws at this time. F.8L Falco Construction Manual 25–5 Revision 4, March 1, 2002...

  • Page 275: Engine Mount

    ❏ Install the nose gear assembly on the engine mount. See Drawing No. 105. You may have to file on the washers of the engine mount slightly to get a good fit. F.8L Falco Construction Manual 25–6 Revision 4, March 1, 2002...
  • Page 276 114. If the bolts are too tight in P/N 708, ream the holes with a 5/16” reamer or drill. ❏ Install P/N 619A on P/N 618A. See Drawing No. 105. ❏ Install P/N 619A (with the other parts installed) on the nose gear. See Drawing No. 105. F.8L Falco Construction Manual 25–7 Revision 4, March 1, 2002...

  • Page 277: Rudder Pedal Assembly

    Chapter 12 “Making the Fuselage Frames”. If you wish, you may just trace the shape of the existing fuselage frame No. 1, but we prefer the precise layout method. F.8L Falco Construction Manual 25–8 Revision 4, March 1, 2002...

  • Page 278: Fuselage Frame No. 1

    The bulkhead fitting which will be installed here has a maximum grip length of 5/16” and will grip both the firewall and the plywood on the forward face of the fuselage frame. F.8L Falco Construction Manual 25–9 Revision 4, March 1, 2002...
  • Page 279 W.L. –120. ❏ On the aft face of the fuselage frame, draw W.L. –150, B.L. 110 and B.L. 410 for the rudder pedal supports. See Drawing No. 114. F.8L Falco Construction Manual 25–10 Revision 4, March 1, 2002...
  • Page 280 ❏ Glue on the 2mm plywood pads on the face just closed. These pads are installed on both the forward and aft faces, so if they have not already been installed on the opposite face, do so now. Figure 10 F.8L Falco Construction Manual 25–11 Revision 4, March 1, 2002...
  • Page 281 During inverted flight or negative-G turbulence, the landing gear will “flop” up into the wheel wells as the springs are compressed. This is not desirable since it F.8L Falco Construction Manual 25–12 Revision 4, March 1, 2002...
  • Page 282 ❏ Drill the four holes through the triangular blocks. These holes are for the wiring. ❏ Drill the 7/16”Ø hole for the brake line. This hole is at the same location as the 40Ø hole in the underlying wood blocking. See Drawing No. 302. F.8L Falco Construction Manual 25–13 Revision 4, March 1, 2002...
  • Page 283 ❏ Drill the 3/16”Ø holes for the two P/N 772-10 exhaust hangers. See Drawing No. 302 for the location for these holes. F.8L Falco Construction Manual 25–14 Revision 4, March 1, 2002...
  • Page 284 The only purpose of this step is to correctly locate P/N 826. ❏ Drill the two 3/16”Ø holes for P/N 826 through the fuselage frame. F.8L Falco Construction Manual 25–15 Revision 4, March 1, 2002...
  • Page 285 ❏ If applicable, drill the four 3/16”Ø holes for the Christen P/N 802 oil valve. See Drawing No. 302 for the location of these holes. If possible, use the actual part to locate the holes. F.8L Falco Construction Manual 25–16...
  • Page 286 To allow for the 2mm plywood skin of the nose gear bay wall, the width (before application of the skin) should be 164mm. ❏ Cut the four 15x15 cutouts for the exhaust port framing. F.8L Falco Construction Manual 25–17 Revision 4, March 1, 2002...
  • Page 287 3/16”Ø holes and the centerline of P/N 734 should be located 12 to 13mm from the outside of the fuselage frame. This will put this point at the center of the lamination. F.8L Falco Construction Manual 25–18 Revision 4, March 1, 2002...
  • Page 288 These details can later be transferred to a cardboard template. As you add more parts to the aft face of the frame, you should update the template. F.8L Falco Construction Manual 25–19 Revision 4, March 1, 2002...
  • Page 289 ❏ Install the two 30x11 spruce pieces on the aft face of fuselage frame No. 1. See Drawing No. 121. Figure 20 ❏ Install P/N 116-62 alternator shunt and the fuse holder for F3 and F4 fuses on the aft face of frame No. 1. F.8L Falco Construction Manual 25–20 Revision 4, March 1, 2002...
  • Page 290 ❏ Clamp the firewall in place on the forward face of fuselage frame No. 1. ❏ Use a transfer punch to locate the centers of the holes through the firewall. F.8L Falco Construction Manual 25–21 Revision 4, March 1, 2002...
  • Page 291 5/8”Ø hole in the firewall. The screw holes for the cabin heat fitting must be located by doing a “rubbing” with paper and a soft lead pencil. Figure 23 F.8L Falco Construction Manual 25–22 Revision 4, March 1, 2002...
  • Page 292 ❏ If available, you may install P/N 867 fuel pump mounting bracket and P/N 879 gascolator mounting bracket on the bolts for the rudder pedals as shown in Figure 24. The support bracket for the Christen oil separator is also shown. F.8L Falco Construction Manual 25–23 Revision 4, March 1, 2002...
  • Page 293 (.166”Ø) drill. You will find this much easier if you have two drills. The screws should be located at B.L. 36, 130, 204 and 273 and about 10mm from the outside of the cowling support flange. F.8L Falco Construction Manual 25–24 Revision 4, March 1, 2002...
  • Page 294 ❏ When all of the screws are installed, use a transfer punch to locate the holes for the 3/16”Ø fuel tank band mount bolts. Use a transfer punch to locate the holes for the cowling support bolts just outboard of the exhaust port shield. F.8L Falco Construction Manual 25–25 Revision 4, March 1, 2002...

  • Page 295: Fuselage Frame No. 2

    ❏ Drill a small vent hole through the aft plywood face on the right side of the aircraft. ❏ Mask and varnish the inside of the plywood to be used to close the frame. Varnish the inside of the frame except for those areas to be glued. F.8L Falco Construction Manual 25–26 Revision 4, March 1, 2002...
  • Page 296 20x18 cutouts for the nose gear bay framing should be marked only. If you wish to start the sawcut, you may do so. F.8L Falco Construction Manual 25–27 Revision 4, March 1, 2002...
  • Page 297 ❏ On the right side of the aircraft, drill a 1/8”Ø hole just to the right of the top center longeron cutout. This hole will be used for a few small wires. F.8L Falco Construction Manual 25–28 Revision 4, March 1, 2002...
  • Page 298 ❏ If the lower floor is to be installed (see Drawing No. 315), install the flooring supports on the aft face of the frame. These supports may be 10x10 spruce as shown above, or you may use 10x15 spruce for greater strength under the cutouts. Figure 31 F.8L Falco Construction Manual 25–29 Revision 4, March 1, 2002...

  • Page 299: Fuselage Frame No. 7

    If the lower floor is installed (see Figure 30), then these gussets are not needed. Fuselage Frame No. 7 Figure 32 ❏ If not already done, install the tank support blocks and glue on all plywood gussets to “close” the frame. F.8L Falco Construction Manual 25–30 Revision 4, March 1, 2002...
  • Page 300 ❏ Cut the two 20x10 stringer cutouts. See Drawing No. 312. Use master template. ❏ Cut the two 30x15 cutouts for the shoulder belt support. See Drawing No. 312 and 123. F.8L Falco Construction Manual 25–31 Revision 4, March 1, 2002...
  • Page 301 315. See Drawing No. 315. Saddle gussets are not possible at this location. ❏ Install the saddle gussets for the 30x15 luggage compartment floor supports located at the junction of the luggage compartment floor and the inside fuselage skin. F.8L Falco Construction Manual 25–32 Revision 4, March 1, 2002...
  • Page 302 Above the upper side longerons there should be a 20mm gap in this strip. The reason for this is that the coaming will extend all the way back to the forward face of frame No. 7. Figure 36 F.8L Falco Construction Manual 25–33 Revision 4, March 1, 2002...

  • Page 303: Fuselage Frame No. 8

    B.L. 276. All of the holes should be centered on the lamination. ❏ If not already done, add a single 3mm strip of spruce to the forward frame to allow for sanding to the taper of the fuselage. F.8L Falco Construction Manual 25–34 Revision 4, March 1, 2002...

  • Page 304: Battery Box Lamination

    The lamination should be made to extend from W.L. 0 to W.L. 240. Per Drawing No. 301, the curve dimensions are: “L” = 415 and “S” = 309. F.8L Falco Construction Manual 25–35 Revision 4, March 1, 2002...

  • Page 305: Fuselage Frame No. 9

    ❏ Draw the installed location of the two 30x15 lower side longerons on the forward face of the frame. These are located at W.L. –350, like the other fuselage frames, but the frames are not cut out for the longerons. F.8L Falco Construction Manual 25–36 Revision 4, March 1, 2002...

  • Page 306: Fuselage Frame No. 10

    ❏ Install a spruce block on the horizontal brace as shown in Figure 41. This brace is 15mm high, 30mm wide at the top and its center is at B.L. 35 on the right side of the airplane. F.8L Falco Construction Manual 25–37...

  • Page 307: Fuselage Jig

    Notch the aft end of the jig for the channel-nut and bolt heads for the lower fin hinges. F.8L Falco Construction Manual 25–38 Revision 4, March 1, 2002...

  • Page 308: Fuselage Assembly, Part 1

    You should also consider some way of firmly securing the jig to the shop floor. When you work on the assembly of the fuselage, it is likely that you will bump against the structure and throw F.8L Falco Construction Manual 26–1...

  • Page 309: Fuselage Assembly

    The inboard support must be slightly lower than the outboard support. Install additional diagonal supports as shown in Figure 3. Cover the top of the supports with something soft—carpeting, old blankets—to protect the bottom of the wing. F.8L Falco Construction Manual 26–2 Revision 4, March 1, 2002...
  • Page 310 F.8L Falco Construction Manual 26–3 Revision 4, March 1, 2002...
  • Page 311 Two methods are shown in Figure 6. In addition, hardware stores sell floor levelers which may by used. Figure 7 F.8L Falco Construction Manual 26–4 Revision 4, March 1, 2002...
  • Page 312 11 over the jig. See Figure 8. Figure 9 ❏ Level the fuselage jig, align it with the wing and install the one-by-two’s for fuselage frames No. 3, 4, 5 and 6. See Figure 9. F.8L Falco Construction Manual 26–5 Revision 4, March 1, 2002...
  • Page 313 Figure 10 ❏ Install the one-by-two’s for fuselage frames No. 7, 8, 9, 10 and 11. Figure 11 ❏ Glue the fin spars to the horizontal stabilizer spars. See Figure 11. F.8L Falco Construction Manual 26–6 Revision 4, March 1, 2002...
  • Page 314 ❏ Install fuselage frame No. 2 on the jig with its “one by two” brace. See Figure 13. ❏ Install the engine mount and nose gear on fuselage frame No. 1. F.8L Falco Construction Manual 26–7 Revision 4, March 1, 2002...
  • Page 315 Align the frame so that the nose gear is located in the center of the nose gear bay. F.8L Falco Construction Manual 26–8 Revision 4, March 1, 2002...
  • Page 316 Note: In Figure 16 and thereafter, the engine mount and nose gear are not shown in the illustrations, but they should be left installed until the framework is solidly glued together. Figure 17 F.8L Falco Construction Manual 26–9 Revision 4, March 1, 2002...
  • Page 317 Clamp this longeron in position when finished. ❏ Sand the longeron cutouts to fit the bottom center longeron. The other longerons should hold the frames in position. Clamp this longeron in position when finished. F.8L Falco Construction Manual 26–10 Revision 4, March 1, 2002...
  • Page 318 Figure 19 ❏ Clamp the left 20x10 stringer in position. See Figure 19. Sand the cutouts to fit. ❏ Clamp the right 20x10 stringer in position. Sand the cutouts to fit. F.8L Falco Construction Manual 26–11 Revision 4, March 1, 2002...
  • Page 319 ❏ Check the alignment of the nose gear with the nose gear bay. The nose gear should be centered at the aircraft centerline. Adjust the position of frame No. 1. F.8L Falco Construction Manual 26–12 Revision 4, March 1, 2002...
  • Page 320 ❏ Glue the right side longeron in place. ❏ Glue the left 20x18 nose wheel bay framing strip in place. ❏ Glue the right 20x18 nose wheel bay framing strip in place. F.8L Falco Construction Manual 26–13 Revision 4, March 1, 2002...
  • Page 321 ❏ Fit the right cockpit coaming strip in place. ❏ Glue the left cockpit coaming strip in place. ❏ Glue the right cockpit coaming strip in place. F.8L Falco Construction Manual 26–14 Revision 4, March 1, 2002...
  • Page 322 No. 3. The purpose of this strip is to provide a gluing surface for the inside cockpit skin. ❏ In the same fashion, glue a strip of spruce on the inboard face of the right upper side longeron between frame No. 2 and 3. F.8L Falco Construction Manual 26–15 Revision 4, March 1, 2002...
  • Page 323 ❏ Fit and glue the two 35x150 corner blocks for the right side longeron at frame No. 1. F.8L Falco Construction Manual 26–16 Revision 4, March 1, 2002...
  • Page 324 ❏ Fit and glue the two 35x150 corner blocks for the bottom center longeron at the forward face of frame No. 8. ❏ Fit and glue the two 35x150 corner blocks for the bottom center longeron at the aft face of frame No. 8. F.8L Falco Construction Manual 26–17 Revision 4, March 1, 2002...
  • Page 325 ❏ Remove the clamps for the top center longeron at frames No. 7 and 8. Place a small block of wood under this longeron at frame No. 8 to provide room to install the diagonal frame No. 6. F.8L Falco Construction Manual 26–18 Revision 4, March 1, 2002...
  • Page 326 See Section D-D, Drawing No. 315. ❏ Glue the diagonal frame No. 6 in place. F.8L Falco Construction Manual 26–19 Revision 4, March 1, 2002...
  • Page 327 ❏ Sand the longeron cutout for the top center longeron in this diagonal frame. Clamp the top center longeron in place. Figure 30 ❏ Cut, fit and sand the cutouts for the 20x10 stringers in the diagonal frame. Clamp the 20x10 stringers in place. F.8L Falco Construction Manual 26–20 Revision 4, March 1, 2002...
  • Page 328 ❏ Glue the right 20x10 stringer in place. (The left 20x10 is not installed until after the battery box is completed.) ❏ Glue the 30x15 shoulder belt supports in place. F.8L Falco Construction Manual 26–21 Revision 4, March 1, 2002...
  • Page 329 ❏ Cut and fit the 15mm wide spruce tank support. See Figure 33. This strip of spruce is installed just under the forward top center longeron and is shown in Drawing No. 121. F.8L Falco Construction Manual 26–22 Revision 4, March 1, 2002...
  • Page 330 Figure 35 ❏ Cut the top of the diagonal frame No. 2 for the forward top center longeron, and glue the longeron and the diagonal frame in place. See Figure 35. F.8L Falco Construction Manual 26–23 Revision 4, March 1, 2002...
  • Page 331 40mm corner block on the forward face of the frame and upper face of the upper side longeron. See Figure 36. F.8L Falco Construction Manual 26–24 Revision 4, March 1, 2002...

  • Page 332: Fuselage Assembly, Part 2

    Figure 2. The vertical brace for the left nose gear bay wall is made of 20x18 spruce. The vertical brace of the right nose gear bay wall is made of 50x18 spruce as shown in Drawing No. 105. F.8L Falco Construction Manual 27–1 Revision 4, March 1, 2002...
  • Page 333 ❏ Fit and glue in place the extra blocking for the forward end of the nose gear bay. See Figure 4. These are not dimensioned on any drawing, but we suggest that the blocking end 70mm aft of the aft face of frame No. 1. F.8L Falco Construction Manual 27–2 Revision 4, March 1, 2002...
  • Page 334 No 3 as shown in Figure 6. Use a long drill to drill these holes from the right side of the airplane. The channel-nut for the rudder cable pulley must be removed for this operation. F.8L Falco Construction Manual 27–3...
  • Page 335 P/N 717-2 must be shorter, obviously. On the outside of the nose gear bay walls, the corner blocking must be notched to fit around the channel-nuts for P/N 717-2 and drilled for the rudder cables. F.8L Falco Construction Manual 27–4 Revision 4, March 1, 2002...
  • Page 336 To accommodate this, some builders have put 2mm-thick plywood plates between the forward face of frame No. 1 and the drag strut supports. F.8L Falco Construction Manual 27–5 Revision 4, March 1, 2002...

  • Page 337: Cockpit Flooring

    Our intent is to accomplish as much of this work as possible while the bottom side longerons are not installed for easier access. F.8L Falco Construction Manual 27–6 Revision 4, March 1, 2002...
  • Page 338 If you wish, you may notch the 30x15 pieces just enough so that the 15x15 are firmly located in place while gluing. Figure 12 F.8L Falco Construction Manual 27–7 Revision 4, March 1, 2002...
  • Page 339 ❏ Install corner blocks between the seat supports and the 20x20 spruce strip on the forward face of frame No. 6. The purpose of this is to provide some additional strength for the center seat belts. See Figure 14. F.8L Falco Construction Manual 27–8 Revision 4, March 1, 2002...
  • Page 340 No. 7, the best way to make the joint is to install a 25mm corner block on each side and glue a plywood gusset on the bottom. See Figure 16. F.8L Falco Construction Manual 27–9...
  • Page 341 You will have ample opportunities to varnish the bottom of the floor board later, so just glue the plywood in place. F.8L Falco Construction Manual 27–10 Revision 4, March 1, 2002...
  • Page 342 ❏ Fit and install the flooring between Sta. 2 and 3. Cut the holes for the rudder cables. Leave 10mm on the outboard edge for the gluing strips for the cockpit side walls. See Figure 20. F.8L Falco Construction Manual 27–11 Revision 4, March 1, 2002...
  • Page 343 Figure 22 ❏ Fit and install the flooring on the outboard sides of the luggage compartment. Leave 10mm for the side wall gluing strip. F.8L Falco Construction Manual 27–12 Revision 4, March 1, 2002...
  • Page 344 Drill the four 3/16” holes and set the power supply aside. Figure 24 F.8L Falco Construction Manual 27–13 Revision 4, March 1, 2002...
  • Page 345 ❏ Install the gluing strips for the inside cockpit side walls between Sta. 6 and 7 on each side of the aircraft. See Figure 25. ❏ In Chapter 25 you were supposed to make a rear cockpit bulkhead of 2mm plywood. If you didn’t, do it now. F.8L Falco Construction Manual 27–14 Revision 4, March 1, 2002...
  • Page 346 ❏ Install the two spruce blocks located at B.L. 200. These provide two places for screws to fasten the rear cockpit bulkhead. See Figure 27. F.8L Falco Construction Manual 27–15 Revision 4, March 1, 2002...

  • Page 347: Battery Box Installation

    Scottsdale, Arizona 85260. Telephone (602) 991-0110. ❏ Remove the 20x10 stringer on the left side of the airplane. It will just be in the way when you build the battery box. F.8L Falco Construction Manual 27–16 Revision 4, March 1, 2002...
  • Page 348 7.66” x 5.13” and the Electro Marketing is 7.75” x 5.2”. In all cases, the long dimension runs fore-and-aft. See Figure 30. ❏ Drill two 13/16”Ø holes as shown in Figure 30. These are for MS35489-14 grommets for the main battery wires. F.8L Falco Construction Manual 27–17 Revision 4, March 1, 2002...
  • Page 349 ❏ Use 15x15 spruce strips and install a “picture frame” for the battery as shown in Figure 32. ❏ Install a 15x15 spruce strip along the centerline of the aircraft. See Figure 32. F.8L Falco Construction Manual 27–18 Revision 4, March 1, 2002...
  • Page 350 ❏ Make two 20x15 spruce strips as shown in Figure 34. These will be for the hold-down bolts and channel-nuts. Do not install the blocks at this time since they will intefere with the installation of the floor braces which go to the lower side longerons. F.8L Falco Construction Manual 27–19 Revision 4, March 1, 2002...
  • Page 351 Figure 35 ❏ Glue the floorboard assembly in place. See Figure 35, which is a view looking forward at frame No. 8. F.8L Falco Construction Manual 27–20 Revision 4, March 1, 2002...
  • Page 352 Figure 36 ❏ Fit and install the center wall of the battery box. See Figure 36. F.8L Falco Construction Manual 27–21 Revision 4, March 1, 2002...
  • Page 353 Figure 37 ❏ Fit and install the 15x15 brace on the center wall of the battery box. See Figure 37. F.8L Falco Construction Manual 27–22 Revision 4, March 1, 2002...
  • Page 354 ❏ Fit and install the 15x15 spruce brace on the center wall of the battery box at frame 8. See Figure 38. ❏ Fit and install the 15x15 spruce brace on the center wall of the battery box at frame 9. F.8L Falco Construction Manual 27–23 Revision 4, March 1, 2002...
  • Page 355 ❏ Fit and install the 15x15 gluing strip on the battery box floor at frame 8. See Figure 39. ❏ Fit and install the 15x15 gluing strip on the battery box floor at frame 9. F.8L Falco Construction Manual 27–24...
  • Page 356 ❏ Fit and install the forward wall of the battery box at frame 8. See Figure 40. ❏ Fit and install the aft wall of the battery box at frame 9. Figure 41 F.8L Falco Construction Manual 27–25 Revision 4, March 1, 2002...
  • Page 357 ❏ Install the bob-tailed 35x150 corner block on the top of the side longeron. See Figure 43. ❏ Install the 35x150 corner block on the left side of the top center longeron at the aft face of F.8L Falco Construction Manual 27–26...

  • Page 358: Exhaust Port Framing

    In addition to letting noise through, the shield will become quite hot during flight, so the air space is needed for insulation against both heat and noise. F.8L Falco Construction Manual 27–27 Revision 4, March 1, 2002...
  • Page 359 In either case, you may use the curve of the nose gear bay as a pattern. Figure 45 ❏ Install the 15x15 stringers on the outboard side of the exhaust ports. F.8L Falco Construction Manual 27–28 Revision 4, March 1, 2002...
  • Page 360 No. 2. Figure 47 ❏ Glue the plywood for the sides of the box in place. F.8L Falco Construction Manual 27–29 Revision 4, March 1, 2002...

  • Page 361: Nose Gear Screwjack Support Assembly

    ❏ Mask off the bearing and paint the screwjack support assembly with zinc chromate primer. There is really no point in putting the part back in the airplane until after you have varnished the wood under the fitting. F.8L Falco Construction Manual 27–30 Revision 4, March 1, 2002...

  • Page 362: Fuselage Assembly, Part 3

    Kit No. 807-1 Canopy Equipment (or 807-2) Kit No. 809-1 Fuel Tanks and Equipment Figure 1 ❏ Install the gluing strip on the bottom aft face of frame No. 6 Figure 2 F.8L Falco Construction Manual 28–1 Revision 4, March 1, 2002...
  • Page 363 9 and on the inside of frame 9 so that they could clamp the longeron in place, and later sanded this blocking off. Figure 4 ❏ Install the corner blocking for the lower side longerons. F.8L Falco Construction Manual 28–2 Revision 4, March 1, 2002...
  • Page 364 There is no harm in installing the additional access panel, so you should do as you please. ❏ Install the gluing blocks for the fuselage skin. These are installed on the main fin spar and forward fin spar. See Drawing No. 410. F.8L Falco Construction Manual 28–3 Revision 4, March 1, 2002...
  • Page 365 Figure 7 ❏ Skin from frame 10 to 12 on the top of the fuselage. F.8L Falco Construction Manual 28–4 Revision 4, March 1, 2002...
  • Page 366 ❏ Skin from Sta. 10 to 8. You should skin over the battery box and then cut the opening after the glue is dry. If you do not do this, the skin will tend to go ‘flat’ around the opening. F.8L Falco Construction Manual 28–5 Revision 4, March 1, 2002...
  • Page 367 ❏ Cut out the fuselage jig in front of the forward fin spar. ❏ Install the block for tail tie down. Measure and note the location of the center of the hole for the tail tie down. F.8L Falco Construction Manual 28–6 Revision 4, March 1, 2002...
  • Page 368 See Drawing No. 402, Sheet 2, Section B-B. Because of the size of the wires, many builders have used 1/2” tubing. Figure 12 ❏ Skin the fin at the bottom. F.8L Falco Construction Manual 28–7 Revision 4, March 1, 2002...
  • Page 369 ❏ Skin the bottom of the fuselage at the aft end on the left side of the airplane only. ❏ In anticipation for removing the fuselage jig, make a cradle to support the horizontal tail. Figure 14 F.8L Falco Construction Manual 28–8 Revision 4, March 1, 2002...
  • Page 370 ❏ Secure the forward end of the elevator trim tab cable conduit at the forward end by blocking around it with wood blocks or by reinforcing it with epoxy and flox. ❏ Drill the hole for the tail tie-down fitting and epoxy it in place. F.8L Falco Construction Manual 28–9 Revision 4, March 1, 2002...
  • Page 371 ❏ Drill the two holes in P/N 520 retraction gearbox housing for the installation of the elevator trim tab control cable. See Drawing No. 117. ❏ Install the P/N 520 housing in the airplane. F.8L Falco Construction Manual 28–10 Revision 4, March 1, 2002...
  • Page 372 Figure 19 ❏ Skin the left side of the airplane from Sta. 10 to 12. F.8L Falco Construction Manual 28–11 Revision 4, March 1, 2002...
  • Page 373 Figure 21 ❏ Skin the right side from Sta. 9 to 11. ❏ Varnish the inside of this fuselage skin. F.8L Falco Construction Manual 28–12 Revision 4, March 1, 2002...
  • Page 374 ❏ Install the static port fitting on the left side of the airplane. Figure 24 ❏ Install skin from Sta. 8 to 9 on the right side of the airplane. F.8L Falco Construction Manual 28–13 Revision 4, March 1, 2002...
  • Page 375 Then after you have glued on the outside skins, you can varnish the wall cavity and then pop the pre-fitted, pre-scarfed interior skins in place. Attempting to fit the interior cockpit skins at a later stage is a nightmare. F.8L Falco Construction Manual 28–14 Revision 4, March 1, 2002...
  • Page 376 Installing the skin dry works very well and is much easier than it sounds—in fact, many builders say these skins are the easiest skins to install. The curve of the skin is exceptionally smooth. The F.8L Falco Construction Manual 28–15...
  • Page 377 Install corner blocks and trace the outlines of the frames for varnishing. F.8L Falco Construction Manual 28–16 Revision 4, March 1, 2002...
  • Page 378 ❏ Glue on the fuselage skin from Sta. 3 to 6 on both sides of the aircraft. Figure 30 ❏ Make the cabin fresh air inlet. (Install earlier?) Figure 31 ❏ Fit the interior cockpit skins between Sta. 2 and 3. F.8L Falco Construction Manual 28–17 Revision 4, March 1, 2002...
  • Page 379 ❏ Glue on the fuselage skin from Sta. 1 to 3 on both sides of the aircraft. Figure 33 ❏ Cut the opening for cabin fresh air inlet. Figure 34 F.8L Falco Construction Manual 28–18 Revision 4, March 1, 2002...

  • Page 380: Bottom Forward Fuselage Skin

    ❏ At this time you should break out your electrical kit manual and install the heavier wires in the airframe. In particular, you should pull the main battery wires through the forward part of the fuselage and out the firewall. F.8L Falco Construction Manual 28–19 Revision 4, March 1, 2002...
  • Page 381 ❏ Skin the bottom front of the fuselage from Sta. 1 to 3. Be sure to skin over the exhaust port openings. Figure 38 ❏ Cut the openings in the skin for the exhaust ports. F.8L Falco Construction Manual 28–20 Revision 4, March 1, 2002...

  • Page 382: Aft Top Fuselage Section

    ❏ Varnish the inside of the skin just installed forward of frame 7. ❏ Varnish the inside cockpit skin for this area. F.8L Falco Construction Manual 28–21 Revision 4, March 1, 2002...
  • Page 383 ❏ Install the shoulder belt mounts. Figure 42 ❏ Install P/N 823 canopy stop. See Drawing No. 107 or 107A. F.8L Falco Construction Manual 28–22 Revision 4, March 1, 2002...
  • Page 384 Figure 44 ❏ Glue the framework for the dorsal fin in place. ❏ Fit the skins for the dorsal fin and varnish the inside of the dorsal fin. Figure 45 F.8L Falco Construction Manual 28–23 Revision 4, March 1, 2002...

  • Page 385: Forward Top Fuselage Section

    ❏ Install the forward fuel tank. ❏ Install the framing for the forward fuel tank filler cap opening. ❏ Scarf the plywood on each side in preparation for skinning the top of the fuselage. F.8L Falco Construction Manual 28–24 Revision 4, March 1, 2002...
  • Page 386 One view of these gluing strips is on Drawing No. 121. Until the instrument panel installation is complete, this skin will not be installed. ❏ Install the forward fuel tank access door. F.8L Falco Construction Manual 28–25 Revision 4, March 1, 2002...
  • Page 387 F.8L Falco Construction Manual 28–26 Revision 4, March 1, 2002...

  • Page 388: Woodworking Tools

    Exaktor Tools (formerly J. Philip Humfrey Ltd), 3241 Kennedy Road, Unit 7, Scarborough, Ontario, Canada M1V 2J9. Telephone (800) 387-9789 Canadian retailer of power tools—tilting- arbor saws, band saws, wood lathes, etc. Catalogue: $1.00. www.exaktortools.com F.8L Falco Construction Manual A–1 Revision 4, March 1, 2002...
  • Page 389 328-0457 or (612) 224-4859. Complete line of power tools and clamps. www.7cornershdwe.com Woodworkers Supply of New Mexico, 5604 Alameda N. E., Albuquerque, New Mexico 87113. Complete line of woodworking tools and supplies. Catalogue: $2.00. F.8L Falco Construction Manual A–2 Revision 4, March 1, 2002...

  • Page 390: General Tools, Metal & Wood

    An excellent source of aircraft tools. www.usatco.com U. S. Industrial Tool & Supply, 15101 Cleat St, Plymouth, Michigan 48170. Telephone: (800) 521-7394, (800) 482-4167 (in Michigan), or (313) 455-3388. www.ustool.com F.8L Falco Construction Manual A–3 Revision 4, March 1, 2002...

  • Page 391: Aircraft Hardware And Materials

    Falco builders who want to be able to pump up their main gear shock absorbers. F.8L Falco Construction Manual A–4 Revision 4, March 1, 2002...

  • Page 392: Engines And Accessories

    Telephone: (307) 886-3151. Fax: (307) 886-9674. Manufacturers of inverted oil system. www.aviataircraft.com Engine Components, 9503 Middlex, P. O. Box 17099, San Antonio, Texas 78286. Telephone: (512) 828-3131 or (800) 531-7398. Respected overhauler of aircraft engines. www.eci2fly.com F.8L Falco Construction Manual A–5 Revision 4, March 1, 2002...
  • Page 393 F.8L Falco Construction Manual A–6 Revision 4, March 1, 2002...

  • Page 394: Aircraft Woodwork, The Best Books

    ANC-19 is the “Bible” of aircraft woodwork. There isn’t a builder who will not profit from reading it, but many of the most pertinent sections have been summarized in the F.8L Falco Construction Manual. Reproductions of these books can be obtained from John Roby.

  • Page 395: Aircraft Woodwork, Other Books

    FAA inspectors will and will not accept. It is, in effect, the standard reference for what is acceptable and what is not. You should have this publication if you are planning to build an aircraft in the U.S. F.8L Falco Construction Manual B–2 Revision 4, March 1, 2002...

  • Page 396: Aircraft Construction-General, Other Books

    The two Pazmany aircraft are aluminum sheet metal aircraft, and much of what is in these books will not apply to the Falco. Available from Pazmany Aircraft Corporation, P. O. Box 80051S, San Diego, California 92138. F.8L Falco Construction Manual B–3 Revision 4, March 1, 2002...

  • Page 397: Aircraft Covering & Painting, The Best Books

    By Randolph Products Company. This is an excellent reference on painting and surface preparation. Available from Aviation Maintenance Foundation, or Randolph Products Company, P. O. Box 67, Carlstad, New Jersey 07072. Aircraft Engines Lycoming Manuals Available from Avco Lycoming, Williamsport, Pennsylvania. F.8L Falco Construction Manual B–4 Revision 4, March 1, 2002...

  • Page 398: Aircraft Engineering

    Available from Zenith Aviation Books. Theory of Wing Sections By Abbot & von Doenhoff. This is the best book on airfoils. Available from Zenith Aviation Books. F.8L Falco Construction Manual B–5 Revision 4, March 1, 2002...

  • Page 399: Publications

    The English equivalent of Fine Woodworking. A superb publication for the serious craftsman. Wood Working, Quailcraft, Pankridge Street, Crondal, Farnham, Surrey, England. Kitplanes By the editors of Private Pilot. Subscription information at www.kitplanes.com F.8L Falco Construction Manual B–6 Revision 4, March 1, 2002...

  • Page 400: Paint Scheme Colors

    Met. Gray Black Imron: 6282 6334 White Gray Black Imron: 6561 60659 White Yellow Orange Black Imron: 6282 5321 White Black Imron: 92095 5351 2063 White Blue Blue Blue Black F.8L Falco Construction Manual C–1 Revision 4, March 1, 2002...
  • Page 401 Lite Lime Green Green Black Black Imron: 43073 7456 White Green Green Black Black Imron: 71537 75334 White Gray Purple Black Black Imron: 43073 7456 White Green Green Black Black F.8L Falco Construction Manual C–2 Revision 4, March 1, 2002...
  • Page 402 White Orange Imron: 43938 60659 96704 Cream Orange Imron: 4296 96704 7444 White Brown Imron: 60659 6282 White Orange Imron: 60659 5027 White Orange Imron: 43073 7456 White Green Green F.8L Falco Construction Manual C–3 Revision 4, March 1, 2002...
  • Page 403 Imron: 5351 5027 White Blue Imron: 5027 2063 White Blue * Pure white. No color tint added to base white paint. F.8L Falco Construction Manual C–4 Revision 4, March 1, 2002...

  • Page 404: Aerolite 306

    Surface Preparation. Thoroughly sand the surfaces to be joined. Ensure that all surfaces are free from dust or other deposits. F.8L Falco Construction Manual D–1 Revision 4, March 1, 2002...
  • Page 405 The rate at which the glue-line matures to its ultimate strength greatly depends on the ambient temperature: because of this, destructive testing of glued joints should be deferred about 14 days. F.8L Falco Construction Manual D–2 Revision 4, March 1, 2002...
  • Page 406 Products and Vinyl Emulsion Adhesives which is available on request and should be referred to for fuller information. The Aerolite GB Hardeners. These materials contain formic acid—a corrosive chemical which is harmful if taken internally or allowed to come in contact with F.8L Falco Construction Manual D–3 Revision 4, March 1, 2002...
  • Page 407 Plastics Division Ciba-Geigy Plastics and Additives Company Duxford Cambridge CB2 4QA England Telephone: Cambridge (0223) 832121 Telex: 81101 F.8L Falco Construction Manual D–4 Revision 4, March 1, 2002...

  • Page 408: Penacolite Adhesive G-1131

    Federal Specification MMM-A-181c Military Specification MIL-A-22397-1 (ships) Military Specification MIL-A-46051 (Ord) N. B. S. Voluntary Product Standard PS 56-73 AITC Inspection Manual AITC-200-73 Product Fabrication Service Quality Control System F.8L Falco Construction Manual D–5 Revision 4, March 1, 2002...
  • Page 409 The joints may be double or single spread. In double spreading, the glue is applied to both surfaces of the joint, the F.8L Falco Construction Manual D–6...
  • Page 410 10 hours 75°F 6 hours 8 hours 80°F 4 hours 6 hours 90°F 2-1/2 hours 3-1/2 hours 100°F 1-1/2 hours 2 hours For curved stock the above times should be doubled. F.8L Falco Construction Manual D–7 Revision 4, March 1, 2002...
  • Page 411 Neoprene requires a more severe cyclizing treatment with concentrated nitric acid. C. Porous materials such as paper, leather, textiles, or fibers, plastic foam, plaster, cement, fiber boards such as “Masonite” or “Celotex,” asbestos or asbestos-cement boards. F.8L Falco Construction Manual D–8 Revision 4, March 1, 2002...
  • Page 412 Such recommendations, technical advice or services are not to be taken as a license to operate under or intended to suggest infringement of any existing patent. Bulletin No. OM-645-Nov. 1982 F.8L Falco Construction Manual D–9 Revision 4, March 1, 2002...

  • Page 413: Weldwood Waterproof Resorcinol Glue

    It should not be used where any such stain might be undesirable. F.8L Falco Construction Manual D–10 Revision 4, March 1, 2002...
  • Page 414 In no instance should Resorcinol be used at temperatures below 70°F since poor bonds are almost always the result. F.8L Falco Construction Manual D–11 Revision 4, March 1, 2002...
  • Page 415 Mating the surfaces from one to the other may cause excessive loss of adhesive from one area and create nonuniform glue spread and thus bond strength. F.8L Falco Construction Manual D–12 Revision 4, March 1, 2002...
  • Page 416 (but not hot) water. Faster cleaning may be obtained by using caustic soda solution (Caution: caustic may cause burns; do not F.8L Falco Construction Manual D–13 Revision 4, March 1, 2002...
  • Page 417 These containers should be kept tightly closed as much as possible to prevent solvent loss. F.8L Falco Construction Manual D–14 Revision 4, March 1, 2002...
  • Page 418 If used for other than personal, family or household purposes, any implied warranty of MERCHANTABILITY or FITNESS FOR PARTICULAR USE is excluded. Roberts Consolidated Industries 600 North Baldwin Park Boulevard, City of Industry, CA 91749 Telephone: (213) 338-7311 F.8L Falco Construction Manual D–15 Revision 4, March 1, 2002...

  • Page 419: Aerodux 500

    Mixture. Mixing proportions are the same for each of the three resins. Aerodux 500 (Fast, Medium or Slow): 100 parts by weight or volume* Hardener 501: 100 parts by weight or volume* F.8L Falco Construction Manual D–16 Revision 4, March 1, 2002...
  • Page 420 3% moisture content. Application. Whenever practicable it is advisable to spread the resin-hardener mixture evenly on both of the bonding surfaces. For coverage see "Control of Spread to Counteract Drying-Out" below. F.8L Falco Construction Manual D–17 Revision 4, March 1, 2002...
  • Page 421 1 minute per millimeter of distance to the farthest glue-line 5-8mm 1.25 minute per millimeter of distance to the farthest glue-line 8-12 mm 1.5 minute per millimeter of distance to the farthest glue-line` F.8L Falco Construction Manual D–18 Revision 4, March 1, 2002...
  • Page 422 At the end of each working period, wash the hands thoroughly with soap and warm water. Disposable paper towels should be used to dry the skin. These precautions are described in F.8L Falco Construction Manual D–19 Revision 4, March 1, 2002...
  • Page 423 No statements shall be incorporated in any contract unless expressly agreed in writing nor construed as recommending the use of any product in conflict of any patent. F.8L Falco Construction Manual D–20 Revision 4, March 1, 2002...

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