Silverwing AEROPRAKT A22 FOXBAT Manual

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Page 2 - © SilverWing Aviation, 2005

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Summary of Contents for Silverwing AEROPRAKT A22 FOXBAT

Page 2 Introduction to the Aeroprakt A22 Foxbat The prototype A22 was conceived during 1996 on the drawing board of Antonov Design Bureau engineer Yuri Yakovlev - purely as an easy-to-fly 450-525 kg aircraft with excellent pilot and passenger comfort and competitive all-round performance. It was intended that pilots of average ability would be able to operate the A22 in safety from the typically short ultralight airstrips found around the world.
Page 3 Final Inspection and trailer transportation to the airfield for Test Flying. With a little practice, two people can detach the standard wings quite easily in about 30 minutes. Re- assembly takes about the same. Page 4 - © SilverWing Aviation, 2005...
Page 4 6. If you are in doubt about anything – call SilverWing Aviation for clarification. Once a hole is drilled, it can’t be un-drilled! So take your time.
Page 5 38. GUSSET R/L (1.220) 2.0147 4. J/TUBE (17.010) 3.6100.01 39. BEAM (1.310) 1.0121 5. F/COCK X 2 (17.100) 40. ANGLE (1.310) 0.0194 6. T/PIECE X 2 (17.020) 41. BELT (18.020) 0.7626 7. DRAIN VALVE (17.020) Page 6 - © SilverWing Aviation, 2005...
Page 6 13. CABLE (14.030) 1.5407 6. SHAPE (13.030) 1.5124.05 14. C/STOP (14.030) 1.5404.03 7. HINGE (13.030) 1.5124.01 15. C/SHAFT (13.050+) 1.5410 8. PLATE (13.030) 1.5124.03 16. C/RING (13.050+) 1.5410.01 9. BRACKET (13.010) 1.5168 17. C/SHAFT (13.060+) 0.5123.00 Page 7 - © SilverWing Aviation, 2005...
Page 7 SUCH AS AIRCRAFT SPRUCE. COVERING AND PAINT A FOXBAT-SPECIFIC KIT OF “POLYFIBER” MATERIALS CAN BE SUPPLIED BY SILVERWING AVIATION. CONTACT US DIRECTLY FOR INFORMATION. THE 2- PACK STRUCTURAL ADHESIVE FOR FABRIC-TO-DURAL ATTACHMENT IS AVAILABLE IN ONE-JOB QUANTITIES FROM SILVERWING AVIATION.
Page 8 Clico in place then check the fit and alignment. 3. Re-check steps 1 and 2. 4. Working from side to side alternately replace the clicos with rivets. 5. Thoroughly examine the finished work and compare it with the drawing. Notes: Page 9 - © SilverWing Aviation, 2005...
Page 10 Clico in place. 3. Re-check steps 1 and 2. 4. Working from side to side alternately replace the clicos with rivets. 5. Thoroughly examine the finished work and compare it with the drawing. Notes: Page 11 - © SilverWing Aviation, 2005...
Page 12 3. Re-check steps 1 and 2. 4. Working from end to end alternately replace the clicos with rivets. 5. Thoroughly examine the finished work. 6. Repeat on right-hand side. Notes Page 13 - © SilverWing Aviation, 2005...
Page 14 2. Loosely assemble both hinges in turn on the left side exactly as shown on the drawing. 3. Re-check steps 1 and 2. 4. Tighten stiff-nuts until the hinges are snug and firm. Don’t over-tighten. 5. Thoroughly examine the finished work. 6. Repeat on right-hand side. Notes: Page 15 - © SilverWing Aviation, 2005...
Page 16 4. Very carefully centre-punch, drill and pop-rivet the bottom of the bracket to the cross-spar as shown in the drawing. Make certain to use the correct drill and rivet size. Double-check before drilling. 5. Thoroughly examine the finished work. Notes Page 17 - © SilverWing Aviation, 2005...
Page 18 2. Offer up and loosely assemble parts exactly as shown in the drawing. 3. Re-check steps 1 and 2. 4. Tighten stiff-nuts until the assembly is snug and firm. Don’t over- tighten. 5. Thoroughly examine finished work. 6. Repeat on left-hand side. Notes: Page 19 - © SilverWing Aviation, 2005...
Page 20 2. Offer up and loosely assemble parts exactly as shown on the drawing. 3. Re-check steps 1 and 2. 4. Tighten stiff-nuts until the assembly is snug and firm. Don’t over- tighten. 5. Thoroughly inspect finished work. 6. Repeat on right-hand side. Notes Page 21 - © SilverWing Aviation, 2005...
Page 22 3. Re-check steps 1 and 2. 4. Tighten the stiff-nuts until the assembly is snug and firm. Don’t over- tighten. 5. Thoroughly examine the finished work. 6. Repeat on right-hand side. Notes: Page 23 - © SilverWing Aviation, 2005...
Page 24 2. Offer up parts and pre-assemble with clicos exactly as shown in the drawings. 3. Re-check steps 1 and 2. Ensure good fit and alignment. 4. Replace clicos with rivets. 5. Thoroughly examine the finished work. 6. Repeat on right-hand side. Notes Page 25 - © SilverWing Aviation, 2005...
Page 30 2. Offer up parts and pre-assemble with clicos exactly as shown in the drawings. 3. Re-check steps 1 and 2. Ensure good fit and alignment. 4. Working from end to end alternately replace clicos with rivets. 5. Thoroughly examine the finished work. Notes: Page 31 - © SilverWing Aviation, 2005...
Page 35 3. Re-check steps 1 and 2. Be especially careful to ensure correct positioning and alignment with the pre-drilled holes in the fuselage. 4. Replace clicos with rivets working in an alternating “spread” pattern. 5. Thoroughly examine the finished work. Notes: Page 36 - © SilverWing Aviation, 2005...
Page 37 4. Working alternately and from side to side replace clicos with rivets but do not rivet the holes circumscribed on the drawing (4 and 6 from the front on each side). 5. Thoroughly examine the finished work. Notes: Page 38 - © SilverWing Aviation, 2005...
Page 39 3. Re-check steps 1 and 2. 4. Replace clicos with rivets in the holes in the indicated holes only. Note. Pre-view page fourteen for clarification of nose leg support assembly. 5. Thoroughly examine the finished work. Notes: Page 40 - © SilverWing Aviation, 2005...
Page 41 3. Re-check 1 and 2. 4. Replace Clicos with rivets then progressively tighten the stiff-nuts working from side to side until the assembly is snug and firm. Don’t over-tighten. 5. Thoroughly examine the finished work. Notes: Page 42 - © SilverWing Aviation, 2005...
Page 43 Clico in place. 3. Re-check 1 and 2. 4. Replace clicos with rivets working from end to end and diagonally in a “spread” pattern. 5. Thoroughly examine the finished work. Notes: Page 44 - © SilverWing Aviation, 2005...
Page 46 Note. Many paint types will either not cover, or react with, silicone sealants. Consult your paint supplier for more specific guidance. 2. Thoroughly examine and make good. Notes: Page 47 - © SilverWing Aviation, 2005...
Page 49 3. Re-check 1 and 2. 4. Replace clicos with rivets where shown. Leave the circumscribed holes just clico’d for now. 5. Thoroughly examine the finished work. Notes: Page 50 - © SilverWing Aviation, 2005...
Page 51 5. Offer up the Matco brake components, plate, block and axle. Assemble them exactly as shown on drawing number 1.300. Tighten nuts securely. Lightly grease the axle before fitting the wheel. 6. Thoroughly examine the finished work. 7. Repeat on right hand side. Notes: Page 52 - © SilverWing Aviation, 2005...
Page 54 3. Re-check 1 and 2, in particular check for free rotation. 4. Tighten assembly until firm and snug. Don’t over-tighten. 5. Thoroughly examine the finished work and check again for free rotation. Notes: Page 55 - © SilverWing Aviation, 2005...
Page 57 2. Offer up the part and clico in place exactly as shown in the drawing with the nuts finger-tight. 3. Re-check 1 and 2. 4. Replace clicos with rivets alternately and then tighten the nuts. Don’t over-tighten. 5. Thoroughly examine the finished work. Notes: Page 58 - © SilverWing Aviation, 2005...
Page 59 Option: some Foxbats have a MAC electric trim activator mounted in the aft fuselage and operated by a rocker switch on the control stick. See separate fitting instructions with the electric trim, if you ordered this option. 4. Re-check 1, 2 and 3. Notes: Page 60 - © SilverWing Aviation, 2005...
Page 61 4. Replace clicos with rivets. Note. You can rivet the hinge bearing plate (6) and plate (7) to the bracket (3) before offering up to the fuselage. 5. Thoroughly examine the finished work. Notes: Page 62 - © SilverWing Aviation, 2005...
Page 63 1. Locate and inspect the bracket as illustrated on the drawing. 2. Offer up the part and clico in place exactly as shown on the drawing. 3. Re-check 1 and 2. 4. Replace clicos with rivets. 5. Thoroughly examine the finished work. Notes: Page 64 - © SilverWing Aviation, 2005...
Page 65 2. Clico in place exactly as shown on the drawing with the nut finger-tight. 3. Re-check 1 and 2. 4. Replace clicos with rivets and tighten the bolt. Don’t over-tighten. 5. Thoroughly examine the finished work. Notes: Page 66 - © SilverWing Aviation, 2005...
Page 67 2. Offer up the parts and clico in place exactly as shown on the drawing. 3. Re-check 1 and 2. 4. Replace clicos with rivets. 5. Thoroughly examine the finished work. Notes: Page 68 - © SilverWing Aviation, 2005...
Page 69 (1.260). Re-check the entire assembly. Tighten castle nut and fit cotter pin. 4. Thoroughly examine the finished work and check for free rotation of the central control shaft. Notes: Page 70 - © SilverWing Aviation, 2005...
Page 72 2. Offer up the part and assemble exactly as shown in the drawing with the nut finger-tight. 3. Re-check 1 and 2. 4. Tighten the bolt (don’t over-tighten). 5. Thoroughly examine the finished work and check for free rotation of the bellcrank. Notes: Page 73 - © SilverWing Aviation, 2005...
Page 74 2. Offer up using the rod to connect the control stick to the elevator bellcrank. Assemble finger-tight. 3. Re-check 1 and 2. 4. Tighten castle-nuts (don’t over-tighten) and insert cotter pins. 5. Thoroughly examine the finished work. Notes: Page 75 - © SilverWing Aviation, 2005...
Page 76 1. Locate and inspect the cover as illustrated on the drawing. Select the correct size screws. 2. Offer up the part and start screws in the captive stiff-nuts. 3. Re-check 1 and 2. 4. Tighten screws. 5. Thoroughly examine the finished work. Notes: Page 77 - © SilverWing Aviation, 2005...
Page 78 2. Offer up the parts and hold loosely in place with pop rivets exactly as shown on the drawing. 3. Re-check 1 and 2. 4. Compress the pop rivets. 5. Thoroughly examine the finished work. Notes: Page 79 - © SilverWing Aviation, 2005...
Page 80 PAGE THIRTY-ONE DRAWING NUMBER 15.020 Installing the Manual trim lever SEE DRAWING FOR PARTS REQUIRED Recommended job for two persons with fuselage monocoque supported as required Page 81 - © SilverWing Aviation, 2005...
Page 82 Examine the forward ends of the supplied rudder cables to confirm. 3. Re-check 1 and 2. 4. Replace clicos with rivets. 5. Repeat on the left-hand side. 6. Thoroughly examine the finished work. Notes: Page 83 - © SilverWing Aviation, 2005...
Page 84 4. Tighten the nuts until the assembly is snug and firm (don’t over- tighten). Ensure that the pulley can rotate freely. 5. Repeat on the right-hand side. 6. Thoroughly examine the finished work. Notes: Page 85 - © SilverWing Aviation, 2005...
Page 86 3. Re-check 1 and 2. 4. Tighten the nuts until the assembly is snug and firm (don’t over- tighten). Ensure that the pulleys rotate freely. 5. Thoroughly examine the finished work. Notes: Page 87 - © SilverWing Aviation, 2005...
Page 88 2. Offer up the part and clico in place. 3. Re-check 1 and 2. 4. Replace clicos with rivets. 5. Thoroughly examine the finished work. Notes: Page 89 - © SilverWing Aviation, 2005...
Page 90 3. Re-check 1 and 2. 4. Tighten the nuts and install the cotter pins (don’t over-tighten). Ensure free rotation at each rod-to-bellcrank connection and at both bellcrank pivots. 5. Thoroughly examine the finished work. Notes: Page 91 - © SilverWing Aviation, 2005...
Page 92 Insert bolts and finger-tighten the nuts. 4. Re-check 1, 2 and 3. 5. Replace clicos alternately with rivets then tighten the nuts. 6. Thoroughly examine the finished work. Notes: Page 93 - © SilverWing Aviation, 2005...
Page 94 3. Re-check 1 and 2. 4. Tighten the nuts (don’t over-tighten) and insert the cotter pins. 5. Thoroughly examine the finished work and check for free action of the partly-assembled mechanism. Notes: Page 95 - © SilverWing Aviation, 2005...
Page 96 3. Re-check 1 and 2. 4. Tighten the nuts (don’t over-tighten) and install the cotter pins. 5. Thoroughly examine the finished work and re-check for free action of the assembled mechanism. Notes: Page 97 - © SilverWing Aviation, 2005...
Page 98 90 degrees to its final position. 3. Re-check 1 and 2. 4. Tighten screws. 5. Thoroughly examine the finished work. Notes: Page 99 - © SilverWing Aviation, 2005...
Page 100 3. Re-check 1 and 2. 4. Tighten the castle-nut (don’t over-tighten) and fit the cotter pin. 5. Repeat on the right-hand side. 6. Thoroughly examine the finished work. Notes: Page 101 - © SilverWing Aviation, 2005...
Page 102 2. Offer up the parts and loosely assemble them exactly as shown in the drawing. 3. Re-check 1 and 2. 4. Tighten the nuts (don’t over-tighten) and fit the cotter pins. 5. Repeat on the right-hand side. 6. Thoroughly examine the finished work. Notes: Page 103 - © SilverWing Aviation, 2005...
Page 104 Ensure that the fin tip is correctly aligned with the fin. 3. Re-check 1 and 2. 4. Compress the pop rivets. 5. Thoroughly examine the finished work. Notes: Page 105 - © SilverWing Aviation, 2005...
Page 106 Ensure that the wing tip is correctly aligned with the wing. 3. Re-check 1 and 2. 4. Compress the pop rivets. 5. Repeat for starboard wing and tip. 6. Thoroughly examine the finished work. Notes: Page 107 - © SilverWing Aviation, 2005...
Page 108 “tabs” for fit. Starting at the front and working from side to side begin compressing the pop rivets. Ensure that the rivet is fully inserted and that the gun is properly aligned before squeezing the trigger. 5. Thoroughly examine the finished work. Notes: Page 109 - © SilverWing Aviation, 2005...
Page 111 4. Tighten the nuts as normal but don’t over-tighten and insert the cotter pins where shown. Note. The friction clamp (6) will be adjusted later to resist throttle-spring pressure. 5. Thoroughly examine the finished work. Notes: Page 112 - © SilverWing Aviation, 2005...
Page 113 Repeat 2 to 4 on right-hand side. Install the cables as shown on the drawing. 5. Thoroughly examine the finished work. Note. The throttle cables should be coiled on the fuselage floor until engine installation. Notes: Page 114 - © SilverWing Aviation, 2005...
Page 115 (don’t over-tighten). Offer up the engine mounts part 2 and loosely assemble exactly as shown on the drawing. 3. Re-check 1 and 2. 4. Tighten the castle nuts as normal and insert the spring pins. 5. Thoroughly examine the finished work. Notes: Page 116 - © SilverWing Aviation, 2005...
Page 117 Give the mountings one more check then gradually transfer the weight to the fuselage. 5. Remove the lifting tackle and thoroughly examine the finished work. Note that the bolts 8 and 9 are secured with locking wire. Page 118 - © SilverWing Aviation, 2005...
Page 119 4. Tighten the nuts until the assembly is snug but don’t over-tighten. 5. Thoroughly examine the assembly checking for good alignment and free movement of the flying surfaces. Consult your PFA Inspector then dismantle all except rudder. Notes: Page 120 - © SilverWing Aviation, 2005...
Page 127 11.040. 3. Re-check 1 and 2. 4. Proceed with the cable connection sequence. 5. Thoroughly examine the finished assembly and check operation with the nosewheel clear of the ground. Notes: Page 128 - © SilverWing Aviation, 2005...
Page 130 Choke and throttle arms should close fully at the carburettors. Adjust the lever frictions so that they stay set in position but don’t over- tighten. Final adjustment and balancing will be carried out later in accordance with the Rotax engine manual. Notes: Page 131 - © SilverWing Aviation, 2005...
Page 134 5. Thoroughly inspect the finished work. The brake fluid can be added and bled later according to the instructions provided elsewhere. Note. The Matco brake system is fitted with seals designed for use with “Aviation Hydraulic Fluid”. DO NOT USE AUTOMOTIVE BRAKE FLUID! Notes: Page 135 - © SilverWing Aviation, 2005...
Page 137 This will require a small hole to be cut in the floor panel. 3. Recheck 1 and 2. 4. Tighten the hose clips and secure the lines with cable-ties as shown. 6. Thoroughly inspect the finished work. Notes: Page 138 - © SilverWing Aviation, 2005...
Page 143 Note 2. Incorrect wiring can damage electrical components beyond repair or can lay the foundations for serious problems in the future! So, unless you are certain of your skills, consult a professional! Notes: Page 144 - © SilverWing Aviation, 2005...
Page 150 3. Offer up and fit the luggage bag followed by the seat belts and seats exactly as shown in the drawings. 4. Thoroughly inspect the finished work. Notes: Page 151 - © SilverWing Aviation, 2005...
Page 157 Make sure the gaps are equal each side between the wing root mouldings and leading edges. Check the flaperon function using the control stick and flap lever, then carefully remove the wings by the reverse sequence to that described above. Notes: Page 158 - © SilverWing Aviation, 2005...
Page 163 Cut the panel carefully with a pair of shears or get it professionally cut. Notes: Page 164 - © SilverWing Aviation, 2005...
Page 165 “set”. Finally, replace the clicos with pop rivets by working carefully outwards or in an appropriate sequence to avoid “pie-crusting” the edges of the Lexan. Page 166 - © SilverWing Aviation, 2005...
Page 167 Connect the gas strut as shown in drawing 1.610 and tighten the nuts. Fit the air vent and draught strip. Thoroughly examine the finished work and then repeat on the right-hand side. Notes: Page 168 - © SilverWing Aviation, 2005...
Page 174 (but not the inner ribs at this time). This MEK mix will soften the previously applied cement (see #2 above). Use a light rubbing action with a finger to help draw the cement up through the fabric weave. Allow the cement to dry. Page 175 - © SilverWing Aviation, 2005...
Page 175 The following six drawings show the general fabric lay-out of an A22. The three drawings 4.400 (a, b and c) show the wings, 6.400 the flaperons, 8.400 the elevator, and 3.400 the rudder. There’s no fabric on the fuselage. Page 176 - © SilverWing Aviation, 2005...
Page 182 (Bolts, nuts and fasteners, root and spar ends, dowels, flaperon cardan rings, etc) 3.8. Attachment of rudder to fin checked. (Bolts, nuts and fasteners, dowels, bearings, etc) 3.9. Attachment of elevator to tailplane checked. (Bolts, nuts and fasteners, dowels, bearings, etc) Page 183 - © SilverWing Aviation, 2005...
Page 183 Seats inspected and energy-absorbing under-seat foam checked. (Stitching, padding, Velcro positioning, mount security, foam sculpting, etc) 6.4. Windscreen and rear side and top glazing checked. (Security and neatness of fitting, rivets, rear supports, rear access panel- screws, etc) Page 184 - © SilverWing Aviation, 2005...
Page 184 Hoses and connections secure and installed as per Rotax manual. (Routing okay, no kinks, doublers/heat shields fitted as required, fittings) 9.2. Coolant radiator, oil cooler, pressure cap and expansion tank (Cush-mounts, cap seal, connections, coolant level, etc) Page 185 - © SilverWing Aviation, 2005...
Page 185 14.1. Wingtips to prop flange are equal to within 5 mm. 14.2. Wingtips to elevator horn are equal to within 5 mm. 14.3. Wingtips to fuselage lift-strut mount are equal to within 3 mm. Page 186 - © SilverWing Aviation, 2005...