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Rans S-7S COURIER Text Manual

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S-7S COURIER
TEXT MANUAL
Serial Number:
Registration Number:
COPYRIGHT ©
RANS DESIGNS
4600 HWY 183 Alt
HAYS, KANSAS, USA 67601
785-625-6346
www.rans.com
09/01/2014

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  • Page 1 S-7S COURIER TEXT MANUAL Serial Number: Registration Number: COPYRIGHT © RANS DESIGNS 4600 HWY 183 Alt HAYS, KANSAS, USA 67601 785-625-6346 www.rans.com 09/01/2014...
  • Page 2 00-01 AFTER PRINTING THE S-7S MANUAL. HOW DO I ASSEMBLE THE MANUAL? Obtain three 2" wide 3-ring binders. Place the TEXT, PARTS and FIGURES manuals in separate binders. Every page has a section number then a page number within that section. (Example: parts page 006-02) Parts pages have an exploded view and a parts listing.
  • Page 3 00-02 09/01/2014...
  • Page 4 00-03 Labels for the exterior spine of each manual may be made from self-stick labels. The format below may be used. RANS RANS RANS S-7S S-7S S-7S COURIER COURIER COURIER TEXT PARTS FIGURES MANUAL MANUAL MANUAL 09/01/2014...
  • Page 5 00-04 RANS Designs 4600 Highway 183 Alternate Hays, KS 67601 Technical Support (785) 625-0069 actech@rans.com Parts Department (785) 625-6346 parts@rans.com When calling Technical Support or Parts Department please have the following ready: • Aircraft Model • Serial Number • Engine Model •...
  • Page 6 RANS has taken care to provide clear, comprehensive, and straightforward instructions for assembly, maintenance, and operation by reference to manuals alone. In the event a question arises for which no answer seems apparent, feel free to contact RANS headquarters. Physical and mailing address:...RANS Designs...
  • Page 7 00-06 RANS S-7S Courier AIRCRAFT TOOL LIST The following is a list of tools that will be helpful when assembling your RANS aircraft. HAND TOOLS Pliers Safety Wire Pliers Needle Nose Pliers Linesman Pliers Side Cutters Electrical Wire Stripers Aviation...
  • Page 8 00-07 DRILL BIT SIZES A full set of fractional drill bits ranging from 3/32" to 5/8" is strongly recommended. In addition to these the following number bits will be required to assemble your S-7S Courier. NUMBERED BITS FRACTIONAL BITS 1/4”...
  • Page 9 RADIO SHACK #275-644 Pushbutton Switch Local Avionic shops can wire your avionic harnesses for you. Switches, circuit breakers, and other electrical parts are also available from RANS. Contact RANS Parts Department for pricing. RED Illuminated Master Switch KSES0017 Non-illuminated Switch...
  • Page 10 S-7S COURIER - GENERAL INFORMATION INTRODUCTION As the builder of the S-7S COURIER kit you are considered the manufacturer by law. The rules state that you must build 51% of the total. In essence, we are your parts supplier. You have the final say in regard to every single item that goes into your project.
  • Page 11 00-10 ENGINEERING DEPT. DRAWING NUMBERING SYSTEM RANS TYPICALLY DESIGNATES PARTS BY EIGHT VARIABLES. THIS SYSTEM CONSISTS OF LETTERS AND NUMBERS. THE FOLLOWING IS A BREAK DOWN OF THIS SYSTEM. XXXX CLASSIFICATION DWG TYPE AIRCRAFT SECTION ID NUMBER K = KIT...
  • Page 12 00-11 IMPORTANT: PLEASE READ FIRST PLEASE READ: We highly recommend that you completely read the manual cover to cover before beginning assembly of your aircraft. This will help to eliminate costly mistakes and considerably speed up your build time. As you read through the Assembly Manual, follow along in the Parts and Figure Drawings Manual.
  • Page 13 00-12 CLECOS: These are temporary fasteners that will be used to hold things together while fitting and drilling. A pair of pliers is also required to install and remove the clecos. The cleco's are color coded as to hole size. Silver Copper Gold...
  • Page 14 HAVE FUN: A RANS aircraft is almost as much fun to build as it is to fly and with a little care and planning, your ship could be a show-stopper...Send us and the magazine's pictures of your work in progress or your finished plane.
  • Page 15 00-14 S-7S ASSEMBLY FLOW CHART – GENERAL For a general overview refer to the following chart. For more detailed information refer to ASSEMBLY FLOW CHARTS – DETAILED. Note: The headings in the general chart refer to headings in the detailed flow charts. S-7S FUSELAGE PRE-COVERING ASSEMBLY S-7S TAIL SURFACES...
  • Page 16 00-15 S-7S ASSEMBLY FLOW CHART – DETAILED Note: The headings in the detailed flow charts on the following pages refer to text manual headings. S-7S FUSELAGE – PRE-COVERING ASSEMBLY Refer to Section 1 and complete the following items: • RUDDER SYSTEM ASSEMBLY AND INSTALLATION o RUDDER FIT UP •...
  • Page 17 00-16 Refer to Section 8 and complete the following items: • BAGGAGE COMPARTMENT ASSEMBLY AND INSTALLATION • SEAT BELT ASSEMBLY AND INSTALLATION  AFTER PRIMING OF FUSELAGE FRAME/ BEFORE COVERING COVERING (Refer to Section 7) PAINTING (Manual does not provide guidance for painting) 09/01/2014...
  • Page 18 00-17 S-7S FUSELAGE – FINAL ASSEMBLY Refer to Section 1 and complete the following items: • MAIN GEAR ASSEMBLY AND INSTALLATION o FINAL INSTALLATION • GEAR LEG FAIRING ASSEMBLY AND INSTALLATION o FAIRING FIT UP o INSTALLATION • TAIL WHEEL ASSEMBLY AND INSTALLATION Refer to Section 2 and complete the following items: •...
  • Page 19 00-18 Refer to Section 2 and complete the following items: • THROTTLE LEVER INSTALLATION • AILERON CABLE SYSTEM INSTALLATION FUSELAGE Refer to Section 3 and complete the following items: • FUEL LINE INSTALLATION – FUSELAGE  AFTER COVERING AND PAINT OF FUSELAGE •...
  • Page 20 00-19 Refer to Section 6 and complete the following items: • BOOT COWL AND INSTRUMENT PANEL INSTALLATION o FINAL INSTALLATION Refer to Section 3 and complete the following items: • FUEL LINE INSTALLATION – FUSELAGE  AT BOOT COWL &INSTRUMENT PANEL INSTALLATION Refer to Section 6 and complete the following items: •...
  • Page 21 00-20 Refer to Section 8 and complete the following items: • SEAT ASSEMBLY AND INSTALLATION o ASSEMBLY o INSTALLATION • SEAT BELT ASSEMBLY AND INSTALLATION  AFTER COVERING AND PAINT OF FUSELAGE • RUDDER CABLE GUARD INSTALLATION • STATION 3 CLOSE OUT INSTALLATION •...
  • Page 22 00-21 S-7S TAIL SURFACES – PRE-COVERING ASSEMBLY Refer to Section 1 and complete the following items: • HORIZONTAL STABILIZER AND ELEVATOR ASSEMBLY AND INSTALLATION o FIT UP AND PRE-COVERING ASSEMBLY  BEFORE PRIMING OF HORIZONTAL STABILIZER AND ELEVATOR FRAMES • PREP AND PRIME HORIZONTAL STAB.
  • Page 23 00-22 S-7S TAIL SURFACES – FINAL ASSEMBLY& INSTALLATION Refer to Section 1 and complete the following items: • HORIZONTAL STABILIZER AND ELEVATOR ASSEMBLY AND INSTALLATION o INSTALLATION OF HORIZONTAL STABILIZERS o FINAL ASSEMBLY OF ELEVATOR • TRIM TAB ASSEMBLY AND INSTALLATION o ASSEMBLY o INSTALLATION Refer to Section 9 and complete the following items:...
  • Page 24 00-23 S-7S WINGS – PRE-COVERING ASSEMBLY Refer to Section 5 and complete the following items: • WING- MAIN STRUCTURE ASSEMBLY o WING SPAR ASSEMBLY o WING FRAME ASSEMBLY • FUEL TANK ASSEMBLY AND INSTALLATION o ASSEMBLY o INSTALLATION o FUEL CAP ASSEMBLY o FUEL AND VENT LINE INSTALLATION •...
  • Page 25 00-24 S-7S WINGS – FINAL ASSEMBLY & INSTALLATION Refer to Section 5 and complete the following items: • AILERON AND FLAP ASSEMBLY AND INSTALLATION o ASSEMBLY  AFTER COVERING AND PAINT Refer to Section 5 and complete the following items: •...
  • Page 29 01-01 S-7S FUSELAGE FORMER INSTALLATION NOTE: All fuselage formers must be cut to exact length from raw stock provided. Mark and check fit carefully before cutting. In addition, pay attention to the wall thickness of the raw stock called out in the parts manual. Formers are fabricated from 0.028”...
  • Page 30 01-02 FUSELAGE SIDE FORMER (AFTER PRIMING OF FUSELAGE FRAME/ BEFORE COVERING) Each fuselage side uses 3 formers to support the fabric. Refer to FIGURE 01-08 for the proper location of each side former. Determine the length of each former, mark and check fit before cutting from provided raw stock. Note that there are two different diameters of formers (1/4”and 1/2”).
  • Page 31 01-03 RIB VERTICAL STABILIZER (AFTER PRIMING OF FUSELAGE FRAME/ BEFORE COVERING) The vertical stabilizer receives 1 rib formed from aluminum sheet for fabric support. The forming process leaves the rib slightly bowed. To straighten the rib, use fluting pliers and crimp the rib flanges slightly between the holes at the notch locations.
  • Page 32 01A-01 S-7S MAIN GEAR ASSEMBLY AND INSTALLATION MAIN GEAR FIT UP NOTE: Please be sure to refer to parts page when installing. Fuselage should be covered and painted before final installation. Become familiar with the Main Gear Installation Parts Drawings and collect the parts shown in the drawing.
  • Page 33 01A-02 MAIN GEAR WHEEL/BRAKE INSTALLATION Become familiar with the Main Gear Wheel/Brake Installation Parts Drawings and collect the parts shown in the drawings. Bolt caliper mount, and axle to the gear leg assembly as per parts drawing. Assemble the wheel and brake kit as per parts manual and manufacturer’s instructions.
  • Page 34 01A-03 Apply Thread Sealant to the threads of the brake fitting and install the fitting into the caliper. The fitting should face upward. FINAL ASSEMBLY Install D-Cell Rubber Seal to bottom side of Station 2 crossing tube to help seal against Gear Legs and Boot Cowl.
  • Page 35 01B-01 S-7S TAIL WHEEL ASSEMBLY AND INSTALLATION (AFTER COVERING AND PAINT OF FUSELAGE) Bolt the tail spring to the tail wheel assembly. Refer to the parts drawing. NOTE: It may be necessary to lightly file or grind the tail spring to fit within the spring mount channel.
  • Page 36 01C-01 S-7S HORIZONTAL STABILIZER AND ELEVATOR ASSEMBLY AND INSTALLATION FIT-UP AND PRE-COVERING ASSEMBLY (BEFORE PRIMING OF HORIZONTAL STABILIZER AND ELEVATOR FRAMES) The elevator hinges must be secured in position. Temporarily bolt the elevators to the horizontal stabilizers. NOTE: There are left and right stabilizers and elevators.
  • Page 37 01C-02 (AFTER PRIMING OF HORIZONTAL STABILIZER AND ELEVATOR FRAMES) Refer to FIGURE 01-11 Install the nut plates to the elevator horn attach holes on both elevators. Refer to parts page. Each horizontal stabilizer receives two ribs formed from aluminum sheet to support the fabric.
  • Page 38 01C-03 The tail brace rods are made from stainless steel rod and are reduced in diameter toward the threaded ends. The transition area should extend over approximate 1” to 1.5” and must be smooth. If this area is NOT smooth, then modify the tail brace rods as shown in FIGURE 01C-17. The setup in FIGURE 01C-17 makes the task of filing and polishing easy and quick.
  • Page 39 01C-04 FINAL ASSEMBLY OF ELEVATOR (AFTER COVERING AND PAINT OF ELEVATOR) Use a hot iron or soldering iron and burn holes through drain grommets, elevator horn attach holes, holes for the mass balance weight attach at the elevator tips, and the 3 servo attach holes on top of the right elevator (through welded tangs).
  • Page 40 01C-05 FINAL INSTALLATION OF ELEVATOR (AFTER COVERING, PAINT, ASSEMBLY AND MASS BALANCE OF ELEVATOR) Bolt both elevators at their hinge points to the corresponding horizontal stabilizer. Lubricate hinge points and check for free movement without binding or excessive friction. Connect elevators to elevator yoke as per parts manual. IMPORTANT: Make sure the rod ends are at least 10 full threads engaged into the elevator yoke.
  • Page 41 01D-01 S-7S TRIM TAB ASSEMBLY AND INSTALLATION ASSEMBLY (BEFORE PAINT OF TAB) Cleco each trim tab half together along the leading edge. Place the each half on a flat surface and clamp or weigh them down. This will assure that the tab is straight.
  • Page 42 01D-02 INSTALLATION Attach the trim tab to the right hand elevator as per parts drawing. Safety wire the attach bolts to the End Ribs. HINT: There are small openings in each End Rib, at the bend, which works well. Install the hinge lock into the trim tab and slide over the center pivot stub. Hold the hinge lock tight into position and transfer drill # 30 through the top two holes in the trim tab into the hinge lock.
  • Page 43 01E-01 S-7S FLOORBOARD INSTALLATION FIT UP (AFTER PRIMING OF FUSELAGE FRAME/ BEFORE COVERING) Insert the forward floorboard with the two openings centered on the upright tangs of the fuselage. The floorboard typically touches the backside of the two tangs on the station 1 bottom crossing tube. Center from side to side and clamp the forward floorboard in position.
  • Page 44 01E-02 FINAL INSTALLATION For final installation refer to RUDDER PEDAL INSTALLATION. 09/01/2014...
  • Page 45 01F-01 S-7S RUDDER PEDAL INSTALLATION (AFTER COVERING AND PAINTING OF FUSELAGE) Rudder pedals and floorboards are installed together after the fuselage is covered and painted. It is also recommended to fit and drill the fiberglass boot cowl before the forward floorboard and pedals are installed. The rudder pedals, rudder pedal push pull tubes and brake push pull tubes must be prepped, primed and painted before installation.
  • Page 46 01G-01 S-7S RUDDER SYSTEM ASSEMBLY AND INSTALLATION RUDDER FIT UP (BEFORE PRIMING OF FUSELAGE AND RUDDER FRAME) The rudder hinges must be secured in position. Temporarily bolt the rudder to the fuselage. Adjust the rudder vertically to create a gap between the top of the vertical fin and the overhang of the rudder of approximate 3/16”.
  • Page 47 01G-02 FINAL INSTALLATION (AFTER COVERING AND PAINT OF FUSELAGE) Attach the rudder with the hardware shown in the parts manual. Lubricate hinges and swivel rudder about 30 degree left and right. The rudder should swivel freely without any excessive friction. Also, check for sufficient clearance (gap) between rudder and fuselage.
  • Page 48 01H-01 S-7S FIREWALL ASSEMBLY AND INSTALLATION ASSEMBLY (BEFORE COVERING AND PAINT OF FUSELAGE) NOTE: Parts call out for items other than those shown on the Firewall Installation parts page are referenced in Section 003 - Engine. The metal firewall is supplied pre-cut. Most required openings are cut. Some minor adjustments on some of the holes might be required to achieve a perfect fit.
  • Page 49 01H-02 FORWARD SIDE FIREWALL ITEMS INSTALLATION Refer to FIGURE 01H-07 for forward side mounted items. NOTE: It is possible to install many of the firewall-mounted items before the firewall is installed to the fuselage. It is also possible to mount the firewall first. Do, as you prefer.
  • Page 50 01H-03 Install the oil tank vent tube using the clamps and spacers in the appropriate mount holes as shown. NOTE: The small hole in the overflow tube is there to provide a source of venting in case the main opening is plugged.
  • Page 51 01H-04 INSTALLATION (AFTER COVERING AND PAINT OF FUSELAGE) At this time the firewall will be secured to the fuselage only with the five engine mount attach bolts and four rivets through the oil tank mount bracket. Refer to ENGINE MOUNT ASSEMBLY AND INSTALLATION and bolt the AFT engine mount and the firewall to the fuselage frame.
  • Page 52 01I-01 S-7S HYDRAULIC BRAKE INSTALLATION (AFTER COVERING AND PAINTING OF FUSELAGE) Rudder pedals and floorboards must be installed and the airplane should be on the main gear with wheel assemblies mounted. In addition, the FIREWALL ASSEMBLY AND INSTALLATION should be completed. The boot cowl should be fit up but not installed.
  • Page 53 01I-02 Fill the system from the bottom through the bleed valves in the caliper cylinders. HINT: A small hand held oil pump can with a short piece of small diameter hose attached works well. With the oil pump full of hydraulic oil, slide the hose on the oil pump over the lower left bleed valve.
  • Page 54 01J-01 S-7S DOORFRAME BATTERY ACCESS PANEL INSTALLATION (AFTER PRIMING OF FUSELAGE FRAME/ BEFORE COVERING) Rivet single-ear nut plates to the inside of the battery access doorframe. Position, transfer drill #30 and rivet doorframe to the tabs on fuselage station 6. Refer to parts manual. The door should be fitted by drilling the screw holes to #11.
  • Page 55 RANS S-7S COURIER TEXT MANUAL 01K-01 S-7S FUEL SYSTEM - FUSELAGE FUSELAGE PREPARATION (BEFORE COVERING AND PAINTING OF FUSELAGE) Locate Header Tank Mount per FIGURE 01K-01. Locate and drill #11 through each tab. Remove Tank Mount and rivet nut plates to bottom side of tabs.
  • Page 56 RANS S-7S COURIER TEXT MANUAL 01K-02 Perform a leak test by capping off all fittings and pressurizing the tank to 1 PSI and let sit for a period of time. CAUTION: Damage may result from over-pressurization. While the tank is pressurized, check for any leaks by spraying a soap/water mixture onto the tank and around the fittings.
  • Page 57 RANS S-7S COURIER TEXT MANUAL 01K-03 OPTIONAL LOW FUEL WARNING KIT Become familiar with the Optional Low Fuel Warning Kit on the Header Tank Parts Drawings and collect the parts shown in the drawings. A 5/8" hole should have been located in the side of the Header Tank. If not, refer back to FIGURE 01K-02.
  • Page 58 RANS S-7S COURIER TEXT MANUAL 02-01 S-7S CONTROL STICK ASSEMBLY AND INSTALLATION INSTALLATION (AFTER PAINTING OF FUSELAGE) NOTE: The Control Stick Torque Tube does not require paint or finish applied. Both Control Sticks and the Control Stick Push-Pull Tube Assembly are ready for finishing as delivered.
  • Page 59 RANS S-7S COURIER TEXT MANUAL 02-02 Temporarily install Torque Tube to the fuselage frame by bolting between the forward Pillow Blocks to the two welded forward facing tabs at Station 2 (upper tube of gear truss). IMPORTANT: Be sure to position a stop ring to either side of the Pillow Blocks.
  • Page 60 RANS S-7S COURIER TEXT MANUAL 02-03 Bolt forward end of Torque Tube Push-Pull Tube to lower end of fwd control stick. Check the entire assembly for free movement without excessive friction. Friction in the control system will have negative influence on the flying qualities of your airplane.
  • Page 61 02A-01 S-7S FORWARD PUSH-PULL TUBE ASSEMBLY Assemble AFT 1" Push-Pull Tube by pressing End Fitting into aft end, transfer drill #30 and rivet. Drill pre-located thru-hole in forward end of AFT Push-Pull Tube to #11 and deburr. Install Rod End, with jam nut, into End Fitting. CAUTION: Rod End must be engaged at least 10 full turns.
  • Page 62 02B-01 S-7S AFT PUSH-PULL TUBE & ELEVATOR YOKE ASSEMBLY Modify AFT 1-1/2" Push -Pull Tube per FIGURE 02B-01 and deburr. Press End Fitting into forward end of Push-Pull Tube. Transfer drill #30 and rivet. Install Rod End, with jam nut, into End Fitting. CAUTION: Rod End must be engaged at least 10 full turns.
  • Page 63 02C-01 S-7S AILERON CABLE SYSTEM INSTALLATION FUSELAGE (AFTER COVERING AND PAINT OF FUSELAGE) For a general overview over the aileron control system, refer to FIGURE 02C-01. Assemble the pulley shackles as shown in the parts drawing and FIGURE 02C-02. The shackle bolts should be tight enough to eliminate any play and yet still allow free rotational movement.
  • Page 64 02C-02 Install cotter pins into all cable keepers as shown in FIGURE 02C-11. CAUTION: The cotter pins must not rub on the cables and should not be used to retain the keepers in position. The keepers are retained in position by the tightening of the bolt.
  • Page 65 02D-01 S-7S FLAP LEVER ASSEMBLY AND INSTALLATION ASSEMBLY Refer to the parts catalog and select the required components for assembly. Press the plastic End Caps into each end of the Flap Trip Release Tube. Transfer drill 1/4" though the hole at the base of the Release Tube to remove material of End Cap for bolt insertion.
  • Page 66 02D-02 (AFTER COVERING AND PAINT OF FUSELAGE) Install the flap lever assembly into the cockpit by slipping the upper forward part of the assembly between the welded fuselage tangs at seat crossing tube and bolt in place. Refer to the parts drawing. Bolt the U- Bracket to the 1/2"...
  • Page 67 02E-01 S-7S THROTTLE LEVER INSTALLATION (AFTER COVERING AND PAINT OF FUSELAGE) Assemble the forward throttle lever to the throttle cable guide as shown in the parts drawing. Refer to FIGURE 02E-01. Assemble the throttle lever knobs to each lever. Refer to the parts drawing and FIGURE 02E-01.
  • Page 68 02E-02 Remove the retention block and mark the two holes on the topside of the block as per FIGURE 02E-13. Drill completely through the throttle retention block from top to bottom with a #40 drill bit. Drill only the top half of the retention block to #30.The machine screw will self-tap into the bottom.
  • Page 69 Assembly bushings are made to fit 10mm bolts. If desired fabricate a thin bushing sleeve to take up this difference, or simply bolt up and fly. RANS has found the latter to be perfectly airworthy and is a common practice in the U.S.
  • Page 70 03-02 Install the drain lines from the carburetor drip trays to the drain tubes located on the firewall. Refer back to FIGURE 01H-07 and the parts manual. NOTE: The fuel overflow lines should route continuously down to the overflow tube. 09/01/2014...
  • Page 71 03A-01 S-7S FUEL LINE INSTALLATION - FIREWALL FORWARD NOTE: When installing fittings use thread tight or similar as a thread sealant. NOTE: The Gascolator is Optional. If no Gascolator is installed, then it is recommended to install a fuel filter as recommended by ROTAX. INSTALLATION WITHOUT OPTIONAL GASCOLATOR NOTE: Contact ROTAX for recommended Fuel Filter.
  • Page 72 03B-01 S-7S THROTTLE CABLE AND CHOKE INSTALLATION The throttle lever installation in the cabin should be completed. Refer to THROTTLE LEVER INSTALLATION. THROTTLE CABLE INSTALLATION Install the adjuster ferrule into the throttle cable mounts as per parts manual. Position the ferrule at the mid of its adjustment range to allow for later adjustments in both directions.
  • Page 73 03B-02 CHOKE INSTALLATION Determine the cable housing routing and cut to length. Note: Cable housing routing is left to the discretion of the builder. Route the choke cable housing. Operate the choke lever to verify free movement. It is important that the choke operates smoothly and completely returns to its run position.
  • Page 74 03C-01 S-7S LUBRICATION SYSTEM ASSEMBLY AND INSTALLATION AFTER ENGINE IS INSTALLED The engine needs to be installed to the airframe. CAUTION: When working with the oil cooler, take care not to induce stress or over tighten fittings or bolts. Damage to the cooler may result. With a band saw or hacksaw, remove the mount tabs from the oil cooler leaving a 1/16"...
  • Page 75 03C-02 Inspect Oil Cooler threaded boss for nicks or burrs in O-ring contact area that might cause O-ring failure. Inspect the Cooler port threads for any buildup of coating. If needed, gently clean threads. Apply light petroleum oil to port threads. Lubricate O-ring of 90-Dergee Swivel Fitting by coating with light petroleum oil and install the O-ring onto the fitting.
  • Page 76 03C-03 Install the spark plugs and start the engine. Watch the oil pressure gauge as the engine starts. At the moment the engine starts, allow 10 seconds for oil pressure to come up. If there is no pressure indication within 10 seconds, shut the engine off and repeat the previous procedures.
  • Page 77 03D-01 S-7S COOLING SYSTEM INSTALLATION Bolt the radiator mount bracket to the front of the radiator as show n in the parts manual. Modify the tw o multi-hole tangs as per FIGURE 03-12. Bolt the modified tangs to the rear of the radiator as show n in the parts manual.
  • Page 78 03E-01 S-7S MUFFLER / HEATER WRAP ASSEMBLY AND INSTALLATION Rivet heater flanges t o the AFT heater w rap. NOTE: Apply high temp silicone to the flange before riveting as a sealant . Install the FWD and AFT heater w rap to t he exhaust muffler using the hard w are show n in the parts manual.
  • Page 79 03F-01 S-7S HEATER INSTALLATION Install the flapper arm to the air diverter assembly. You need to transfer drill a # 40 hole for the cott er pin into the air diverter shaft. NOTE: Before drilling, position the flapper arm, so that a pull on the heater control knob w ill open the valve t o the cabin complet ely.
  • Page 80 03G-01 S-7S CARB HEAT INSTALLATION The S-7S is equipped w ith carburetor heat. For a description of t he design and adjust ment refer to the RIGGING section. A selector valve is mounted to the rear of each carburetor. The selector valve must be assembled from several part s.
  • Page 81 03G-02 Secure int ake hose to carb heat body w ith a hose clamp. Slide assembly onto carburetor. Secure w ith a hose clamp. Tighten hose clamps firmly to assure secure fit. NOTE: Check and re-tight en these clamps after the first engine run and thereafter frequently. Safety-w ire the carburetor heat assembly to the carburetor and the carburetor to the manifold.
  • Page 82 04-01 S-7S BATTERY BOX ASSEMBLY AND INSTALLATION (REFER TO PARTS PAGE # 004-02 FOR PARTS SELECTION) BATTERY BOX AND BATTERY CABLES (AFTER PRIMING OF FUSELAGE FRAME/ BEFORE COVERING) Refer to FIGURES 04-01 & 04-01A. NOTE: It is easiest to install the battery box and battery cables before the fuselage is covered.
  • Page 83 Refer to parts page 004-04. Due to the different instruments and flight systems that S-7S builders are choosing, RANS does not supply gauges with the kit. Bolt the ground cable to the battery box mount tab without the nut plate. Refer to the battery box section.
  • Page 85 05-01 S-7S WING – MAIN STRUCTURE ASSEMBLY NOTE: 3M Brand DP-460 Epoxy Adhesive is recommended for bonding the sheet metal wraps to the FWD & AFT wing spars. Leading Edge, Root, and Tip Wraps are riveted with 1/8” Stainless Steel Flush rivets. A suitable 1/8” Dimpling Tool and Counter Sink will be required.
  • Page 86 05-02 Transfer drill through Spar and Root Doubler #40 in 4 places using the Leading Edge Patch as a guide and cleco. Refer to FIGURE 05-05. Remove one cleco at a time and drill out to #30 (4 places) and cleco. Drill out the one hole to #11 as per FIGURE 05-05.
  • Page 87 05-03 When attaching the Strut Attach Plates to the Spars, it will be necessary to drill out the spars to 3/8" diameter. IMPORTANT: Do NOT drill the Strut Attach Plates to 3/8”. The most accurate way to drill the 3/8 " holes is to first drill 1/4”...
  • Page 88 05-04 WING FRAME ASSEMBLY Select either a Right or Left hand set of Leading and Trailing Edge Spars. Place on padded sawhorses and bolt in root Inner Compression Tube. IMPORTANT: Be sure to install the Aileron Cable Rub Block and the Aileron Cable Retention Plate at the Trailing Edge Spar.
  • Page 89 05-05 Drill out the first hole on each leg of the Tip Bow to #30. Locate and mark the trailing edge side of the Tip Bow. NOTE: The trailing edge side has an additional hole drilled (this hole is NOT used on the S-7S). Refer to FIGURE 05-35.
  • Page 90 NOTE: Each fuel tank is pressure tested from the supplier and guaranteed leak proof. RANS also performs a pressure test on each fuel tank before they are packed. After you have installed the fuel fittings, it is advisable to perform a final leak test.
  • Page 91 05A-02 Use a 1/4" Allen wrench inserted into the tank fitting to hold the fitting while tightening the retaining nut. IMPORTANT: Do not allow the fitting or 1/2” thick washer to rotate while tightening or leaks may occur. HINT: Prevent the 1/2” thick washer from turning by holding with needle-nose Vise-Grips.
  • Page 92 05A-03 FUEL CAP ASSEMBLY Collect Fuel Cap Assembly and metal Retainer. Notice the Flush Fuel Cap must be orientated correctly to insert and lock into its Mounting Flange. Center metal Retainer on bottom side of Mounting Flange. Refer to FIGURE 05A-14. Transfer Drill #11. Cleco as you drill. NOTE: Mark Mounting Flange to allow re-alignment of Retainer during assembly into tank.
  • Page 93 05B-01 S-7S AILERON BELL CRANK AND CABLE INSTALL - WING (AFTER WING FRAME ASSEMBLY/ BEFORE COVERING OF WINGS) Locate the parts for the Bell Crank Assembly as per parts manual. Assemble 2 Upper and 2 Lower Bell Crank Assemblies per FIGURE 05B- 02 and FIGURE 05B-02A.
  • Page 94 RANS S-7S COURIER TEXT MANUAL 05C-1 S-7S WING – RIB & SHEET METAL INSTALLATION WING RIB ASSEMBLY NOTE: LORD brand FUSOR 108B/109B Adhesive is recommended for bonding the sheet metal wraps to the FWD & AFT wing spars. Leading Edge, Root, and Tip Wraps are riveted with 1/8”...
  • Page 95 RANS S-7S COURIER TEXT MANUAL 05C-2 INSTALLATION (AFTER ASSEMBLY OF WING FRAME) Pre-drilled #30 rib mounting holes are located in Leading & Trailing Edge Spars. De-burring of holes may be required. Modify 2 FWD Rib Attach Clips per FIGURE 05C-06. Orientate with tabs to the outboard side and rivet to pre-drilled holes at root of Leading Edge Spar.
  • Page 96 RANS S-7S COURIER TEXT MANUAL 05C-3 RIB STRINGER INSTALLATION Slide Outboard Rib Stringers into wing from the outboard side and cleco to upper and lower tabs on Ribs #3 thru #11. IMPORTANT: Outboard end of Outboard Rib Stringer may be identified by hole to hole dimension of 12.75”.
  • Page 97 RANS S-7S COURIER TEXT MANUAL 05C-4 UPPER AND LOWER ROOT SKINS The root skins consist of an Upper and Lower Skin. IMPORTANT: Upper Root Skin orientation is determined by an extra hole in the FWD Tip side of the skin. Refer to FIGURE 05C-23 for orientation.
  • Page 98 Scupper. Cover Ring will be removed for covering. Secure Fuel Cap Assembly to Fuel Tank. Be sure to use a fuel resistant sealant on the screw threads. RANS uses DOW 730 Solvent Resistant Sealant. Do NOT install Fuel Vent at this time; it will be installed after covering and painting.
  • Page 99 RANS S-7S COURIER TEXT MANUAL 05C-6 LEADING EDGE TIP WRAP The Leading Edge Tip Wrap must be pre-fit before final installing the Leading Edge Wrap. The tip wraps are pre-formed at the factory to match the radius of the Leading Edge Spar and the Tip Bow.
  • Page 100 Edge Spar. Refer to FIGURE 05C-57 Use a long straight board (1x2x144") and several (6 minimum) “C” clamps (or similar devices, RANS uses Stanley brand cushioned quick clamps) to retain the Wrap in position until the adhesive cures. A piece of wax paper between the board and the Wraps will prevent bonding the board to the Wraps.
  • Page 101 RANS S-7S COURIER TEXT MANUAL 05C-8 PITOT AND STATIC SYSTEM INSTALLATION - WING (AFTER WING FRAME ASSEMBLY) NOTE: The Pitot and Static Lines and the Pitot/Static Probe Assembly are located in the left wing only. Temporarily install the Pitot/Static Tube through the previously drilled 3/4"...
  • Page 102 RANS S-7S COURIER TEXT MANUAL 05C-9 FLAP TELEFLEX CABLE INSTALLATION - WING (AFTER WING FRAME ASSEMBLY) Route the Flap Teleflex Cable as per FIGURE 05C-69 and secure with plastic ties as shown to the Compression Tube and Inner Drag Brace.
  • Page 103 05D-01 S-7S AILERON AND FLAP ASSEMBLY AND INSTALLATION ASSEMBLY (BEFORE COVERING) Aileron and Flap Frames are factory assembled. Install nut plates for the hinges to the AFT side (inside) of the Flap Frame Leading Edge Spar before covering. NOTE: Aileron Frames do NOT require nut plates for hinge attachment.
  • Page 104 05D-02 INSTALLATION (AFTER COVERING AND PAINT OF WINGS) Install Flaps and Ailerons as per parts manual. NOTE: Flap Hinges are placed on the root side of the Trailing Edge Spar Hinges. Refer to FIGURE 05D-09. Tighten the castle nuts only to take out excessive play to avoid friction in the hinge point.
  • Page 105 05D-03 The Flaps must move freely without rubbing on the Gap Seals. A minimum clearance of 0.060” must be maintained between Gap Seal and Flap Leading Edge. Final fit the Gap Seal by filing, sanding, or planeing until proper clearance is obtained. HINT: A miniature Wood Plane works great to shave off excess material.
  • Page 106 Include strut inspection in your pre-flight. ASSEMBLY The S-7S Courier Lift Struts are cut to length and pre-drilled at the factory. Locate FWD and AFT Lift Struts and mark with “LEFT” and “RIGHT” on a strip of Masking Tape. Refer to FIGURE 05E-01. At this point it does not matter which one is left or right.
  • Page 107 05E-02 NOTE: Due to dimensional variation in extruded material, it may be necessary to shim the Strut Fittings. No gap should exist between the Fittings and the Struts. CAUTION: If a gap exists, do NOT eliminate by tightening down the Bolts. This action may crack the Struts. Instead fabricate and use the 0.020”...
  • Page 108 05F-01 S-7S WING TIP ASSEMBLY AND INSTALLATION WING TIP FIT UP AND ASSEMBLY (AFTER COVERING AND PAINTING OF WINGS / AFTER INSTALLATION OF AILERONS AND FLAPS) When fitting the Wing Tip, work carefully not to scratch the paint on the Wing.
  • Page 109 05G-01 S-7S ROOT SKIN INSTALLATION INSTALLATION (AFTER PAINTING OF WINGS) Apply desired finish to Root Rib Closeouts. Final install Root Rib Closeouts and Fuel Sight Gauge parts before the Wings are mounted to the aircraft. Refer to ROOT SKIN parts page and place Grommets and Serrated Strip in correct locations in FWD and AFT Root Rib Closeouts.
  • Page 110 05H-01 S-7S WING INSTALLATION Please read the entire section before you continue with Wing Installation. We recommend having all assemblies and installations related to the Wing completed before the Wings are final installed to the airplane. It is NOT necessary to trial-fit the Wings to the Fuselage at an earlier assembly stage. The following items should be completed at this stage: •...
  • Page 111 A helper is required to hold the wing secure at the wing tip, while drilling. Below is two ways of drilling the AFT hole. You may decide which one you use. RANS’ Assembly Crews have done it both ways, but Method #2 is recommended.
  • Page 112 I.D. to fit a long drill bit you have (a long #11 or 1/4” bit will work well). The bushing should fit tight in the “T”-Bone and extend long enough out of it to allow pulling it out. RANS uses a steel bushing with a welded on handle. Lubricate the bushing for ease of removal and insert through the front of the Leading Edge Spar and the “T”-Bone until bottomed...
  • Page 113 05H-04 Temporarily bolt the upper end of the AFT Jury Strut to the Teleflex Retainer Bracket. Use the tab on the AFT end of the Jury Strut Assembly to mark the lower end of the AFT Jury Strut. Drill using a #11 bit. Bolt the lower end of the AFT jury strut to the tab.
  • Page 114 05H-05 Install the assembled Pitot/Static Tube through the previously drilled 3/4" hole in the left Wing Leading Edge Spar. Refer to WING SPAR ASSEMBLY. Position the aft end even with the end of the Mount Angle and secure with two hose clamps. NOTE: Be sure the end of the Pitot/Static Tube is downward in relation to the wing.
  • Page 115 06-01 S-7S BOOT COWL AND INSTRUMENT PANEL INSTALLATION BOOT COWL FIT-UP (AFTER COVERING AND PAINTING OF FUSELAGE) NOTE: The Boot Cowl must be fit-up and drilled to the fuselage frame before the surface finish can be applied. It is recommended, to do this after the fuselage is covered and painted and the gear is installed.
  • Page 116 06-02 The receptacles should be approximate centered on the cut outs in the firewall. To install the receptacle, drill a # 11 hole and cleco the receptacle in place. Transfer drill the two # 40 holes through the receptacle. Countersink the # 40 holes to allow the rivet heads to be flush with the outside of the joggle surface.
  • Page 117 06-03 If installing panel-mounted radios, set-up the radio supports (side plate mounts) at this time. The aft end of the radio supports will be riveted to the instrument panel. Trim the forward ends as needed to clear Station 1. Attach the forward end to the two diagonal frame tubes, under the supports, with cushion clamps.
  • Page 118 06-04 FINAL INSTALLATION OF BOOT COWL AND INSTRUMENT PANEL Cut and finish the instrument panel as desired. NOTE: When laying out the panel, it is important to check that the instruments will clear the fuselage frame tubes under the Dash. The Boot Cowl should be final installed after the finish is applied and most of the assemblies and installations in the cabin and firewall forward are finished.
  • Page 119 06-05 Check that the panel clears the fuselage frame to avoid vibration transmitted directly to the panel. 09/01/2014...
  • Page 120 06A-01 S-7S FORMED WINDSHIELD / SKYLIGHT ASSEMBLY AND INSTALLATION FIT UP (AFTER WING INSTALLATION) IMPORTANT: This section does NOT go into the detail of trimming and drilling your Windshield, as there are volumes written on this already. More information may be found at http://www.plexiglas.com/. Both the literature and the viewing software are free.
  • Page 121 06A-02 Bring the ribs up to contact the straight edges. Place the outer rib to the outside of the standoff tube. Drill outer ribs # 30 using the standoff tubes as a guide and cleco. Drill outer ribs # 30 at the aft end through the fuselage tabs (rib mounts to the outside of tab).
  • Page 122 06A-03 Cut away a small portion of the protective plastic coating from the perimeter of the windshield. Cleco the Trim Strip Spacer to the "Z" Strip. Position the “Z” strip to the upper fuselage door frame tube on the inside of the fuselage so that the drilled flange is flat against the windshield and the cupped portion is capturing the tube.
  • Page 123 06A-04 trim strip and place on top of the skylight. Cleco in place. NOTE: The left outboard tab also captures the antenna plate for the ELT. Remove Skylight and drill all #30 holes in skylight to #28 and deburr. Do NOT drill the holes in the ribs larger than #30.
  • Page 124 06A-05 INSTALLATION Glue rubber trim to the outside edge of the skylight. Leave the forward end un-glued until trimmed for the mating strips. Apply foam tape to the “Z” strips at the tube contact points as shown in FIGURE 06-06. Apply foam tape to the top of the three windshield support ribs as shown in FIGURE 06-07.
  • Page 125 Rinse thoroughly and dry with a clean soft cloth or towel. RANS recommends “Brillianize” for windshield care. Brillianize is available from RANS Parts Department. NOTE: Never use gasoline, benzine, alcohol, acetone, thinner or glass cleaner on plastic surfaces (windshield, skylight and windows).
  • Page 126 06B-01 S-7S DOOR ASSEMBLY- LEXAN AND TRIM (REFER TO PARTS PAGE # 006-06 FOR PARTS SELECTION) (AFTER COVERING AND PRIMING OF DOORS/ BEFORE PAINT) Refer to FIGURE 06-09 Position the fwd & aft window support tubes as shown in FIGURE 06-09. The outer curve will be flush with the outer door frame.
  • Page 127 06B-02 Re-position the Lexan on the door frame and clamp in place. Starting at the top and bottom center, transfer drill through the Lexan into the pre-drilled holes in the door frame and support tubes. Cleco as you go. Remove the Lexan and chase drill all holes in the Lexan only to #28. This will allow for rivet expansion without inducing undue stress into the Lexan.
  • Page 133 IMPORTANT: The Boot Cowl, Engine, 1” Spacer and Spinner Backing Plate must be installed prior to fitting the cowling. If Firewall Forward was purchased less prop, contact RANS for the proper 1” Spacer. NOTE: It is also recommended to have the entire engine installation completed.
  • Page 134 06F-02 Install top and bottom cowls to the aircraft. Center the cowling at spinner backing plate. Cowling must rest firmly against 3/8” spacer. Tape both halves securely together. Check fit. If satisfied mark the bottom and top cowling around the rear edge at the hole locations of the receptacles located at the boot cowl joggle.
  • Page 135 Refer to the manual for basic covering technique. RANS currently uses SuperFlite U-500 glue, thinned with MEK when required. U- 500 will also be used to seal fabric or glue down tapes and patches. References may be made to applying a coat of glue over the entire surface.
  • Page 136 07-02 Thick & Thinned glue is referred to and is normally in the following approximate ratios. Thick = 3 parts glue : 1 part MEK Thinned = 1 part glue : 3 parts MEK Throughout this section, we will be referring to “sizing material”. Sizing material is U-500 adhesive thinned to water like consistency.
  • Page 137 07-03 COVER / PAINT STANDS Cover / Paint Stands may be fabricated from the plans provided in the FIGURES MANUAL. Refer to PARTS MANUAL for assembly and required hardware. Below is a list of the provided drawings. KP-100 A-FRAME STAND KP-103 WING ROOT ATTACH KP-107...
  • Page 138 07A-01 WINGS Clean the entire frame thoroughly. Blow out all Ribs and Wing Spars to remove metal shavings. Scotch-Brite all sheet metal surfaces and clean with Acetone. Cut out the 2 formed Bolt Covers to lay flat against the Leading Edge Spar and to cover the 3 FWD Strut Attach Plate Bolts.
  • Page 139 07A-02 Position the Wing top side up on sawhorses or other suitable work surface. HINT: RANS uses two "A" frame stands with pivots so the Wing can rotate and be locked in any position. You may consider purchasing or building such a device. Contact the factory for information. If you are using such a stand, it is acceptable to drill a 1/4"...
  • Page 140 07A-03 Size and cut the fabric around the Lift Strut Attach Plates, and Jury Strut Bracket. Thoroughly iron the entire Wing surface to final tension the top and bottom fabric. The fabric will need to be riveted under reinforcement Cover Straps to the center of each rib.
  • Page 141 07A-04 Cut to length and glue the 2" and 4" surface tape in place. Refer to FIGURES 07A-33 and 07A-37 and the following text. • TOP RIBS - 2" tape - centered on each Rib starting flush with the AFT edge of the Leading Edge Wrap and ending on AFT centerline of the Trailing Edge Spar.
  • Page 142 07B-01 AILERONS AND FLAPS Use a light hammer and form AFT ends of ribs to follow contour of trailing edge spar. Clean the entire frame thoroughly with Acetone or similar. Apply anti chafe tape around sharp edges of ribs (masking tape) as shown in FIGURE 07B-03.
  • Page 143 07C-01 FUSELAGE Clean the entire frame thoroughly. Apply anti chafe tape around sharp edges of vertical stabilizer rib (masking tape). Perform pre-covering check using the following items.  Vertical stabilizer former installed  Lower aft side former installed  Center aft side former installed ...
  • Page 144 07C-02 Position the fuselage bottom side up. Roll out and cut a piece of fabric long enough to cover the bottom of the fuselage. Slide the fabric to one side of the fuselage and trim off the excess material. Leave approximately 5" of material on all sides. Secure the fabric to the longerons using cloth pins.
  • Page 145 07C-03 Let dry. Iron the fabric along all the frame tubes and iron all the fabric edges down. Pre-iron the fabric all the way around to remove wrinkles and to pre-tension the fabric. Size the fabric around the horizontal stabilizer bushings using thinned glue.
  • Page 146 07C-04 Apply all patches and surface tapes (in this order) as per FIGURES 07C-34, 07C-35, 07C-35A, and 07C-36. NOTE: All exit rings, reinforcement rings, access ring, drain grommets, the rudder cable exit fairings and the vertical stabilizer rib receive a fabric patch on top. Iron all surface tape and patches, concentrating on the pinked edges.
  • Page 147 07D-01 HORIZONTAL STABILIZER Clean the entire frame thoroughly. Add anti-chafe tape (masking tape) around sharp edges of ribs similar to flaps and ailerons. Perform pre-covering check using the following items. Stabilizer frame is primed. Ribs installed Anti-chafe tape applied to sharp edges of ribs NOTE: Both sides of the horizontal stabilizers are covered with a separate piece of fabric.
  • Page 148 07D-02 Use a hot knife with a pointed tip or a soldering iron and melt through the cover strap and the fabric into the rib holes. Cut the melted build up on top of the Lexan straps off using a razor blade. Insert a rivet in each hole and rivet.
  • Page 149 07E-01 RUDDER Clean the entire frame thoroughly. Perform pre-covering check using the following items.  Hinge stop collars set and riveted.  Rudder frame primed. NOTE: Both sides of the rudder are covered with a separate piece of fabric. Cut fabric large enough to fit the frame and with enough excess to allow gluing around the frame tubes all the way around.
  • Page 150 07F-01 ELEVATOR Clean the entire frame thoroughly. Perform pre-covering check using the following items.  Hinge stop collars set and riveted.  Balance weight mount holes drilled and tapped  Elevator frames primed  Second control horn holes drilled  Nut plates for control horns attached NOTE: Both sides of the elevators are covered with a separate piece of fabric.
  • Page 151 07G-01 DOORS Clean the entire frame thoroughly. Perform pre-covering check using the following items. Door frames primed NOTE: Both sides of the lower doorframes are covered with a separate piece of fabric. Cut fabric large enough to fit the frame and with enough excess to allow gluing around the frame tubes all the way around.
  • Page 152 08-01 S-7S BAGGAGE COMPARTMENT ASSEMBLY AND INSTALLATION ASSEMBLY (BEFORE COVERING OF FUSELAGE) IMPORTANT: The baggage compartment must be fit-up before the fuselage is covered. Tape all sheet metal parts of the Baggage Compartment together. Refer to parts page drawing for proper orientation in relationship to the flanges. HINT: When assembled, flanges will NOT be visible from the inside of the Baggage Compartment.
  • Page 153 08-02 BAGGAGE COMPARTMENT INSTALLATION INSTALLATION (AFTER COVERING AND PAINTING OF FUSELAGE) Cover interior of Baggage Compartment with lightweight fabric or paint as desired. If covered in fabric, burn through mounting holes with a hot knife or soldering iron. Slip Baggage Compartment into fuselage. Retain with Machine Screws. CARGO NET Cargo Net will be retained by upper aft and fwd outer machine screws retaining Baggage Compartment.
  • Page 154 08A-01 S-7S SEAT ASSEMBLY AND INSTALLATION ASSEMBLY Using a #40 bit, drill through the center of the PVC inserts. Install the inserts into the Seat Tensioning Rib flush with the end of the Rib. Using a center punch, dimple the Rib near the end to secure the inserts. See FIGURE 08A-02.
  • Page 155 08A-02 Tape a straight edge to the forward side of the Seat as shown in FIGURE 08A-07. Position the Seat Attach Channels on centerline of each Bottom Tube, touching the straight edge and transfer drill through the Channels into the Seat Frame. NOTE: It is important to locate the Channels on the centerline to ensure that the Seats slide freely.
  • Page 156 08B-01 S-7S SEAT BELT ASSEMBLY AND INSTALLATION (REFER TO PARTS PAGE # 008-06 FOR PARTS SELECTION) (AFTER PRIMING OF FUSELAGE FRAME/ BEFORE COVERING) Prior to covering drill the fuselage lap belt mount tabs out to ¼". Refer to the parts drawing for the mount tab locations. Install the aft shoulder belt mount bolt into the bushing and temporarily finger tighten the nut onto the bolt.
  • Page 158 08D-01 S-7S STATION 3 CLOSE OUT INSTALLATION The Station 3 Close Out is a thermal formed plastic cover. Some trimming is required before installation. Modify Hold Down Strip per FIGURE 08D-01. Slide Hold Strip between welded fuselage tabs and Baggage Compartment Bottom. Locate and drill #11 holes.
  • Page 159 08E-01 S-7S THROTTLE CABLE COVER INSTALLATION The throttle cable cover is made from thermal formed plastic. Some trimming is required before installation. Follow the molded in trim lines and check fit. Refer to the parts drawing for general configuration. Locate the 3 small dimples in the cover and drill #11. Two will be used for mounting to the welded stubs.
  • Page 160 09-01 S-7S ELEVATOR MASS BALANCE The ELEVATORS must be a 100% static mass balanced in reference to the surface hinge line. Balance each surface separately, before mounting to the airplane. At the time of balancing the surface and attachments must be completely assembled and painted (ready for mounting).
  • Page 161 09A-01 S-7S WINGS WING WASHOUT RIGGING (AFTER WING INSTALLATION) NOTE: Washout is set after the Wings and Struts are installed. Washout is set by adjusting the lower rear strut fitting (rod end). A Digital Level can simplify rigging procedures. CAUTION: The Rod End must be screwed into the strut fitting a minimum of 10 complete turns.
  • Page 162 09A-02 AILERON RIGGING Neutral position and cable tension (AFTER WING INSTALLATION/ AFTER SETTING OF WASHOUT) Center forward control stick in neutral position (aileron neutral) and securely fix in this position. By adjusting the turnbuckles set the aileron bell cranks to neutral position as shown in FIGURE 09A-09.
  • Page 163 09A-03 Surface clearance Refer to FIGURE 05F-04. • The minimum clearance between aileron and wing tip is 0.13”. • The minimum clearance between aileron and flap is 0.2”. Operational check Move the controls in the cockpit throughout the full range of deflection. Check for: •...
  • Page 164 09A-04 Deflections For deflection measurements move flap lever all the way up (second notch). Measurement is taken on top surface of flap at approximate half span on top of flap rib. • Down: (Tolerance is +2.0 / -2.0 ) Surface clearance Refer to FIGURE 05F-04 •...
  • Page 165 09B-01 S-7S TAIL SURFACES TAIL ALIGNMENT AND ROD TENSION Rotating the brace rod in the tie rod ends sets the tail brace rod tension. Rods and rod ends are left and right hand threaded to allow that. The tension in the rods can cause the tail to warp or to get out of alignment.
  • Page 166 09B-02 ELEVATOR Neutral position In neutral position the elevators are level with the horizontal stabilizer. Verify using a straight edge across the surface with a 3/16" shim at the elevator trailing edge. It is possible to adjust at the connection of the elevator horns to the push-pull tube (rod ends).
  • Page 167 09B-03 Static balance Both elevators must be 100% static balanced in reference to the hinge line. For instructions refer to CONTROL SURFACE BALANCE. Operational check Move the controls in the cockpit throughout the full range of deflection. Check for: • Correct deflections of control surfaces.
  • Page 168 09B-04 Operational check • Correct deflections of trim tab. • Visual check trim tab for twist. • Check free movement of trim tab through one full motion and listen for unusual noises from servo. RUDDER Neutral position and cable tension Verify neutral position of rudder with forward rudder pedals neutral (visual).
  • Page 169 09C-01 S-7S CARBURETOR HEAT DESCRIPTION OF DESIGN Each one of the two carburetors of the Rotax 912ULS engine has a separate pre-heating system consisting of a heat exchanger, heat control unit and connecting duct hose. One control knob operates both systems. A heat exchanger is mounted to both sides of the exhaust muffler.
  • Page 170 09D-01 S-7S CABIN HEAT Check cabin heat valve is full “closed” with control knob in “OFF” position and full “open” with control knob in “ON” position. Adjust by loosening the padded clamp close to the control valve at the muffler wrap and sliding the cable housing up and down in the clamp.
  • Page 171 10-01 S-7S WEIGHT AND BALANCE INTRODUCTION This Section describes the procedures for establishing of basic empty weight and moment of the airplane. Procedures for calculating the weight and moment for various loadings are also provided. Sample forms are provided for reference. Refer to FIGURES 10-01 AND 10-01A in the FIGURES manual.
  • Page 172 10-02 WEIGHT AND BALANCE The follow ing w ill enable you to determine the w eight and balance of your aircraft and to operate it w ithin the prescribed center of gravit y limitations. The S-7S is a simple aircraft and so are the w eight and balance calculations. The S-7S is limited to tw o occupants.
  • Page 173 10A-01 S-7S LIMITATIONS INTRODUCTION The following operating limitations are necessary for the safe operation of the airplane. It is recommended to have the engine Operators Manual on board of the airplane. AIRSPEED LIMITATIONS The following airspeed limitations apply. Airspeed Remarks Do not exceed this 135 mph Never Exceed...
  • Page 174 10A-02 AIRSPEED INDICATOR MARKINGS Airspeed indicator markings and their color code meanings are shown in table below. Marking IAS Value or Meaning Range Full Flap Operating Range. Lower limit is 33 – 80 mph maximum weight stalling speed in landing White Arc configuration.
  • Page 175 10A-03 KINDS OF OPERATION LIMITS This aircraft is limited to two occupants only. During solo flights the pilot must sit in the front seat. FUEL LIMITATIONS Approved Fuel Grades: Dependent on engine used. Fuel Capacity: Total Capacity: 28.75 US GAL Total Capacity each Wing Tank: 13.00 US GAL Total Capacity of Header Tank...
  • Page 176 10B-01 S-7S NORMAL PROCEDURES The following checklists are provided for guidance only. It is suggested that the owner of the aircraft adds items they deem necessary. PREFLIGHT INSPECTION Visually inspect the aircraft for its general condition during the walk around. In addition to the items listed on the preflight checklist, look for signs of visible ice if applicable.
  • Page 177 10B-02 The entire outer surface of the AC should be inspected for damage of any kind during the preflight inspection. This is especially important due the fact that the AC is fabric covered. 1 Cabin Parking brake – SET Ignition switch - OFF Master switch - OFF Avionics Master - OFF Circuit Breakers - CHECK IN...
  • Page 178 10B-03 3 Left Wing- Trailing Edge Fuel quick drain valve on bottom of fuselage (behind rear seat); - DRAIN at least a cupful of fuel (using sampler cup) to check for water, sediment and proper fuel grade before first flight of day and after each refueling.
  • Page 179 10B-04 5 Nose Fuel quick drain valve on bottom of cowling (left side); - DRAIN at least a cupful of fuel (using sampler cup) to check for water, sediment and proper fuel grade before first flight of day and after each refueling.
  • Page 180 10B-05 7 Right wing- Trailing Edge Aileron – CHECK freedom of movement and security Flap – CHECK security Rear strut and jury strut attach – CHECK security, dents, nicks Fabric (Surface) - CHECK - for rips, tears, damage BEFORE STARTING THE POWERPLANT Preflight Inspection - COMPLETE.
  • Page 181 10B-06 HOT START Throttle - CLOSED. Choke - OFF. Master Switch - ON. Propeller Area - CLEAR. Ignition Switch - START (release when engine starts) Throttle adjust – IDLE smooth – up to 2500 RPM Oil pressure - CHECK Avionics master - ON. TAXIING Brakes - CHECK.
  • Page 182 10B-07 TAKEOFF NORMAL TAKEOFF Flaps – UP or HALF. Carburetor heat – COLD Fuel pump - ON Throttle – SLOWLY FULL OPEN. Elevator Control - LIFT TAIL WHEEL Climb Speed – 65 - 70 MPH SHORT FIELD TAKEOFF Flaps - HALF. Carburetor heat - COLD Fuel pump - ON Brake - APPLY.
  • Page 183 10B-08 APPROACH Throttle - AS DESIRED. Engine temperatures – MONITOR Carburetor heat – FULL HEAT AS REQUIRED BEFORE LANDING Seat, Belts, Shoulder Harness - ADJUST. Fuel pump – ON Carburetor heat – FULL HEAT AS REQUIRED LANDING NORMAL LANDING Airspeed (on approach) – 66-70 MPH (flaps UP). Flaps (on final) - AS REQUIRED (below 69 MPH) Airspeed (on final) - 64 MPH (with full flaps) Touchdown - MAIN WHEELS FIRST OR THREE WHEEL...
  • Page 184 10B-09 BALKED LANDING Throttle – FULL OPEN Carburetor heat – COLD Airspeed – 55 MPH Wing Flaps – RETRACT TO HALF, Slowly Airspeed – 60 MPH Wing flaps – RETRACT, Slowly AFTER LANDING Wing Flaps - UP. Taxi - SLOWLY. Carburetor Heat- OFF.
  • Page 185 Refer to FIGURE 10-08. Starting at the nose, work around the Rans S-7S aircraft in a clockwise manner as illustrated. NOTE: This suggested outline for a preflight inspection generally covers the critical areas that MUST be checked prior to each flight.
  • Page 186 10B-011 USE UP AILERON USE UP AILERON ON LH WING ON RH WING AND UP ELEVATOR AND UP ELEVATOR USE DOWN AILERON USE DOWN AILERON ON LH WING ON RH WING AND DOWN ELEVATOR AND DOWN ELEVATOR FIGURE 10-09. Taxiing Diagram The arrows identify the wind direction.
  • Page 187 10B-012 The S-7S is equipped with a steerable full swivel tail wheel. To taxi very small radius turns, push the desired rudder pedal and the brake pedal in the same direction. This will disengage the steering cam and will allow the tail wheel to swivel 360 degree.
  • Page 188 10C-01 S-7S EMERGENCY PROCEDURES INTRODUCTION This section provides checklists and amplified procedures for coping with emergencies that may occur. Emergencies caused by aircraft or powerplant malfunctions are rare if proper preflight inspections and maintenance are performed. Emergencies caused by extreme weather situations can be minimized or eliminated by good judgment and proper preflight planning.
  • Page 189 10C-02 OPERATIONAL CHECKLISTS ENGINE FAILURE Engine Failure During Takeoff Run: Fly the Airplane! Throttle - IDLE. Brakes - APPLY as needed. Ignition switch - OFF. Master switch - OFF. Engine Failure Immediately After Takeoff Fly the Airplane! Airspeed - 66 MPH (Flaps up). 59 MPH (Flaps down).
  • Page 190 10C-03 Precautionary Landing With Engine Power Fly the airplane! Select Field - FLY OVER, noting terrain, obstructions and wind direction. Flaps - AS REQUIRED (for landing site). Airspeed 59 MPH (Flaps UP). 55 MPH (Flaps full DOWN) (Use flaps as required for landing site). Master Switch - OFF.
  • Page 191 10C-04 Electrical Fire In Flight Fly the airplane! Master Switch - OFF . All Other Switchs (except Ignition switch) OFF. If fire appears out and electrical power is necessary for continuance of flight: Circuit Breakers - CHECK for faulty circuit, do not reset faulty circuit Master Switch - ON.
  • Page 192 10C-05 AMPLIFIED PROCEDURES ENGINE FAILURE If an engine failure occurs during the takeoff run, the most important thing to do is to stop the aircraft on the remaining runway. Those extra items on the checklist will provide added safety during a failure of this type. The first response to an engine failure, after takeoff, is to promptly LOWER the nose and establishes a glide attitude (check and maintain speed).
  • Page 193 10C-06 FORCED LANDINGS Select a suitable landing site and proceed to it. If all attempts to restart the engine fail and a forced landing is imminent, follow the checklist for Emergency Landing Without Power. Before attempting an off airport landing with engine power available, fly over the landing site at a safe but low altitude to inspect the terrain.
  • Page 194 10C-07 CARBURETOR ICE A sudden engine roughness or loss of rpm could be Carburetor Ice problems. Actuate the Carburetor Ice by pulling on the Carburetor Ice Control Knob. As soon as the engine roughness or suspected carburetor ice is gone turn off the Carburetor Heat.
  • Page 198 11B-01 S-7S WHELEN STROBE INSTALLATION (REFER TO PARTS PAGE # 011-06 FOR PARTS SELECTION) STROBE POWER BOX INSTALLATION (AFTER PAINTING OF FUSELAGE – DURING FINAL ASSEMBLY) Refer to FIGURE 11B-01 Position cushioned tube clamps on the Station 3 lower crossing tube and lower diagonal tube.
  • Page 199 11B-02 Run a 14-gauge wire from the NAV switch back to the strobe box area. Connect a brass "Y" to the end of the wire. The 14-gauge wire coming out of each wing will connect to the "Y". NOTE: Wrap the “Y” with electrical tape, after connection, to prevent shorting.
  • Page 200 11C-01 S-7S SENSENICH COMPOSITE PROP INSTALLATION (REFER TO PARTS PAGE # 011-08 FOR PARTS SELECTION) Refer to FIGURES 06-13, 06-14, 06-15 and 11C-01. Install the flange bushings into the prop flange on the engine from the aft side. Use a “C” clamp to completely seat the bushings into the flange. Place a small wood block between the pad of the clamp and the aluminum bushing to protect them from being damaged.
  • Page 201 11C-02 When servicing your propeller, refer to: SENSENICH PROPELLER CO., INC. EZ-PITCH COMPOSITE AIRCRAFT PROPELLER INSTALLATION AND OPERATION INSTRUCTIONS. DOC#: COMP-AC-CF (Adjustable Pitch) Propellers: Propeller Manufacturer: Sensenich propeller Inc. Propeller Model Number: 2A1R5R70D(N)* Number of Blades: Propeller Diameter: 70” Propeller Type: 2 blade, adjustable pitch * An (N) at the end of the part number denotes a nickel leading edge.
  • Page 202 11D-01 S-7S WARP DRIVE PROP INSTALLATION (REFER TO PARTS PAGE # 011-10 FOR PARTS SELECTION) Refer to FIGURES 06-13, 06-14, 06-15 and 11D-01. Install the flange bushings into the prop flange on the engine from the aft side. Use a “C” clamp to completely seat the bushings into the flange if needed. Place a small wood block between the pad of the clamp and the aluminum bushing to protect them from being damaged.
  • Page 203 11E-01 S-7S WHIRL WIND PROP INSTALLATION 1. Using the template from FIGURE 11E-01, mark and cut out the openings in the spinner dome. 2. Drill and install the spinner dome to the backing plate. Refer to SECTION 06 – SPINNER and PROPELLOR INSTALLATION sections. 3.

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