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R
Title or
Hard landing repair + oil thermostat addition
Task Description
(MRA request received 30
NOTE: Any external documents referenced on this form should include revision level, issue date, and title as appropriate.
BLOCK 1 – AIRCRAFT INFORMATION (to be filled out by the manufacturer)
S/N:
891 SNM 912 LSA
BLOCK 2 – OWNER INFORMATION (to be filled out by the manufacturer)
Name:
Mr Joel Garris
Address:
129 Spinnaker Mall, Marina Del Rey, 90292 California
Equipment
Manufacturer
Fuselage
Pipistrel
Powerplant
Rotax GmbH
Propeller
Pipistrel
The Aircraft OEM confirms the
aircraft being repaired or altered
still meets the requirements of the
applicable ASTM design and
performance specification
subsequent to completion of the
repair or alteration specified in the
MRA
DISCLAIMER: It is the responsibility of the person that performs this MRA to ensure the equipment installed or item repaired functions properly and
doesn't negatively affect any other installations/equipment close to where the MRA was performed, as this is something the manufacture cannot check.
This MRA has been generated based on the aircraft configuration data provided by the owner/requester and is to be rendered invalid if the
owner/requester doesn't provide the manufacturer with any/all information regarding repairs/alterations performed on the aircraft prior to the issue of
this MRA. The information provided in this MRA is, by no means, task specific training and must not be considered as such.
BLOCK 5 - CONFORMITY STATEMENT - RETURN TO SERVICE (to be filled out by the customer)
I hereby certify the repair and/or alteration has been completed in accordance with this MRA and all
the referenced documents. Potentially unclear procedures have been clarified with the Aircraft OEM.
Certificate holder's name
and address
Return to service declaration
I, the signee and certificate holder,
hereby confirm that I meet the
minimum required level of
qualification as outlined in this
MRA, I have indicated completion
of this MRA in the aircraft's
logbook by referencing MRA011-21
and any/all national
requirements/regulations have
been adhered to
LSA Major Repair and/or
Alteration (MRA)
June 2021)
th
Registration:
N88NN
BLOCK 3 - AIRCRAFT DATA (to be filled out by the manufacturer)
Model
Sinus MAX
Rotax 912 UL2
VARIO D
BLOCK 4 - MRA APPROVAL (to be filled out by the manufacturer)
Date of approval:
16th September 2021
Name:
Andrej B Horvat
No issues were observed that might hinder return to service.
Required level of qualification.
(to be marked by manufacturer, multiple marks indicate
any may perform the MRA)
Pilot/Owner
LSA repairman
AMT
X
Repair station
X
Manufacturer
Other:
Date
Engine time/Hobbs: 261
Total time
since new
n/a
n/a
n/a
Certificate type and number
Signature
Doc#: MRA011-21
Rev: A00
Replaces: n/a
Date: 16.09.2021
Total time
since overhaul
n/a
n/a
n/a
Digitally signed by
ANDREJ BERNARD
HORVAT
Reason: Engineering office
Location: Nova Gorica,
Slovenia, EU
Date: 2021/09/16 21:59
+02'00'
Rating
Airframe class 1
Powerplant class 1
Propeller class 1
Page 1 of 33

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Summary of Contents for Pipistrel LSA-MRA

  • Page 1 BLOCK 3 - AIRCRAFT DATA (to be filled out by the manufacturer) Equipment Manufacturer Model Total time Total time since new since overhaul Fuselage Pipistrel Sinus MAX Powerplant Rotax GmbH Rotax 912 UL2 Propeller Pipistrel VARIO D BLOCK 4 - MRA APPROVAL (to be filled out by the manufacturer)
  • Page 2 Doc#: MRA011-21 LSA Major Repair and/or Rev: A00 Alteration (MRA) Replaces: n/a Date: 16.09.2021 BLOCK 6 – AIRCRAFT CONFIGURATION PREREQUISITES (to be filled out by the manufacturer) This MRA is only valid for the aircraft identified in Blocks 1 and 3, when the configuration conforms with the following definitions.
  • Page 3 Primer and adhesive foam tape, All the material stated in the Quotation Nr: 310009112-1 BLOCK 8 - ACCOMPLISHMENT INSTRUCTIONS (to be filled out by the manufacturer) Applicable references: [1] POM-VARIO-00-65-001 Pipistrel VARIO propeller operators manual (latest revision) [2] AMM-100-00-60-001 LSA maintenance manual (latest revision)
  • Page 4 Airplane preparation instructions: Drain the fuel from the fuel reservoirs (See chapter 12 in [2]). Remove the wings (See 57-10 in [2]). Remove the horizontal stabilizer (See 55-10 in [2]). Disconnect the throttle/choke cables (See 0:55 in [6]). Disconnect the steering mechanism cables from the nose gear. Remove all the firewall forward material (See chapters 61, 71, 75.
  • Page 5 Figure 00-001: Example of template of the holes for of the rudder springs retaining fastening material in the fuselage belly Follow 31-10 in [2]: and remove the switch panel, instrument panel cover, instrument panel and the instrument panel housing (For better visual presentation see 31-10 in [8]).
  • Page 6 Take measure of the distance between engine mount reinforcements on the firewall (port and starboard side) and the fwd fuselage edge. See Figure 00-003. The measured value will be a reference at firewall inserts installation. Make a template out of a cardboard or similar material, in the shape of a firewall. Try to pull the damaged material in its original form, place the template on the firewall and mark all the bolts and holes on the firewall for later re-installation (See Modification 13).
  • Page 7 Figure 02-001 part 2. e. Prepare some resin and cut the plies of 92125 ((Pipistrel P/N 5071006) 0°/90° and top layer 1x 92110 (Pipistrel P/N 5071002) 0°/90° so that they extend beyond the damaged and grinded area by 2 cm.
  • Page 8 1x 92110 (Pipistrel P/N 5071002) 45°/45° Seat backrest laminate plan from inner ply to outer: 1x 92110 (Pipistrel P/N 5071002) 45°/45° 1x Kevlar 200 g/m2 twill (Pipistrel P/N: 5073002) 45°/45° 1x C160 (8048) – GG160P (Pipistrel P/N: 5072005) 45°/45° 1x 92125 (Pipistrel P/N 5071006) 45°/45°...
  • Page 9 Apply the plies and resin over the tapered and sanded area on the seat pan and on the seat backrest from the cabin and baggae compartment side (Figure 02-001 part 3). Allow to cure for 8 hours at 56°C. m. Sand all sides of the repair area and make them flush with the rest of the surface. On the bottom side of the sat pan and on the seat backrest a light bulge can be left for additional material strength.
  • Page 10 Figure 04-001: White silicone application and M14 nuts, hexagon socket bolts and conical washers installation. Apply to M10 bolts to the holes drilled earlier and apply some Loctite 243 to the nut thread. Then remove the two M8 bolts from before. Ream the two 8 mm holes with the 10 mm drill bit, fit the last two M10 bolts and once again apply some Loctite 243 (See 32-10 in [8] and Figure 04-001).
  • Page 11 Figure 04-003: Bottom cover preparation. Drill ø3.2mm holes on all four corners and in the middle too. 6 holes in total (Figure 04-004 step 5). Drill a M4 thread into the ø3.2mm holes with tap drill & taps bit and fasten the M4 button bolts (Figure 04-004 step 5).
  • Page 12 Modification 5 – BERRINGER MAIN UNDERCARRIGE WHEELS INSTALLATION a. Reinstall the wheel/brake system according to [5]. CORRECTION: Be sure to tighten the M14 nut at the end of the wheel axle to 55 Nm instead of the 40 Nm indicated on page 2 of [5] b.
  • Page 13 Figure 05-002 Whell fairing alignment and installation. Modification 6 – FIREWALL REMOVAL a. Keep the aircraft in right side up position b. Perform steps 12 to 16 in [3]. Modification 7 –SEAT PAN INSERT REMOVAL AND FWD FUSELAGE BELLY REPAIR. a.
  • Page 14 NOTE: The airex foam has to be firmly pressed to the fuselage and has to form the crease in the fwd fuselage belly. Prepare some resin and cut the plies of 92125 (Pipistrel P/N 5071006) 0°/90° and top layer 1x 92110 (Pipistrel P/N 5071002) 0°/90° so that they extend beyond the damaged area by 2cm inside the fuselage (Figure 07-003 Step 2).
  • Page 15 NOTE: Make sure the length of the newly formed fwd fuselage belly is exactly the length of the original. m. Apply the plies and resin over the crack and damaged area on the front edge of the fuselage belly. Allow to cure for 8 hours at 56°C (Figure 07-003 step 2). n.
  • Page 16 Fuselage repair laminate plan from inner ply to outer: 2x 92125 (Pipistrel P/N 5071006) 0°/90° 1x 92125 (Pipistrel P/N 5071006) 45°/45° 1x 92125 (Pipistrel P/N 5071006) 0°/90° 1x 92110 (Pipistrel P/N 5071002) 0°/90° r. Apply resin and first four plies from the fuselage repair laminate plan over the crack on the fuselage belly and damaged area on the front edge of the fuselage belly (Figure 07- 003 Step 3).
  • Page 17 Cut plies according to the seat pan repair laminate plan. Seat pan laminate plan from inner ply to outer: 1x 92125 (Pipistrel P/N 5071006) 45°/45° 1x 92110 (Pipistrel P/N 5071002) 45°/45° 1x GG200P (Pipistrel P/N 5072006) 45°/45°...
  • Page 18 Modification 9 – WINDSHIELD REPLACEMENT and CABIN SUPPORT ASSEMBLY WITH BUSHINGS REPAIR a. Assemble the cabin support assembly with bushing levelling tool (Figure 09-001) as shown in the Figure 09-002 Figure 09-001: Cabin support assembly with bushing levelling tool (Pipistrel P/N: 1190613). Page 18 of 33...
  • Page 19 b. Determine the amount, location and direction of the damage on the cabin support assembly and accordingly apply force in the opposite direction by tightening the central bolt. NOTE: First bring the cabin support assembly with bushing to a levelled position and then apply slightly more force.
  • Page 20 NOTE: Inspect the bushing rod reinforcement from inside the cabin with a tap test (See 51-10: 2.2. in [2]). Run a tap test with a smaller metal rod and if any hollow sounds can be heard the fuselage has been damaged. Please contact support@pipistrel-aircraft.com for information about how to proceed.
  • Page 21 Modification 11 – FIREWALL PROTECTION INSTALLATION a. Perform steps 68 to 78 in [3]. Modification 12 – RUDDER PEDALS REINSTALLATION. a. Place the Template made in step 00-n on the seat-pan and mark the drill holes (Figure 12-001). b. Drill the bigger holes with Ø 8,5 and smaller ones with Ø4 drill bit (Figure 12-001). Figure 12-003: Installation of rudder cable insert.
  • Page 22 NOTE: Install the shorter spring to the starboard side and longer spring to the port side rudder pedals. Figure 12-004: Upper insert and PVC tube installation. Make sure the angle is correctly oriented (Figure 12-005). k. Mark 45 mm aft of the installed insert. (Figure 12-005 – middle figure). Position the pedals to the fwd most position and run the braided cable through the lower PVC tube, through spring and back into the cabin through the upper PVC tube.
  • Page 23 n. Cut the braided wire at the marked spot and install the rubber grommet, handle and all its fastening material. o. Apply silicone grease along the pedals guide and adjustable base and move the pedals fwd and aft to inspect their movement. Modification 13 –...
  • Page 24 q. Install the fuel system hoses (See [6] 48:16 and 111-73.10.000 in [8]) Connect fuel feed line to the gascolator and the return line to the firewall pass through fitting using hose clamps (See 44:44 in [6] and 73-10 in [8]). Connect the two grounding cables to the starter and to the starboard intake manifold.
  • Page 25 Modification 16 – ENGINE FAIRINGS INSTALLATION NOTE: Mounting engine cowling requires patience and attention to detail. While going through this manual make sure you take your time, ensuring each step is carried out properly. 1. Place upper and lower cowling on the workbench, fit them together and tape one to the other using masking tape.
  • Page 26 7. Redrill the holes in the lower cowling with a Ø11.5 mm drill bit. Use dremel tool and an appropriate grinding bit to give the holes a nice chamfer. Apply Loctite 243 on the quick connect bolt´s base and then use the spacer and nut to secure the quick connect bolt´s base in place.
  • Page 27 NOTE: The process explained in step 13 may have to be repeated after later steps. 14. Slide the cowling over the engine and temporarily mount your propeller Push the cowling over the fuselage`s front edge until gap between the spinner`s back edge and the cowling`s front face is 10-15 mm (Figure 16-001 green marking).
  • Page 28 20. Extend the lines along the cowling´s back edge which were drawn in step 9). More lines should be added for later better orientation/accuracy (Figure 16-005). 21. Trace the back edge of the cowling onto the fuselage (Figure 16-005). This helps to determine the new length of the cowling´s and the amount of material that needs to be removed.
  • Page 29 force the star washer over the bolt housing to the cowling and, at the same time, clear the pin at the base of the bolt. Figure 16.007: Slotted tool and quick connect bolts installation. 30. Widen all the new holes drilled in the fuselage´s rim with Ø7 drill bit and give the holes outer edge a nice chamfer with dremel tool and a round grinding bit.
  • Page 30 34. Cut the hole for the bottom oil cooler by removing the cowling from the fuselage and placing it to the workbench. Use a Dremel tool to cut a hole 22-23 cm long, 7-8 cm wide and 1.5 – 2 cm away from the bottom edge. After reinstalling and taping the cowling to the fuselage inspect the bottom oil cooler opening.
  • Page 31 41. Mount both cowlings to the fuselage. Determine where the brackets are positioned and on the lower cowling drill Ø2 holes through the cowling into the brackets. 42. Redrill all the brackets holes with Ø4 drill bit and after that remove the cowling, place it to the workbench, redrill the holes with Ø4,2 drill bit and using M4 bolts install the cowlings to the fuselage.
  • Page 32 46. Another strip of adhesive foam tape needs to be applied to the inside surface of the lower cowling, just above the oil cooler opening (Figure 16-012). Line up the tape´s lower edge with the opening´s upper edge. Apply a bead of black silicone along the outer edge of the tape.
  • Page 33 Carry out a thorough visual inspection of the fuselage belly, main LDG strut, firewall and seat pan, after the first flight, subsequent to the modifications being performed. Check for any signs of damage. Notify your local Pipistrel dealer of all and any issues. BLOCK 10 - ENGINEERING DATA (not applicable)