Rans N512DT Text Manual
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Rans N512DT Text Manual

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S-21 OUTBOUND
TEXT MANUAL
Serial Number:
Registration Number:
COPYRIGHT ©
RANS DESIGNS
4600 HWY 183 Alt
HAYS, KANSAS, USA 67601
785-625-6346
www.rans.com
09/11/2018

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  • Page 1 S-21 OUTBOUND TEXT MANUAL Serial Number: Registration Number: COPYRIGHT © RANS DESIGNS 4600 HWY 183 Alt HAYS, KANSAS, USA 67601 785-625-6346 www.rans.com 09/11/2018...
  • Page 2 RANS S-21 OUTBOUND TEXT MANUAL ASSEMBLING 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 RANS S-21 OUTBOUND TEXT MANUAL 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-21 S-21 S-21 OUTBOUND OUTBOUND OUTBOUND TEXT PARTS FIGURES MANUAL MANUAL MANUAL...
  • Page 4 RANS S-21 OUTBOUND TEXT MANUAL REVISION FORM Revision # Pages Description Date Affected Original Original Issue 09/11/2018 09/11/2018...
  • Page 5 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. When calling for technical support or parts department, please have the following ready: •...
  • Page 6 RANS S-21 OUTBOUND TEXT MANUAL ENGINEERING DEPT. DRAWING NUMBERING SYSTEM RANS DESIGNATES DRAWINGS 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...

  • Page 7: Table Of Contents

    RANS S-21 OUTBOUND TEXT MANUAL TABLE OF CONTENTS GENERAL INFORMATION _____________________________________________ 10 IMPORTANT: PLEASE READ FIRST _______________________________ 12 AIRCRAFT TOOL LIST __________________________________________ 15 RECOMMENDED AVIONICS LIST __________________________________ 17 AIRCRAFT REGISTRATION ______________________________________ 18 SAMPLE CHECKLIST FOR A CONDITION INSPECTION _______________ 25...
  • Page 8 RANS S-21 OUTBOUND TEXT MANUAL WING ______________________________________________________________ 57 WING SPAR ASSEMBLY _________________________________________ 57 OPTIONAL LANDING LIGHTS INSTALLATION _______________________ 58 AILERON BELLCRANK ASSEMBLY _______________________________ 59 FLAP BELLCRANK ASSEMBLY ___________________________________ 60 WING RIB / SPAR ASSEMBLY ____________________________________ 61 WING SKIN INSTALLATION ______________________________________ 64...
  • Page 9 RANS S-21 OUTBOUND TEXT MANUAL FUSELAGE INTERNAL _______________________________________________ 102 FLOORBOARD INSTALLATION __________________________________ 102 RUDDER PEDAL ASSEMBLY - (FINISHING KIT) _____________________ 102 RUDDER SYSTEM ASSEMBLY AND INSTALLATION - (FINISHING KIT) _ 103 HYDRAULIC BRAKE INSTALLATION _____________________________ 104 SLIDING SEAT ASSEMBLY ______________________________________ 106...
  • Page 10 AIRPLANE WEIGHING PROCEDURES ____________________________ 154 WEIGHT AND BALANCE ________________________________________ 156 POST FLIGHT RIGGING ______________________________________________ 157 DETERMINING ACTION _________________________________________ 157 RANS S-21 OUTBOUND - THREE VIEW ____________________________ 162 GENERAL INFORMATION _______________________________________ 163 STEERING AND BRAKING ______________________________________ 164 OPERATING LIMITATIONS ______________________________________ 165...

  • Page 11: General Information

    RANS S-21 OUTBOUND TEXT MANUAL GENERAL INFORMATION INTRODUCTION The S-21 Outbound is a 51% FAA approved kit. Some inspectors may still require a build log, therefore it is recommended to keep a build log. A build log can be as simple as photos of the kits' assembly throughout the process or using one of the many on-line offers.
  • Page 12 RANS S-21 OUTBOUND TEXT MANUAL BEFORE BEGINNING ASSEMBLY TAKE INVENTORY: You must complete an inventory within 60 days of receiving your kit. We check and re-check and are 99.9% certain that if we say we shipped it, we did. The first task in building your kit is to inventory the parts using the packing list provided.

  • Page 13: Important: Please Read First

    RANS S-21 OUTBOUND TEXT MANUAL 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 the Assembly Manual, follow along in the Parts and Figure Drawings Manual.
  • Page 14 RANS S-21 OUTBOUND TEXT MANUAL Primer is always a debate when it comes to aluminum aircraft. Part of the decision to use 6061 was to get away from priming, as 6061 exhibits good corrosive resistance. We recommend priming overlaying surfaces. If you live near the ocean, your aircraft will be on floats, or the aircraft will be stored outside it may be a good idea to prime all aluminum surfaces.
  • Page 15 Please record your serial number and have it handy whenever you call the factory for assistance. 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...

  • Page 16: Aircraft Tool List

    RANS S-21 OUTBOUND TEXT MANUAL 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 17 RANS S-21 OUTBOUND TEXT MANUAL LUBRICANTS, ADHESIVES, TAPES & ETC Small Can Lithium Grease Clear Silicone WD40 Super Glue Lubricating oil Loctite Blue Thread locker DOW 730 Sealant, PRC or similar 3M Super 77 Spray Adhesive 3M 2216 Adhesive (4 oz.) PRO-SEAL 890-B2 Sealant 1/4”...

  • Page 18: Recommended Avionics List

    RANS S-21 OUTBOUND TEXT MANUAL RECOMMENDED AVIONICS LIST Digital Display GARMIN G3X WITH G5 BACKUP Comm Radios GARMIN GTR 200B Transponder GARMIN GTX 335 Encoder GARMIN GPS (for non-digital display systems) GARMIN AERA 660 ACK Technologies E-04 Push to Talk Switch...

  • Page 19: Aircraft Registration

    RANS S-21 OUTBOUND TEXT MANUAL AIRCRAFT REGISTRATION INTRODUCTION: All aircraft of U.S. registry are required to have the following documentation onboard. For aircraft registered in other countries contact your National Aviation Authority. Airworthiness Certificate Registration Operating Limitations Weight and Balance Information NOTE: The bold letters above spell out AROW.
  • Page 20 RANS S-21 OUTBOUND TEXT MANUAL N-Numbers consist of a series of alphanumeric characters. U.S. registration numbers may not exceed five characters in addition to the standard U.S. registration prefix letter N. These characters may be: one to five numbers (N12345)
  • Page 21 RANS S-21 OUTBOUND TEXT MANUAL REGISTERING YOUR AIRCRAFT Refer to the FAA website, www.faa.gov for info on registering your aircraft. After you have written the Aircraft Registry requesting an "N" number, or applied on-line, you will receive a form letter giving your number assignment. After completion of the aircraft, complete the on-line Application for Aircraft Registration (AC FORM 8050-1) and return it to the Aircraft Registry along with the $5.00 registration fee.
  • Page 22 RANS S-21 OUTBOUND TEXT MANUAL MY AIRCRAFT IS COMPLETED, ALL MARKING AND PLACARDS ARE IN PLACE. WHAT ELSE MUST I DO TO MY AIRCRAFT BEFORE I AM READY FOR MY PRE- CERTIFICATION INSPECTION? Included in your manual is a weight and balance sheet. This will need to be completed before the inspection.
  • Page 23 RANS S-21 OUTBOUND TEXT MANUAL FINAL INSPECTION Use the 2 lists below for inspection of the aircraft. Refer to www.faa.gov. These should be very helpful in getting your airplane signed off by the FAA Inspector and ensuring that your airplane is safe for operation.
  • Page 24 RANS S-21 OUTBOUND TEXT MANUAL (3) Internal engine—for cylinder compression and for metal particles or foreign matter on screens and sump drain plugs. If there is weak cylinder compression, for improper internal condition and improper internal tolerances. (4) Engine mount - for cracks, looseness of mounting, and looseness of engine to mount.
  • Page 25 RANS S-21 OUTBOUND TEXT MANUAL (g) Each person performing an annual or 100-hour inspection shall inspect (where applicable) all components and systems that make up the complete empennage assembly for poor general condition, fabric or skin deterioration, distortion, evidence of failure, insecure attachment, improper component installation, and improper component operation.

  • Page 26: Sample Checklist For A Condition Inspection

    RANS S-21 OUTBOUND TEXT MANUAL SAMPLE CHECKLIST FOR A CONDITION INSPECTION AC90-89 APPENDIX 1 AIRCRAFT IDENTIFICATION: TYPE/SN ENGINE MODEL/SN “N” NUMBER PROPELLER MODEL/SN A/F TOTAL TIME ENGINE TOTAL TIME OWNER PROPELLER TOTAL TIME BUILDER INSPECTOR Unsat Unsat GENERAL: REGISTRATION/AIRWORTHINESS/OPERATING LIMITATIONS...
  • Page 27 RANS S-21 OUTBOUND TEXT MANUAL POPPED RIVETS/CRACKED/DEFORMED SKIN FABRIC/RIB STITCHING/TAPE CONDITION LUBRICATION WING ATTACH POINTS FLYING/LANDING WIRES/STRUTS FOR SECURITY CORROSION FLIGHT CONTROL PLACARDS INSPECT FIREWALL FOR DISTORTION AND CRACKS INSPECT RUDDER PEDALS AND BRAKES FOR OPERATION AND SECURITY INSPECT BEHIND FIREWALL FOR LOOSE WIRES AND CHAFFING LINES...
  • Page 28 RANS S-21 OUTBOUND TEXT MANUAL ENGINE: PERFORM COMPRESSION TEST #1 CHANGE OIL AND FILTER (CHECK FOR METAL) INSPECT IGNITION HARNESS FOR CONDITION AND CONTINUITY CHECK IGNITION LEAD CIGARETTES FOR CONDITION/CRACKS CLEAN AND GAP SPARK PLUGS CHECK MAGNETO TIMING/POINTS/OIL SEAL/DISTRIBUTOR INSPECT ENGINE MOUNT/BUSHINGS...
  • Page 29 RANS S-21 OUTBOUND TEXT MANUAL ELECTRICAL SYSTEM CHECK COOL DOWN PERIOD/ENGINE SHUT DOWN PERFORM OIL, HYDRAULIC, AND FUEL LEAK CHECK PAPERWORK: AIRWORTHINESS DIRECTIVES RECORD FINDINGS AND SIGN OFF INSPECTION AND MAINTENANCE IN LOGBOOKS 09/11/2018...

  • Page 30: Numbering And Placards

    RANS S-21 OUTBOUND TEXT MANUAL NUMBERING AND PLACARDS WHAT ARE THE SPECIAL REQUIREMENTS AS FAR AS ATTACHING NUMBERS AND PLACARDS TO HOMEBUILT AIRCRAFT? DISPLAY OF MARKS (Reference FAR Part 45.23) After you obtain the registration of your aircraft, the Registration numbers or marks must be affixed to the aircraft in some permanent fashion.
  • Page 31 RANS S-21 OUTBOUND TEXT MANUAL SIZE OF MARKS FAR 45.29 (b) (1) (iii) states “Marks at least 3" high may be displayed on an aircraft for which an experimental certificate has been issued under 21.191 (d) or 21.191 (g) for operating as an exhibition aircraft or as an amateur-built aircraft when the maximum cruising speed of the aircraft does not exceed 180 knots Calibrated Air Speed (CAS).
  • Page 32 RANS S-21 OUTBOUND TEXT MANUAL AIRCRAFT INSTRUMENT MARKINGS & COCKPIT PLACARDS Refer to FAR Part 91.9 Civil Aircraft Operating Limitations and Marking Requirements GENERAL To insure that each person operating an aircraft does so within the operating limitations prescribed for it, the FAA requires that there is available in it a current Flight Manual, appropriate instrument marking and placards, or any combination thereof.
  • Page 33 RANS S-21 OUTBOUND TEXT MANUAL AIRSPEED INSTRUMENT MARKINGS The airspeed indicator should be marked with a red radial line to establish the never- exceed speed. (V The takeoff and any pre-cautionary range should be marked with a yellow arc. The normal range is marked with a green arc.
  • Page 34 RANS S-21 OUTBOUND TEXT MANUAL FLIGHT MANEUVER PLACARD For non-acrobatic category airplanes, there should be a placard in front of and in clear view of the pilot stating: “No acrobatic maneuvers, including spins, approved”. For acrobatic category airplanes, there should be a placard in clear view of the pilot listing the approved acrobatic maneuvers and the recommended entry airspeed for each.

  • Page 35: Operating Limitations

    RANS S-21 OUTBOUND TEXT MANUAL OPERATING LIMITATIONS MANDATORY TEST FLIGHT PROVING PHASE All amateur-built sport aircraft as well as standard aircraft have federally imposed operating limitations. Upon satisfactory completion of the necessary final FAA Inspection of the aircraft and whatever ground tests may be required, the FAA inspector will issue your amateur-built “Experimental”...
  • Page 36 RANS S-21 OUTBOUND TEXT MANUAL DURATION OF MANDATORY FLIGHT TEST PERIOD For standard aircraft type engines: When an FAA approved aircraft engine/propeller combination is installed, the flight test period is usually limited to 25 hours of flight time. For automotive engines, non-FAA approved engines or propellers, or FAA approved...

  • Page 37: Repairman's Certification

    RANS S-21 OUTBOUND TEXT MANUAL Specifically, the duration of each individual flight should be recorded including the number of landings made. A full description of any mishaps, however minor, or any experiences not entirely normal that occur during the flight experience period should also be duly recorded.

  • Page 38: Getting Started

    RANS S-21 OUTBOUND TEXT MANUAL GETTING STARTED Getting to know the RANS S-21 OUTBOUND What is it? If you ask the FAA, it is an Airplane - single engine land. If you ask an aeronautical engineer, it is a single-engine high-wing fixed-gear airplane of aluminum semi-monocoque construction.
  • Page 39 RANS S-21 OUTBOUND TEXT MANUAL Debur all holes and edges as needed. Do NOT put a chamfer on holes when deburring, this will weaken the structure and may cause pre-mature failure of the structure. Use the correct rivet. Do NOT substitute one rivet for another, even though it may have the same size and grip length.
  • Page 40 RANS S-21 OUTBOUND TEXT MANUAL Typical Hardware and Drill Size Table*. Hardware Drill Size 40 APR Rivet AAPQ-41 thru 48 CCPQ-41 thru 48 AAPQ-62 thru 68 CCPQ-62 thru 68 SSPQ-62 thru 68 AACQ-42 CCC-42 AVEX 1691-0410 AN3 Bolt AN4 Bolt 1/4"...
  • Page 41 RANS S-21 OUTBOUND TEXT MANUAL PAINT AND CORROSION PROTECTION Painting of the S-21 OUTBOUND is optional. The information given below is only one example of how an airplane can be painted. There are many ways to do this and this may not represent the best method for your situation, climate, or chosen paint system.

  • Page 42: Rudder

    RANS S-21 OUTBOUND TEXT MANUAL RUDDER Refer to section 2 of parts and figure drawings. RUDDER SKIN FORMING Use a tube with a 1 1/4" outer diameter to roll form the leading edges of the rudder skin. See FIGURE 02-01 for rudder skin bending and orientation.

  • Page 43: Rudder To Vertical Stabilizer Attach

    RANS S-21 OUTBOUND TEXT MANUAL Insert the lower rib, with doubler, into the bottom of the rudder and cleco it in place above the tang on the rudder horn mount tube. Cleco and rivet left side of Rudder Skin to Ribs and Spar. Place Rudder, Left side down on a flat surface and check for twist.

  • Page 44: Vertical Stabilizer

    RANS S-21 OUTBOUND TEXT MANUAL VERTICAL STABILIZER Refer to section 3 of parts and figure drawings. If installing the Optional – Taildragger Pull Handle it is advisable to do so before final riveting the Vertical Stabilizer Side Skins. VERTICAL STABILIZER ASSEMBLY Lay ribs on a flat table with the flanges up.

  • Page 45: Vertical Stabilizer Tip

    RANS S-21 OUTBOUND TEXT MANUAL Cut the 3/4” raw stock Aluminum tube .080 longer than the outside of the doublers. Cut long and trim a little at a time. Refer to FIGURE 003-04. Remove the doublers and final size the side skins to 7/8”.

  • Page 46: Vertical Stabilizer Attachment

    RANS S-21 OUTBOUND TEXT MANUAL Check the clearance between the tip and the rudder through the full range of travel. Rivet the assembly in place. Recheck the clearance between the tip and the rudder through the full range of travel.

  • Page 47: Horizontal Stabilizer

    RANS S-21 OUTBOUND TEXT MANUAL HORIZONTAL STABILIZER Refer to section 4 of parts and figure drawings. FRAME ASSEMBLY Lay ribs on a flat table with the flanges up. Use fluting pliers to straighten the ribs so they lay flat on the table. Nose ribs may require re-shaping where the metal has bulged out at a rivet hole.

  • Page 48: Skin Installation

    RANS S-21 OUTBOUND TEXT MANUAL SKIN INSTALLATION Remove the bend tags from the skins as shown in FIGURE 04-01. Cleco and rivet the inspection tab rings to the inside of the skins. Place the skins on a couple of 2X4 or 4X4. Place the frame assembly on the skins and cleco (#40 Silver) the skins to the top of the frame assembly.

  • Page 49: Horizontal Attachment

    RANS S-21 OUTBOUND TEXT MANUAL HORIZONTAL ATTACHMENT NOTE: Horizontal stabilizer must be installed before the vertical stabilizer and rudder. The tail surfaces may be installed after painting. Fabricate bushings as shown in PARTS MANUAL DRAWING. Insert a bushing into the slot of each incidence adjuster.
  • Page 50 RANS S-21 OUTBOUND TEXT MANUAL HORIZONTAL STABILIZER FAIRING (AFTER FINAL TUNING OF THE HORIZONTAL INCIDENCE) Place the horizontal fairings on the horizontal outboard of their final position. Tape them in place with the aft edge on the top side 1" behind the rivets in the forward spar.

  • Page 51: Elevator And Trim Tab

    RANS S-21 OUTBOUND TEXT MANUAL ELEVATOR AND TRIM TAB Refer to section 5 of parts and figure drawings. ELEVATOR SKIN FORMING Use a tube with a 1 1/4" outer diameter to roll form the leading edges of the elevator skins.

  • Page 52: Elevator Trim Tab Assembly

    RANS S-21 OUTBOUND TEXT MANUAL Rivet the frame together using the appropriate rivets. NOTE: Do NOT rivet the Elevator Horn Ribs to the aft spar. These holes are shared with the trim tab hinge. Drill the mounting holes in the servo ribs to #11 and install the nut plates. Refer to Elevator Trim Tab Assembly.

  • Page 53: Elevator Final Riveting

    RANS S-21 OUTBOUND TEXT MANUAL Fit the hinges to the trim tab/elevator aft spar. See FIGURE 05-02. The aft edge of the hinge may need to be trimmed slightly to clear the trim tab spar and allow the trim tab to move forward to align with the elevator trailing edges.

  • Page 54: Trim Servo Installation

    RANS S-21 OUTBOUND TEXT MANUAL TRIM SERVO INSTALLATION (AFTER PAINTING OF THE ELEVATOR AND TRIM TAB) The trim servo will attach to the elevator trim servo ribs inside elevator with nut plates. The Servo Ribs should have been drilled to #11 and nut plates installed during elevator assembly.

  • Page 55: Elevator Balancing

    RANS S-21 OUTBOUND TEXT MANUAL ELEVATOR BALANCING • Elevator balancing must be performed on a flat work surface. • Elevator and Trim Tab must be final painted. • Trim Tab must be installed onto Elevator. • Servo with Push Rod must be installed in Elevator and connected to Trim Tab.
  • Page 56 RANS S-21 OUTBOUND TEXT MANUAL Make a simple stand with "knives" in which to balance the elevator on. The elevator must balance on the bolts inserted through the hinges. A couple of 2X4s and leftover stringer material works well. Place the elevator on the balancing stand.

  • Page 57: Elevator To Horizontal Stabilizer Attachment

    RANS S-21 OUTBOUND TEXT MANUAL ELEVATOR TO HORIZONTAL STABILIZER ATTACHMENT NOTE: The horizontal stabilizer should be attached to the fuselage and bolts in both aft attach holes before attaching the elevator. IMPORTANT: The tailcone should be assembled and attached before the...

  • Page 58: Wing

    RANS S-21 OUTBOUND TEXT MANUAL WING Refer to section 6 of parts and figure drawings. WING SPAR ASSEMBLY Clean and debur all 4 wing spars. A grease cutting detergent is recommended. Cleco the Wing Tip Rib to the tip of the FWD Wing Spar. Refer to FIGURE 06-01 for location.

  • Page 59: Optional Landing Lights Installation

    Optional landing lights may be installed during or after Wing Assembly is complete. • RANS uses a 10 amp breaker and 18 gauge 3-conductor shielded wire and a separate wire for grounding. Refer to SECTION 006H and collect all the parts shown on the part pages for the Landing Lights.

  • Page 60: Aileron Bellcrank Assembly

    RANS S-21 OUTBOUND TEXT MANUAL (AFTER PAINTING OF WING) With Wing Tip removed, slip Landing Light Lens into position. Trim the Lower edge to be tight against the row of rivets. The pressure will keep the Lens pressed against the inside of the spar.

  • Page 61: Flap Bellcrank Assembly

    RANS S-21 OUTBOUND TEXT MANUAL FLAP BELLCRANK ASSEMBLY NOTE: The Flap Bellcrank has a left/right orientation. Press the bearing into the Flap Bellcrank. HINT: Warming the Bellcrank with a hair drier may help the bearing press into place easier. WARNING: Do NOT press on the center of the bearing.

  • Page 62: Wing Rib / Spar Assembly

    RANS S-21 OUTBOUND TEXT MANUAL WING RIB / SPAR ASSEMBLY Lay the Forward Wing Spar Assembly on a table with the flange up. Locate the wing truss, Lexan wing truss shim, and applicable hardware. Run a 1/4" and a 5/16" drill through the holes in the wing truss where the truss bolts to the front and rear spars to remove the powder coat and allow the bolts to slide freely.
  • Page 63 RANS S-21 OUTBOUND TEXT MANUAL Layout the ribs in the proper locations along the front spar. Rib numbering and flange directions are shown in FIGURE 06-03. Drill the aileron and flap hinges and hinge arms to 5/16" to allow the bronze flange bushings to be pressed in.
  • Page 64 RANS S-21 OUTBOUND TEXT MANUAL Bolt the aileron and flap bellcrank assemblies in place with the lexan shims between the bellcrank mounts and the aluminum doublers. Bolt the smaller arm of the bellcranks to the rear spar. Use Loctite and safety wire as necessary.

  • Page 65: Wing Skin Installation

    RANS S-21 OUTBOUND TEXT MANUAL WING SKIN INSTALLATION PRE-SKIN CHECK LIST □ FWD wing truss doubler is riveted to the front spar. □ AFT truss doubler is riveted to the rear spar. □ Wing truss is bolted in the correct orientation using the appropriate hardware and lexan anti-corrosion shims in the front.
  • Page 66 RANS S-21 OUTBOUND TEXT MANUAL TOP SKIN CAUTION: When working with large pieces of sheet metal such as wing skins, care must be taken to prevent creases or "smiles" from appearing in the sheet metal. If smiles appear, they can be worked out using a large spoon and pressing it against the smile to minimize its visibility.
  • Page 67 RANS S-21 OUTBOUND TEXT MANUAL Use a 120° countersink (preferably a micro stop countersink) to machine countersink the holes in the Forward Spar to accept the dimples in the skin. Lightly lift the leading edge of the skin and debur the holes in the Forward Spar.
  • Page 68 RANS S-21 OUTBOUND TEXT MANUAL Assemble the wing jig by screwing 2X2’s or similar, flush with the bottom with 33.5" between the inside edges of the stand pieces as shown in FIGURE 06-06. Place the wing stands under each end of the wing and secure the stands to the table.
  • Page 69 RANS S-21 OUTBOUND TEXT MANUAL Begin by putting a couple clecos in various wing ribs to line up the skin and then in the tank supports. Use an ice pick or similar tool to line up the holes. Begin placing a few clecos in place next to the rear spar. Note the locations of any interference between the bottom skin and the hinge arms.

  • Page 70: Pitot/Static System

    RANS S-21 OUTBOUND TEXT MANUAL PITOT/STATIC SYSTEM Locate Doubler Plate on 5” Inspection Cover using FIGURE 06-08 as a template. Transfer drill #30 and cleco. Transfer drill 1/4” for the Pitot Tube. Refer to FIGURE 06-08. If the Pitot Tube fits too tight, open the hole with a deburring tool or file.

  • Page 71: Wing Fuel Tank Assembly

    RANS S-21 OUTBOUND TEXT MANUAL WING FUEL TANK ASSEMBLY Using a small piece of scrap aluminum sheet, make a drill guide as shown in FIGURE 06-11. The jigs purpose is to locate a center hole for the fly-cutter or hole-saw. Make the screw holes about 1/4" outside of the small existing hole in the tank to keep the jigs size down.
  • Page 72 RANS S-21 OUTBOUND TEXT MANUAL IMPORTANT: Do not allow the fitting or thick washer to rotate while tightening or leaks may occur. HINT: Prevent the thick washer from turning by holding with needle-nose Vise-Grips. Carefully remove the wire. Repeat this process for the sight gauges using the appropriate hardware and blue thread lock.
  • Page 73 RANS S-21 OUTBOUND TEXT MANUAL Remove the sight gauge tubes Drill the 3/8" hole in the tank for the vent. A clean tank is a safe tank! Vacuum out any debris. If the hose of your vacuum is too large, tape a small piece of flexible hose to the end.

  • Page 74: Flap & Aileron Skin Forming

    RANS S-21 OUTBOUND TEXT MANUAL FLAP & AILERON SKIN FORMING Use a tube with a 1 7/8" to 2” outer diameter to roll form the top leading edges of the flap and aileron skins. See FIGURE 06-14B for flap and aileron skin bending and orientation.

  • Page 75: Flap Assembly

    RANS S-21 OUTBOUND TEXT MANUAL FLAP ASSEMBLY Remove the bend guides as shown in FIGURE 06-15. Carefully use a pair of snips to cut them off close and finish with a file. Remove the attach tabs of the Flap Hinge - Part Assembly to make individual Flap Hinges.

  • Page 76: Aileron Assembly

    RANS S-21 OUTBOUND TEXT MANUAL Rivet the TOP side using the appropriate rivets. Start at the AFT edge and work your way forward one row at a time. Flip the flap over and check for twist before riveting. Start at the trailing edge and work forward.

  • Page 77: Aileron Balancing

    RANS S-21 OUTBOUND TEXT MANUAL Cleco the ribs in place to the top side of the skin. Use a short 2X4 or similar to space the aileron off the table and prevent damage due to resting on the clecos in future steps.

  • Page 78: Lift Strut Assembly

    RANS S-21 OUTBOUND TEXT MANUAL LIFT STRUT ASSEMBLY The Lift Struts are cut to length and the attach holes pre-drilled at the factory. Smooth the ends of each Lift Strut with fine sand paper and debur. Mark a straight line between the attach holes at either end of the strut. Use a straight edge or a piece of string.

  • Page 79: Lift Strut Fairing Installation

    RANS S-21 OUTBOUND TEXT MANUAL LIFT STRUT FAIRING INSTALLATION (AFTER ATTACHMENT OF WING TO FUSELAGE) Trim base of fairing to allow a slight flange edge where it mates to the wing. See FIGURE 06-18. Cut out opening to fit snugly over Lift Strut. Refer to FIGURE 06-19 for a template.

  • Page 80: Tailcone

    RANS S-21 OUTBOUND TEXT MANUAL TAILCONE Refer to section 7 of parts and figure drawings. INITIAL ASSEMBLY Assemble and rivet the bulkheads as shown in PARTS MANUAL DRAWINGS 007-01, 007-03, 007-05, and 007-07. NOTE: S-10 AFT bulkhead doubler will need the flanges slightly bent to conform to the shape of the tailcone.
  • Page 81 RANS S-21 OUTBOUND TEXT MANUAL Remove the assembly from the table and place upside down on two sawhorses. Rivet on the stringers starting 4 holes back from the front. This is needed to allow the skin to slide together with the tail cone spacer strip and cockpit cage belly skin.

  • Page 82: Tailcone/Cage Attachment

    RANS S-21 OUTBOUND TEXT MANUAL TAILCONE/CAGE ATTACHMENT NOTE: It is recommended to prime the mating surfaces of the aluminum tailcone that mate to the steel cage for dissimilar metal corrosion resistance. The cage is powder coated which provides corrosion resistance and priming of aluminum surfaces provides an additional layer of corrosion resistance.
  • Page 83 RANS S-21 OUTBOUND TEXT MANUAL To check for square, measure from the top engine mount bushings on the firewall to a common place in the tailcone. A hole on the aircraft centerline on the large inspection hole on the bottom skin works well.

  • Page 84: Rudder Cable System

    RANS S-21 OUTBOUND TEXT MANUAL (AFTER LONGERON SUPPORTS, TAILCONE TOP SKINS, FUSELAGE SIDE AND BOTTOM SKINS ARE FIT UP.) Transfer drill any remaining holes between the cage tabs and aluminum skins. Transfer drill any remaining holes between skins. Rivet the tailcone to the cage at the longerons, window support, and attach tabs.

  • Page 85: Aft Baggage

    RANS S-21 OUTBOUND TEXT MANUAL AFT BAGGAGE Temporarily remove the middle longeron support angles. Set the baggage sides in place with the aft edge resting on top of the flange on the S-4 bulkhead. The outside edge of the baggage side flanges should be close to the outside edge of the longeron.

  • Page 86: Tailcone Top Skins

    RANS S-21 OUTBOUND TEXT MANUAL TAILCONE TOP SKINS Set the fuselage right side up on the 12x4 build table. Place a long piece of angle (48") over the top of station 11. FIGURE 07-06A This is used as a sight gauge to make sure the fuselage is square and the horizontal and vertical surfaces are level and square with the cage.

  • Page 87: S-4 Closeout

    RANS S-21 OUTBOUND TEXT MANUAL S-4 CLOSEOUT Trim the S-4 closeout to the outside edge of the trim lines on the top corners. Trim the top middle section and the bottom edges to leave a 1/8" flange for rigidity. Trim the corners for clearance around the window support angles.

  • Page 88: Tailcone Top Front Skins

    RANS S-21 OUTBOUND TEXT MANUAL TAILCONE TOP FRONT SKINS Check alignment of the tailcone to the cage. Refer to figure 07-06A. Check alignment often during final assembly of skins to the tailcone. The top seam will be riveted last, permanently setting the tailcone alignment.
  • Page 89 RANS S-21 OUTBOUND TEXT MANUAL From inside the tail, drill and cleco through the S-4 bulkhead and the top skins and top front skins. Ensure the bulkhead and top skin holes line up when drilling the first couple holes. Repeat the process to fit up the other top front tailcone skin.

  • Page 90: Fuselage Side And Bottom Skins

    RANS S-21 OUTBOUND TEXT MANUAL FUSELAGE SIDE AND BOTTOM SKINS NOTE: The sliding seat position rails must be installed before final riveting of the bottom skin. Refer to Sliding Seat Assembly in the parts manual and FIGURE 09D-01. Check to be sure seat belt bolts will slide into seat belt bushings of fuselage.
  • Page 91 RANS S-21 OUTBOUND TEXT MANUAL Refer to FIGURE 10E-30B. Cut stringer material to length and quantity shown. Apply 1/2” Acrylic tape to widest flange of each stringer. Position stringers on the inside of the Rear Fuselage Side Skin in the location shown. Make sure to press firmly to allow the tape to bond.

  • Page 92: Main Gear Installation

    RANS S-21 OUTBOUND TEXT MANUAL MAIN GEAR INSTALLATION MAIN GEAR FIT UP Become familiar with the Main Gear Installation PARTS MANUAL DRAWINGS and collect the parts shown in the drawings. Examine your Gear Legs. If your inspection reveals any gouges or scratches, polish or sand to remove.

  • Page 93: Main Gear Wheel/Brake Installation

    RANS S-21 OUTBOUND TEXT MANUAL MAIN GEAR WHEEL/BRAKE INSTALLATION NOTE: Trike and Taildragger Wheel/Brake Installations have different parts for assemblies. Please be sure to refer to the correct parts page when installing. Become familiar with the Main Gear Wheel/Brake Installation PARTS MANUAL DRAWINGs and collect the parts shown in the drawings.
  • Page 94 RANS S-21 OUTBOUND TEXT MANUAL The higher rolling drag is completely normal for this bearing and allows for longer bearing life since the seal will keep most contaminants out. Timken specification state, for example, that the two 1.25 inch tapered roller bearing used on the WE51 will produce 18-26 inch pounds of torque (drag) when properly installed.

  • Page 95: Boot Cowl

    RANS S-21 OUTBOUND TEXT MANUAL BOOT COWL IMPORTANT: The strut tangs need to be drilled to 7/16" before the boot cowl is fit up. See below. Locate long 3/8" and 7/16" drill bits. Drill the strut attach tangs to 3/8" from the forward side.
  • Page 96 RANS S-21 OUTBOUND TEXT MANUAL With the Stiffeners clecoed in place, lay the floorboard in the fuselage. Align mounting holes and mark the Floorboard flange where it intersects the skin stiffeners. Remove material from flange to prevent contact with Stiffeners.
  • Page 97 RANS S-21 OUTBOUND TEXT MANUAL Bend the Panel Frame tabs and Firewall Support Angle tabs as required to allow the Top Skins to lay flat between the Firewall and Panel frame. Lay a straight edge from tab to tab as a guide to bend the tabs into alignment. Refer to FIGURE 10E-19.

  • Page 98: Tailwheel Installation

    RANS S-21 OUTBOUND TEXT MANUAL Check for overlap on all a fuselage tubes to the aft of the Skins. Trim if required to the centerline of the tubes. Deburr all parts as needed. Apply High-Temp Silicone Seal to flange of Bottom Skin to seal against Firewall.

  • Page 99: Nose Gear Installation

    RANS S-21 OUTBOUND TEXT MANUAL Install the control linkage as per the exploded view drawing. The linkage will be attached to only the tailwheel at this time. Refer to the RUDDER SYSTEM ASSEMBLY & INSTALLATION for final assembly and adjustment of the linkage.
  • Page 100 RANS S-21 OUTBOUND TEXT MANUAL Chase drill 6.2mm, then ream to 0.249”. Bolt in place. Seat the Spring Washers by sanding on a sheet of 400-grit sandpaper. Refer to FIGURE 08A-20. This will help prevent premature wearing of the Spring Washers.

  • Page 101: Tail Tie-Down Installation

    RANS S-21 OUTBOUND TEXT MANUAL TAIL TIE-DOWN INSTALLATION NOTE: Tail Tie-Down is only used on Trike Installations. Install Trike Tie-Down Eye Bolt thorough bottom skin of tailcone and FWD Attach Block on AFT side of Station 9 Bulkhead. Orientate Ring fore and aft and tighten nut.

  • Page 102: Tailcone Aft Closeouts - (Finishing Kit)

    RANS S-21 OUTBOUND TEXT MANUAL TAILCONE AFT CLOSEOUTS - (FINISHING KIT) Cleco the S-10/11 closeout and closeout angle in place. Transfer drill into the longerons. Refer to FIGURE 08A-31A. Rivet the S-10/11 closeout and angle to S-10, S-11, and the longerons.

  • Page 103: Fuselage Internal

    RANS S-21 OUTBOUND TEXT MANUAL FUSELAGE INTERNAL Refer to section 9 of parts and figure drawings. FLOORBOARD INSTALLATION (THE FLOORBOARD MUST BE TRANSFER DRILLED BEFORE FIT-UP OF BOOT COWL) Lay floorboard in place with the bent flanges facing down. Center side to side and front to back.

  • Page 104: Rudder System Assembly And Installation - (Finishing Kit)

    RANS S-21 OUTBOUND TEXT MANUAL Install Cotter Pins to swivel bushing to retain 1/2" plastic washer. Refer to FIGURE 09A-05 and fabricate four Brake Saddles from the provided part. Be sure to use a drill press when fabricating to assure a straight hole through the Brake Saddle.

  • Page 105: Hydraulic Brake Installation

    RANS S-21 OUTBOUND TEXT MANUAL Pull the rudder cables forward and under the pulleys at Station 3. Install Small Cotter Pins to retain the cables. Continue to route cables forward under the pulleys between Station 2 and 2A. Bolt the small pulleys in place and check for free movement.
  • Page 106 RANS S-21 OUTBOUND TEXT MANUAL NOTE: Brake Line pressed into groove of Gear Leg should NOT have a protective plastic coating installed. If this coating is installed, carefully slit with a razor knife and remove. Do NOT cut into the underlying stainless braid.

  • Page 107: Sliding Seat Assembly

    RANS S-21 OUTBOUND TEXT MANUAL Route the cable through the cable housing swivel stop and through the wire swivel stop in the control arm of the park brake valve. Be sure to install the short length of blue fuel line to act as an up stop.

  • Page 108: Optional Headrest Assembly

    RANS S-21 OUTBOUND TEXT MANUAL Bolt Seat Bottom Frames to Seat Side Plates through the Multi-hole Tangs. Insert washers and bearings between Multi-Hole tangs. Refer to Sliding Seat Assembly parts manual drawing. Tighten nuts retaining Side Plates to Seat Back Frame.

  • Page 109: Seat Final Assembly

    RANS S-21 OUTBOUND TEXT MANUAL Drill a #11 hole through only the AFT side of the Seat Back Frame. Pin the Headrest Frame in place with 3/16" bolts. Place small piece of 400 grit sand paper between seat and headrest frame with the grit against the headrest frame.
  • Page 110 RANS S-21 OUTBOUND TEXT MANUAL 09/11/2018...

  • Page 111: Operation Of Sliding Seat

    RANS S-21 OUTBOUND TEXT MANUAL OPERATION OF SLIDING SEAT The sliding feature of the seat allows quick adjustment of the seat position while sitting in the seat. To change seat position grasp the Seat Back and lean forward, pulling the Seat Back forward with you.

  • Page 112: Seat Belt Installation - (Finishing Kit)

    RANS S-21 OUTBOUND TEXT MANUAL SEAT BELT INSTALLATION - (FINISHING KIT) (AFTER PRIMING OF FUSELAGE FRAME/ BEFORE SKINNING) Prior to covering drill the welded attach bushings to 5/16". Refer to the PARTS MANUAL DRAWING for attach bushing locations. (AFTER SKINNING AND PAINTING OF FUSELAGE) After the fuselage has been covered and painted, bolt each Seat Belt to the respective attach bushing as shown in the PARTS MANUAL DRAWING.

  • Page 113: Fuselage - Controls And External

    RANS S-21 OUTBOUND TEXT MANUAL FUSELAGE - CONTROLS AND EXTERNAL Refer to section 10 of parts and figure drawings. CONTROL STICK ASSEMBLY & INSTALLATION - (FINISHING KIT) ASSEMBLY Refer to the parts catalog and select the required components for assembly.

  • Page 114: Control Stick Push-Pull Tube - (Finishing Kit)

    RANS S-21 OUTBOUND TEXT MANUAL INSTALLATION (AFTER FINAL INSTALLATION OF FLOORBOARD) Bolt the control stick torque tube assembly through the floorboard and into the nut-plated tabs underneath. Apply light machine oil to the rotational collars. Check for free movement of assembly. If movement is restrictive, add a thin or thick washer between the torque tube and floorboard.
  • Page 115 RANS S-21 OUTBOUND TEXT MANUAL Fabricate aluminum bushings as shown in parts pages. NOTE: The 1/4" Bushing inserted through the Sliding Block should be wider than the Block to allow it to swivel. Rotate the small cable keepers to the bottom of the pulleys and tighten the bolt to prevent rotation.

  • Page 116: Elevator Push-Pull Tube - (Finishing Kit)

    RANS S-21 OUTBOUND TEXT MANUAL ELEVATOR PUSH-PULL TUBE - (FINISHING KIT) ASSEMBLY Refer to the parts catalog and select the required components for assembly. Slide Elevator Push-Pull Doubler inside the forward end of Elevator Push-Pull Tube. NOTE: The forward end of Push-Pull Tube only has a through hole drilled in it.

  • Page 117: Aileron Cable System Installation - Fuselage (Finishing Kit)

    RANS S-21 OUTBOUND TEXT MANUAL AILERON CABLE SYSTEM INSTALLATION - FUSELAGE (FINISHING KIT) (AFTER SKINNING AND PAINTING OF FUSELAGE) Refer to parts page and select the required components for assembly. Leave the bolt through the U-bracket slightly loose to allow a small amount of rotation.

  • Page 118: Flap Lever - (Finishing Kit)

    RANS S-21 OUTBOUND TEXT MANUAL FLAP LEVER - (FINISHING KIT) ASSEMBLY Refer to the parts manual and select the required components for assembly. Fabricate the following bushings to the appropriate lengths from Raw Stock: Qty. Length Tube Size 1.0" 1/4" X .028 5/8”...
  • Page 119 RANS S-21 OUTBOUND TEXT MANUAL Temporarily bolt rod ends to each side of the welded tab on the flap handle. The exact adjustment of the rod end on the Teleflex will be determined when adjusting the flaps during final rigging.

  • Page 120: Belly Fairing Installation - (Finishing Kit)

    RANS S-21 OUTBOUND TEXT MANUAL BELLY FAIRING INSTALLATION – (FINISHING KIT) (AFTER ATTACHMENT OF GEAR LEGS TO FUSELAGE) Trim base of fairing to allow a slight flange edge where it mates to the fuselage. See FIGURE 08B-01. Trim outboard edge to be flush with no flange.

  • Page 121: Instrument Panel Installation

    RANS S-21 OUTBOUND TEXT MANUAL INSTRUMENT PANEL INSTALLATION ASSEMBLY (BEFORE SKINNING AND PAINTING) A blank instrument panel is provided with the kit. The builder should design and cut his own instrument and switch holes in the panel or contact a commercial aircraft panel manufacturer.

  • Page 122: Sub-Panel & Radio Mount Plates

    RANS S-21 OUTBOUND TEXT MANUAL Application of OPTIONAL - DASH COVER FOAM and FABRIC requires Windshield to be fit-up. Cleco Windshield Hold Down Strip to Top Skins. Mark the upper contact area on the Top Skins. Remove Hold Down Strip.
  • Page 123 RANS S-21 OUTBOUND TEXT MANUAL The aft end of the Mount Plates will be riveted to the instrument panel. Locate 2 #30 holes in the short flange of each Mount Plate for riveting. NOTE: Mount trays from Comm Radio, Transponder, etc., will be required to position Mount Plates to correct width.

  • Page 124: Wing Installation

    RANS S-21 OUTBOUND TEXT MANUAL 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.
  • Page 125 RANS S-21 OUTBOUND TEXT MANUAL Cut off the FWD side of the T-bone at the mark. Keep as square as possible. Debur both cuts. IMPORTANT: It is recommended to apply some corrosion protective primer to the bare metal. Have one person lift at the wing tip and one person lift at the root.
  • Page 126 RANS S-21 OUTBOUND TEXT MANUAL Route the Flap Teleflex Cable inside the Fuselage. Route both Flap Teleflex Cables aft of Station 3 down the side of the fuselage and forward through the wire loops welded to the fuselage frame at Station 2A. Both Teleflex Cables route forward and connect to the Flap Handle.

  • Page 127: Wing Tip

    RANS S-21 OUTBOUND TEXT MANUAL WING TIP NOTE: Mounting Plate for strobes may be installed before or after fit up of wing tip. ASSEMBLY Cut the round end off the trailing edge of the support rib at the point where it transfers from the round end to the rib.
  • Page 128 RANS S-21 OUTBOUND TEXT MANUAL Cut out the profile saving the material outside of the profile. A hole can be cut in the inside of the profile for access or it can be cut in half at the ends of the profile and reconstituted with a piece of material. Set the fixture aside.

  • Page 129: Optional Strobes Installation

    RANS S-21 OUTBOUND TEXT MANUAL OPTIONAL STROBES INSTALLATION Route wires in wing and out to the tip through the grommets in the wing ribs. Leave extra length to reach through the wing tip and fuselage. Position the Strobe Light Mount centered inside the flat area of the Wing Tip. Be sure the strobe will be straight when mounted.

  • Page 130: Formed Windshield & Skylight Installation

    RANS S-21 OUTBOUND TEXT MANUAL FORMED WINDSHIELD & SKYLIGHT INSTALLATION (FINISHING KIT) Windshield and Skylight assembly require wings to be attached and the boot cowling in place • The windshield is provided in trimmed form and should not need any major trimming.
  • Page 131 RANS S-21 OUTBOUND TEXT MANUAL Hole saws and two-flute Vortex router bits are a few options available. Drill several practice holes in scrap pieces of Acrylic to perfect these techniques before drilling your part. Back-up the windshield with a block of wood.
  • Page 132 Acrylic (windshield) and Lexan (skylight and doors) may scratch very easy. To get a longer service life from your windshield and other Lexan surfaces, we recommend a soft terry cloth and a cleaner made for plastic. RANS uses a product called Brillianize. It is available from RANS or any large aircraft supply company.
  • Page 133 RANS S-21 OUTBOUND TEXT MANUAL Collect all the parts shown on the part pages for the windshield. Extra care should be taken when working with Acrylic and Lexan. Both may scratch easily and as much as possible of the protective plastic should be left in place until the aircraft is ready to be flown.
  • Page 134 RANS S-21 OUTBOUND TEXT MANUAL Using a black Sharpie mark the forward edge of the skylight per FIGURE 10G- 10. Place the windshield mating strip centered on the skylight with the holes over the black line. Clamp or tape in place and transfer drill #30. In a later step the #30 Skylight holes will be drilled to #28.
  • Page 135 RANS S-21 OUTBOUND TEXT MANUAL Position forward edge of rib trim strips 1/4” away from upper mating strip. Align holes with center-line of ribs and transfer drill #30. Cleco as you drill. See FIGURE 10G-17. Position center forward trim strip on the windshield 1/4” forward of the upper mating strip over the center rib.
  • Page 136 RANS S-21 OUTBOUND TEXT MANUAL Drill out the five holes in the middle forward trim strip to #20. Drill out the five holes in the windshield using an 11/64” Acrylic drill bit. Drill out all #30 holes to #28 in the Skylight and debur.

  • Page 137: Wing Cuff Installation

    RANS S-21 OUTBOUND TEXT MANUAL WING CUFF INSTALLATION Trim wing cuffs as in FIGURE 10G-37. Hold cuffs on windshield and leading edge spar. Find position of best fit for wing cuff, press down firmly against the windshield and tape securely in place. Use a fine point marker and mark the perimeter edge of the wing cuff onto the windshield if this was not done in a previous step.
  • Page 138 RANS S-21 OUTBOUND TEXT MANUAL Cleco windshield hold down strip to boot cowl. Re-apply, if necessary, masking tape onto windshield flush with top edge of hold down strip. This is to prevent the adhesive from blemishing the windshield. Un-cleco and apply a generous amount of 3M 2216 adhesive to the outside of the windshield below the tape.

  • Page 139: Door Assembly - Lexan And Trim - (Finishing Kit)

    Lexan windows scratch very easy. To get a longer service life from your window, we recommend a soft terry cloth and a cleaner made for plastic. RANS uses a product called Brillianize. It is available from RANS or any large aircraft supply company.
  • Page 140 RANS S-21 OUTBOUND TEXT MANUAL Transfer drill #40 through Door Trim into outboard side of Door Frame. Cleco as you go. Final size #40 holes to #30. Trim forward and lower end of Lower Door Trim to match FWD Door Trim.

  • Page 141: Door Latch Assembly - (Finishing Kit)

    RANS S-21 OUTBOUND TEXT MANUAL Re-cleco all parts to Door Frame. Place Channel Extrusion centered over Door Frame bow tube. Trim ends to match inside of Door Trim. Refer back to FIGURE 10H-04. Layout holes per FIGURE 10H-18 and debur. Re-position over Door Lexan and transfer drill into Door Frame bow tube centerline.

  • Page 142: Hydraulic Door Lift - (Finishing Kit)

    RANS S-21 OUTBOUND TEXT MANUAL Slip Door Pivot Bushing over Latch and install into AFT bushing of Door Frame. Washers may be added or removed later to adjust the tightness of the door seal. Rivet Handle Stop Plate to lower forward corner of Door Frame. Refer to FIGURE 10H-25.

  • Page 143: Forward Baggage Compartment - (Finishing Kit)

    RANS S-21 OUTBOUND TEXT MANUAL IMPORTANT: The Cylinder portion of the Gas Spring must be oriented upward when final installed to prevent drying out of the shaft seal during operation. Press the Ball Stud on the door into the Gas Spring end. Make sure the Gas Spring is locked in place.

  • Page 144: Baggage Compartment & Cargo Net Installation

    RANS S-21 OUTBOUND TEXT MANUAL BAGGAGE COMPARTMENT & CARGO NET INSTALLATION (FINISHING KIT) INSTALLATION Cover aluminum sheet metal interior of Baggage Compartment with lightweight fabric or paint as desired. Slip Aft Baggage Compartment into place. Cleco, then rivet or install screws as shown in parts manual.

  • Page 145: Instruments And Electrical

    RANS S-21 OUTBOUND TEXT MANUAL INSTRUMENTS AND ELECTRICAL Due to the different instruments and flight systems that builders are choosing, RANS does not supply gauges with the kit. Refer to ENGINE INSTALLATION and Engine Manufacturer's documentation for specific information on engine electrical systems.

  • Page 146: Rigging And Preparation For Flight

    Tighten all connections and turnbuckles. Re-check. Once satisfied with the aileron rigging, safety wire turnbuckles per FAA Advisory Circular AC 43.13-1B section 7. RANS uses a single wrap method but, double wrap methods may be used also. Refer to FIGURE 12A-04.
  • Page 147 RANS S-21 OUTBOUND TEXT MANUAL DEFLECTIONS For deflection measurements, center control stick for neutral position, move and hold control stick against stop and measure. Measurement is taken on top surface of aileron at approximate half span on top of aileron rib. Deflection angle is in reference to trailing edge of Aileron.

  • Page 148: Flap Rigging

    RANS S-21 OUTBOUND TEXT MANUAL FLAP RIGGING NEUTRAL POSITION (AFTER WING INSTALLATION/ AFTER SETTING OF WASHOUT) Place flap handle in flaps retracted position. Align the trailing edge of the Flap with the trailing edge of the Aileron. NOTE: Press lightly up on the Flap trailing edge to remove Teleflex Cable play when setting.

  • Page 149: Horizontal Stabilizer

    RANS S-21 OUTBOUND TEXT MANUAL HORIZONTAL STABILIZER NOTE: Ensure the 2nd hole for the aft attach of the horizontal stabilizer to S-11 has been drilled and both bolts are secured. This is in the Horizontal Stabilizer Attachment section. Due to the various engine options which change the CG and therefore the ideal horizontal stabilizer incidence, incidence adjusters are used to set the incidence of the horizontal stabilizer and minimize drag.
  • Page 150 RANS S-21 OUTBOUND TEXT MANUAL If the front of the balance weights can be seen sticking up above the horizontal stabilizer, adjust the incidence using the method above to raise the nose of the horizontal stabilizer. Lower the nose of the horizontal if the elevator balance can be seen below the horizontal.

  • Page 151: Elevator

    RANS S-21 OUTBOUND TEXT MANUAL ELEVATOR IMPORTANT: The elevator must be mass balanced. If this is not yet completed, instructions can be found in the elevator assembly section of this manual NEUTRAL POSITION In neutral position, the elevator is level with the horizontal stabilizer. Verify by comparing the leading edge of the balance arm portion of the Elevator to the Horizontal Stabilizer with the Control Sticks in neutral position.

  • Page 152: Elevator Trim Tab

    RANS S-21 OUTBOUND TEXT MANUAL SURFACE CLEARANCE • The minimum clearance between elevator and horizontal stabilizer is 0.060” all the way along the hinge line. • The minimum clearance between the elevator balance horn and the horizontal stabilizer tip is 3/16”.
  • Page 153 RANS S-21 OUTBOUND TEXT MANUAL OPERATIONAL CHECK Operate trim tab through full range of motion. • Correct deflections of trim tab. • Visual check trim tab for twist. • Check free movement of trim tab through full motion and listen for unusual noises from servo.

  • Page 154: Rudder

    RANS S-21 OUTBOUND TEXT MANUAL RUDDER NEUTRAL POSITION AND CABLE TENSION Remove the tailwheel chain from the tailwheel. Verify neutral position of rudder with rudder pedals neutral (visual). Change the mounting hole on the multi-hole tang at the front of the rudder cable for course cable tension adjustments.

  • Page 155: Weight And Balance

    RANS S-21 OUTBOUND TEXT MANUAL WEIGHT AND BALANCE Refer to figure drawings. 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.
  • Page 156 RANS S-21 OUTBOUND TEXT MANUAL TRIKE • Shim scales to measure 90º at aft door frame. Refer to FIGURE 13-03. • Place scales under each wheel (500 lb. minimum capacity is recommended) Weighing: • With the airplane level, record the weight shown on each scale. Subtract the weight of the leveling device from the weight indicated at the tailwheel.

  • Page 157: Weight And Balance

    RANS S-21 OUTBOUND TEXT MANUAL WEIGHT AND BALANCE The following will enable you to determine the weight and balance of your aircraft and to operate it within the prescribed center of gravity limitations. The S-21 OUTBOUND is a simple aircraft and so are the weight and balance calculations.

  • Page 158: Post Flight Rigging

    RANS S-21 OUTBOUND TEXT MANUAL POST FLIGHT RIGGING Your first flight in your freshly assembled and signed off S-21 may be one of the most exciting things that you will do. The aim is to keep that excitement limited to experiencing an exhilarating flying machine and not one that is shaking your confidence.
  • Page 159 RANS S-21 OUTBOUND TEXT MANUAL Using common door self-adhesive D-shaped door seal to affect a trim tab. It is easy to use, since you can try different lengths to gauge impact on trim. Plane Briskly Rolls Ball Moves Out This is indicative of roll input, and can also have some yaw. To determine the cause, center the ball and keep on the rudders, and release the stick.
  • Page 160 RANS S-21 OUTBOUND TEXT MANUAL D-shaped weather strip makes a fine bump trim. Permanent bump trim using 1/4” Aluminum tubing. 09/11/2018...
  • Page 161 RANS S-21 OUTBOUND TEXT MANUAL Adjusting Wing Root Angle of Incidence In some cases adjusting the wing at the root can be effective. Raising the rear spar may be the better choice over trim bumps, or in combination with trim bumps, if roll is strong.
  • Page 162 RANS S-21 OUTBOUND TEXT MANUAL An example of using bump trim on the ailerons. Place trim on the bottom of ailerons for best results. Summary Take your time on post flight rigging; the end result will be a plane that flies in perfect trim.

  • Page 163: Rans S-21 Outbound - Three View

    RANS S-21 OUTBOUND TEXT MANUAL RANS S-21 OUTBOUND - THREE VIEW 09/11/2018...

  • Page 164: General Information

    RANS S-21 OUTBOUND TEXT MANUAL GENERAL INFORMATION Refer to Engine Install Manual for more specific information ENTERING AND EXITING AIRCRAFT To enter the S-21 OUTBOUND: • Open the door by rotating the door handle. • Pull out on the door handle •...

  • Page 165: Steering And Braking

    RANS S-21 OUTBOUND TEXT MANUAL DOORS Doors can open in flight if the latches are not secured. CAUTION: If any door opens in flight, continue to fly the plane, trim to hands-off level flight if possible, slow to 65 mph, then close door.

  • Page 166: Operating Limitations

    RANS S-21 OUTBOUND TEXT MANUAL OPERATING LIMITATIONS This section includes operating limitations, instrument markings, and basic placards necessary for the safe operation of the aircraft, power plant, and standard equipment. The Engine Operators Manual must be onboard the aircraft. AIRSPEED LIMITATIONS Airspeed limitations and their operational significance are shown in Table 14A-1.
  • Page 167 RANS S-21 OUTBOUND TEXT MANUAL AIRSPEED INDICATOR MARKINGS Airspeed indicator markings and their color code meanings are shown in Table 14A-2 All speeds are given for maximum takeoff weight. Speed are given in MPH and (KNOTS) IAS Value or Marking...
  • Page 168 The angle of bank should not exceed 60 ° and the pitch attitude may not exceed 30 °. Stalls except whip stalls are approved with slow deceleration. ► Acrobatic maneuvers, including spins are not approved in the RANS S-21 OUTBOUND aircraft. FLIGHT LOAD FACTOR LIMITS Flaps Up: + 6.0 g, - 2.0g...
  • Page 169 RANS S-21 OUTBOUND TEXT MANUAL FLIGHT CONDITIONS OPERATION LIMITS Flight into known icing conditions is prohibited. This aircraft is limited to two occupants only. Night flights according to VFR, flights according to IFR (by instruments) are approved only when instrumentation required for such flights is installed and maintained according to applicable F.A.R.S.
  • Page 170 RANS S-21 OUTBOUND TEXT MANUAL The readings given by the fuel quantity indicator in 3-wheel ground attitude (taildragger) are therefore not correct. The fuel remaining in the tanks after the fuel quantity indicator reads zero (in level flight attitude in cruise condition) cannot be safely used in flight.

  • Page 171: Weight And Balance

    RANS S-21 OUTBOUND TEXT MANUAL WEIGHT AND BALANCE INTRODUCTION This Section describes the basic procedures for establishing of basic empty weight and moment of the airplane. Refer to SECTION 13 for complete Weight & Balance information. Procedures for calculating the weight and moment for various loadings are also provided.
  • Page 172 RANS S-21 OUTBOUND TEXT MANUAL • Place scales under each wheel (500 lb. minimum capacity is recommended) Weighing: • With the airplane level, record the weight shown on each scale and subtract the weight of the leveling device from the weight indicated at the tailwheel.
  • Page 173 RANS S-21 OUTBOUND TEXT MANUAL WEIGHT AND BALANCE The following will enable you to determine the weight and balance of your aircraft and to operate it within the prescribed center of gravity limitations. The S-21 OUTBOUND is a simple aircraft and so are the weight and balance calculations.
  • Page 174 RANS S-21 OUTBOUND TEXT MANUAL EMERGENCY PROCEDURES INTRODUCTION This section provides checklists and amplified procedures for coping with emergencies that may occur. Emergencies caused by aircraft or power plant malfunctions are rare if proper pre-flight inspections and maintenance are performed. Emergencies caused by extreme weather situations can be minimized or eliminated by good judgment and proper pre-flight planning.
  • Page 175 RANS S-21 OUTBOUND TEXT MANUAL 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).
  • Page 176 RANS S-21 OUTBOUND TEXT MANUAL FORCED LANDINGS Emergency Landing Without Engine Power Fly the Airplane! Flaps - As REQUIRED for Landing Site. Airspeed - 70 MPH (Flaps up). 65 MPH (Flaps down). Fuel Selector Valve - OFF. All Switches - OFF.
  • Page 177 RANS S-21 OUTBOUND TEXT MANUAL FIRES During Start On Ground Cranking - CONTINUE, to get a start which would suck the flames and accumulated fuel through the carburetor and into the engine. If Engine Starts: Power – Cruise Power RPM for a few minutes.
  • Page 178 RANS S-21 OUTBOUND TEXT MANUAL Electrical Fire In Flight Fly the airplane! Master Switch - OFF . All Other Switches (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 179: Amplified Procedures

    RANS S-21 OUTBOUND TEXT MANUAL 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.
  • Page 180 RANS S-21 OUTBOUND TEXT MANUAL 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 181 RANS S-21 OUTBOUND TEXT MANUAL As rotation stops, neutralize rudder and apply back pressure on the control stick to slowly reduce airspeed to normal cruise speed. IGNITION MALFUNCTION A sudden engine roughness or misfiring is usually evidence of ignition problems.
  • Page 182 RANS S-21 OUTBOUND TEXT MANUAL NORMAL PROCEDURES The following checklists are provided for guidance only. It is suggested that the owner of the aircraft adds items they deem necessary. PRE-FLIGHT INSPECTION Visually inspect the aircraft for its general condition during the walk around.
  • Page 183 RANS S-21 OUTBOUND TEXT MANUAL FIGURE 14D-01 09/11/2018...
  • Page 184 RANS S-21 OUTBOUND TEXT MANUAL The entire outer surface of the aircraft should be inspected for damage of any kind during the pre-flight inspection. ❑ Aircraft Flight Manual – AVAILABLE IN CABIN ❑ Required Aircraft Documentation – AVAILABLE IN CABIN ❑...
  • Page 185 RANS S-21 OUTBOUND TEXT MANUAL ❑ Main Gear - CHECK ❑ Main wheel tire - PROPERLY INFLATED ❑ Brakes - SECURE ❑ Fuel Filler Cap - CLOSED ❑ Remove Cowling if desired ❑ Fuel quick drain valve on bottom of cowling (left side); - DRAIN & CHECK for water, sediment and proper fuel grade.
  • Page 186 RANS S-21 OUTBOUND TEXT MANUAL ❑ Tailcone - Check for dents, holes and scratches. ❑ Fuselage connections - CHECK ❑ Horizontal Stabilizer and Vertical Stabilizer - CHECK ❑ Control surfaces - CHECK - free movement and SECURE ❑ Hinge points – SECURE ❑...
  • Page 187 RANS S-21 OUTBOUND TEXT MANUAL ❑ Climb aboard ❑ Cockpit checklist - CHECK ❑ Move seat into flight position – CHECK SECURE ❑ Seat belts - SECURE ❑ CONTROLS - FREE and CORRECT ❑ Altimeter - SET ❑ Communication radio - SET ❑...
  • Page 188 RANS S-21 OUTBOUND TEXT MANUAL BEFORE STARTING THE POWERPLANT ❑ Pre-flight Inspection - COMPLETE. ❑ Passenger Briefing - COMPLETE. ❑ Seat, seat belts - ADJUST and LOCK. ❑ Brakes - TEST and SET ❑ Radio, Electrical Equipment - OFF ❑...
  • Page 189 RANS S-21 OUTBOUND TEXT MANUAL TAXIING ❑ Brakes – CHECK ❑ Control deflections as required for wind BEFORE TAKEOFF ❑ Cabin Doors - CLOSED and SECURED ❑ Parking Brake - SET ❑ Flight Controls - FREE and Correct ❑ Flight Instruments - SET ❑...
  • Page 190 RANS S-21 OUTBOUND TEXT MANUAL TAKEOFF Normal Takeoff ❑ Flaps – UP or 1 or 2 notch ❑ Carburetor heat – COLD ❑ Fuel pump - ON ❑ Throttle – SLOWLY FULL OPEN ❑ Elevator Control - Taildragger - LIFT TAILWHEEL ❑...
  • Page 191 RANS S-21 OUTBOUND TEXT MANUAL CRUISE ❑ Throttle – up to MAX Continuous RPM ❑ Elevator Trim - adjust. ❑ Fuel pump – OFF APPROACH ❑ Throttle - AS DESIRED. ❑ Engine temperatures – MONITOR ❑ Carburetor heat – ON AS REQUIRED BEFORE LANDING ❑...
  • Page 192 RANS S-21 OUTBOUND TEXT MANUAL LANDING Normal Landing ❑ Airspeed (on approach) – 66-70 MPH (flaps UP). ❑ Flaps (on final) - AS REQUIRED (below 110 MPH) ❑ Airspeed (on final) - 64 MPH (with full flaps) ❑ Touchdown •...
  • Page 193 RANS S-21 OUTBOUND TEXT MANUAL Balked Landing ❑ Throttle – FULL OPEN ❑ Carburetor heat – OFF ❑ Airspeed – 55 MPH ❑ Wing Flaps – RETRACT TO HALF, Slowly ❑ Airspeed – 60 MPH ❑ Wing Flaps – RETRACT, Slowly AFTER LANDING ❑...
  • Page 194 Refer to FIGURE 14D-01 in the Operations Text. Starting at the pilot side cockpit, work around the RANS S-21 OUTBOUND aircraft in a clockwise manner as illustrated. NOTE: This suggested outline for a pre-flight inspection generally covers the critical areas that MUST be checked prior to each flight.
  • Page 195 RANS S-21 OUTBOUND TEXT MANUAL The arrows identify the wind direction. It is very important to hold the controls as described, even when the aircraft is not moving. Refer to FIGURE 14D-02. When taxing in strong crosswinds a little extra throttle will help the aircraft turn due to the increased airflow over the rudder.
  • Page 196 RANS S-21 OUTBOUND TEXT MANUAL Taildragger - 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 tailwheel to swivel 360 degree. To re-engage, use opposite rudder and brake to stop the turn.

  • Page 197: Aircraft Care

    RANS S-21 OUTBOUND TEXT MANUAL HOT WEATHER OPERATION Avoid prolonged engine operation on the ground. Turn the airplane into the wind to assure better airflow through the cowling during run Monitor engine temperatures and adjust climb speed as required. A higher climb speed will provide better engine cooling.
  • Page 198 Clean the windshield with plenty of water and if you need to, with a mild detergent in low concentration. Rinse thoroughly and dry with a clean soft cloth or towel. RANS recommends “Brillianize” for windshield care. Brillianize is available through RANS Parts Department.
  • Page 199 RANS S-21 OUTBOUND TEXT MANUAL INTERIOR CARE Use a vacuum cleaner to remove dust and loose dirt from the interior and upholstery. Household spot removers or upholstery cleaner may also be used for the seat upholstery. Always test it on an obscure place on the fabric to be cleaned.

  • Page 200: Required Placards And Markings

    RANS S-21 OUTBOUND TEXT MANUAL REQUIRED PLACARDS AND MARKINGS AIRSPEED INDICATOR MARKINGS Airspeed indicator markings and their color code meanings are shown in Table 14F-1. All speeds are given for maximum takeoff weight. Speed are given in MPH and (KNOTS)
  • Page 201 S-21 OUTBOUND and must be displayed in the location described in this section. All placards may be printed by a local Graphics Shop or may be available through RANS Aircraft Parts Department. Placards are NOT shown to scale. ...
  • Page 202 RANS S-21 OUTBOUND TEXT MANUAL SUPPLEMENTARY INFORMATION FAMILIARIZATION FLIGHT PROCEDURES The pilot should familiarize themselves thoroughly with this Manual, Engine Operators Manual, applicable Aviation Regulations, and the aircraft itself, before any solo flight is attempted. Scope and detail of a familiarization flight will depend on level of experience and currency of the pilot.

This manual is also suitable for:

S-21 outbound

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