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Quicksilver MAX Sprint Assembly Manual

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Summary of Contents for Quicksilver MAX Sprint

  • Page 2 WARNING !! YOU HAVE JUST WASTED A LOT OF MONEY, UNLESS YOU FIRST FOLLOW THESE INSTRUCTIONS. CLAIMS FOR DAMAGED OR MISSING PARTS 1. Inventory the kit completely using the supplied packing list. Do not remove any parts from the blister-packed boards until you have finished counting everything. The only exception is parts such as nuts, washers, and pop rivets which you may have to remove for accurate counting.
  • Page 3 NOTE: This aircraft MAY NOT be an ultralight in the United States and MAY NOT conform to the definitions of the Federal Aviation Regulation (FAR) Part 103. Contact the Experimental Aircraft Association (EAA) DIRECTLY in Oshkosh, Wisconsin on how to obtain a copy of the 'EAA Custom-Built Sport Aircraft Handbook' for information on aircraft inspection and registration procedures under (FAR) Part 21, Part 47 and Part 91.
  • Page 5 SECTION 4 WING ASSEMBLY GENERAL NOTES ..........1 BELLCRANK & COMPRESSION STRUTS ....4 GENERAL ARRANGEMENT........7 ROOT TUBE / SPARS .......... 8 WING COVER LOCATION / FABRIC TENSION ..9 FABRIC INSTALL ..........10 RIB END CUT OUT..........11 COMPRESSION STRUT INSTALL ......14 DIAGONAL STRUT INSTALL ........
  • Page 6 WING ASSEMBLY NOTES READ AND UNDERSTAND THE ENTIRE PROCESS BEFORE STARTING !!! ALL CUT OUT TEMPLATES ARE LOCATED IN SECTION 12 These notes are to “assist” the information contained on the assembly pages. ASSEMBLE COMPRESSION STRUTS First part of the Wing Assembly is to assemble the compression struts.
  • Page 7 INSTALL RIBS Install the balance of the ribs. Help is almost mandatory. You can spray the rib tubing with a Dry Silicon Lubricant. This will aid the insertion process. The helper should be pushing down on the Front Tip while it’s sliding inside the rib pocket while you are pushing from the rear.
  • Page 8 Assemble Compression Struts (BELOW) and Aileron Compression Stut (ABOVE). VERY IMPORTANT!! Each Tube should be marked FWD and AFT in respect to the Tube Connector Fitting. AFT END of the Bellcrank Strut has the shorter length AFT of the SLEEVE. Section 4 Air-Tech, Inc...
  • Page 9 1-1/2” AN4-26a (10240) LEFT SIDE ASSEMBLY SHOWN. REPEAT FOR RIGHT SIDE...
  • Page 10 6-3b BLANK PAGE Section 4 Air-Tech, Inc...

  • Page 11: Wing Assembly

    WING ASSEMBLY GENERAL ARRANGEMENT DIAGONAL STRUT (40420) 1 PER WING TRAILING EDGE OF WING COMPRESSION STRUT HOLE IN EACH WING COVERING (8 PLACES EACH WING) RIB POCKET (40196) 9 PER WING COMPRESSION STRUT BOLT HOLE IN WING COVERING COMPRESSION STRUT BELLCRANK COMPRESSION STRUT (40283) (71020) 1 PER WING...
  • Page 12 WING ASSEMBLY ROOT TUBE ATTACH INSTALL SPARS TO ROOT TUBE AS SHOWN AN4-25a (10235) 1/4” WASHER (10560) 1/4” LOCKNUT (10510) IMPORTANT: IN SOME APPLICATIONS THE ENGINE MOUNT COMPONENTS ARE LOCATED UNDER THE T.E. SPAR CHANNELS. IF SO, A SPACER THE THICKNESS OF THE MOUNT MAY BE AN4-17a NEEDED AT THIS TIME TO ALLOW FOR...
  • Page 13 WING COVER LOCATION & FABRIC TENSION 8“ (20.23cm) WING FABRIC 2“ OUTBOARD Above illustration shows both Wings atached to the Root Tube w/ Channels (Section 3) Assembly is Upside Down as the wings are assembled in the upside down position. Cord is thru the Black Webbing Loops sewn onto each wing.
  • Page 14 RIBS (40169) NOTICE WITH VELCRO IN SECTION 12...
  • Page 15 Trace the lines onto the Trailing Edge pocket for each Rib. See NOTE for Tip Rib. Carefull not to cut into the main (TOP) surface fabric. For all 9 Rib locations Section 4 Air-Tech, Inc...
  • Page 16 WING COVER ATTACHMENT CONT. Compression Strut holes are located at 62”(157.48cm) 130” (330.2cm) 159” (403.86cm) from Root End of the spars. Locate the Hidden holes under fabric and mark with pencil as shown. This is the “Center Line” for the Compression Strut Cut Outs.
  • Page 17 WING COVER ATTACHMENT (CONT’D) CUT OUT HOLE IN WING COVER One method of Cutting the holes in the fabric is to use a Razor Knife and then heat seal the fabric edges with a Soldering Iron. The Preferred method is to use a Hot Knife A dedicated tool that is used for Wood Carving.
  • Page 18 COMPRESSION STRUT ATTACHMENT BELLCRANK COMP. STRUT (71020) COMPRESSION STRUT HOLE IN WING FABRIC COMPRESSION STRUTS (40283) COMPRESSION STRUT BOLT HOLE IN FABRIC CUT DURING CABLE INSTALL CUT WITH TEMPLATE ADDITIONAL CUT OUT FOR THIS HOLE TO AID IN ASSEMBLY OF LEADING EDGE OUTBOARD WIRES POP ALL 3 STRUTS INTO PLACE.
  • Page 19 Section 4 Air-Tech, Inc...
  • Page 20 DIAGONAL STRUT ATTACH Cont’d DETAIL A Aircraft using the EXTRUDED Channels DO NOT need this washer Aircraft using the EXTRUDED Channels DO NOT need this washer DETAIL B...
  • Page 21 6-3b BLANK PAGE Section 4 Air-Tech, Inc...
  • Page 22 RIB INSERTSION RIB - 40169 (9- Places) RIB ENTRY POINT Best to have help when installing the ribs. While “carefully” pushing the rib into the pocket help should be pushing down on the front tip of the rib as it moves thru the rib Pocket. While pushing, hold the rib tube close to the Trailing Edge par.
  • Page 23 LEFT WIRE SET (20586) T.E. INBOARD L.E. INBOARD T.E. OUTBOARD SLOT Cut Out TEMPLATE is in SECTION 12 L.E. OUTBOARD WING IS SHOWN TOP IS UP Section 4 Air-Tech, Inc...
  • Page 24 FULL SIZE TEMPLATE WITH INSTRUCTIONS IN SECTION 12 THIS ILLUSTRATION AND TEMPLATE ARE FOR THE LEFT WING FLIP THE TEMPLATE OVER FOR THE RIGHT WING COMPRESSION STRUT COMP STRUT BOLT HOLE LEFT WING SHOWN Section 4 Air-Tech, Inc...
  • Page 25 WING WIRE ATTACHMENT BELLCRANK / COMPRESSION STRUT / Heat cut holes for Grade 5 Bolts, make sure compression struts are in line with holes Assemble Hardware in sequence shown below and in following pages (Steps1-7) VERIFY WIRE PART NUMBERS ON PACKING LIST BOTTOM VIEW OF LEFT WING BELLCRANK STRUT...
  • Page 26 WING WIRES / COMPRSSION STRUTS CON’T CAREFULLY HEAT CUT THIS HOLE USING TEMPLATE AS GUIDE 1/4 LOCKNUT W/ WASHERS L. E. OUTBOARD UPPER WIRE 1“ X 1/4” NYLON WASHER (20346) Not a cut out for clarity only 1/4” X 2-1/2” GRADE 5 (10423) THREADS INTO COMPRESSION STRUT 1-3/4”...
  • Page 27 WING WIRES / COMPRESSION STRUTS CONT. ASSEMBLE AS SHOWN FOR STEPS 4, 5 AND 6 TRAILING EDGE SPAR WING WIRE T.E. LOWER OUTBOARD (20546) 1/4” X 2” BOLT (10410) 1/4” X 2-1/2” BOLT (10428 TRAILING EDGE SPAR WASHERS AS NEEDED LEADING EDGE SPAR 1/4”...
  • Page 28 WING WIRES CONT. / FORKBOLT INSTALL TOP VIEW ANTI DRAG WIRE (71032) AN4-16A (10140) 1/4” WASHER (10560) as req’d 1/4” LOCKNUT (10510) AILERON HINGE INSTALL 1/4” FENDER WASHER (10565) 1/4”-20 X 2” FORKBOLT 1-1/8” SADDLE (10389) (20285) Aileron Hinge holes are located at: 48-11/16”...
  • Page 29 TIP STRUT ATTACHMENT Using Tip Strut as a guide, drill 3/16” hole 12-3/4” from front of Comp Strut. VIEW “A-A” AN3-17a Loosly attach Strut as to get a measurement (10050) on where to cut the end & Fish Mouth. COMP STRUT Ideally help is available.
  • Page 30 SECTION 1 INTRODUCTION CONSTRUCTION NOTES GENERAL / PREPERATION CABLES / BOLTS / NUTS AN BOLTS AN BOLT GAUGE CASTLE NUTS / PINS / THREAD LOC BOLT TIGHTENING TIGHTENING PROCEEDURE LOCATING HOLES / HEAT SEALING STAND OFF ASSEMBLY NICO GAUGE TOOLS / SUPPLIES ABBREVIATIONS Section 1 Air-Tech, Inc...

  • Page 31: Construction Notes

    PREPARATIONS Before starting the assembly of your Quicksilver aircraft, it is imperative that you take the time to inventory the entire kit. This will get you familiar with ALL the parts and their location. With two people this is not a difficult task.
  • Page 32 DO NOT cut the Part Number identifiers off of the cables. BOLTS All bolts used in the airframe of the Quicksilver aircraft are either 'Graded' aircraft quality, military specification or conform to S.A.E. standards (Society of Automotive Engineers). The most commonly used bolts in this aircraft are fine threaded 'AN' (Air Force-Navy) bolts.
  • Page 33 'AN' BOLTS WARNING: 'AN' (Air Force-Navy) Bolts comply with strict quality standards and are used throughout the construction of this aircraft for structural integrity. NEVER USE SUBSTITUTES! See your dealer for replacements if necessary. If the diameter and length is known and an 'AN' Bolt Gauge is not available remember this easy method: The first number following the 'AN' designation is the bolt diameter shank size in 1/16"...
  • Page 34 NOTE: 'AN' bolts are used throughout the construction of the aircraft for structural integrity. NEVER USE SUBSTITUTES! See your Quicksilver Rep for replacements if necessary. For reference, the Gauge below is shown to determine the 'type' and the APPROXIMATE length of 'AN' Bolts.

  • Page 35: Cotter Pins

    BACKING OFF. ENSURE ALL CASTLE NUTS ARE SECURED WITH COTTER PINS! ALL COTTER PINS MUST BE BENT CORRECTLY. COTTER PINS Refer to the figures below for the proper method of bending all Cotter Pins, Quicksilver Part Number (P/N) 10635. WARNING: NEVER RE-USE A COTTER PIN AFTER IT HAS BEEN BENT.

  • Page 36: Bolt Tightening

    BOLT TIGHTENING GENERAL NEVER over tighten a bolt. Tighten ONLY when and as instructed. Particular care is necessary when tightening bolts which pass through aluminum tubes with no solid internal support. BEFORE installing bolts, check that the grip-length is correct. Refer to FAA Advisory Circular AC65-9A, Page 129 for additional information.
  • Page 37 CORRECT TORQUE AND TIGHTENING PROCEDURE The correct torque and tightening procedure for a Bolt (1) that passes through a Tube (2) is to tighten the Nut (3) or Bolt (1) only to the point that all the Items (4), between the Nut (3) or Fitting (5) and the Bolt Head (1), come into contact with one another and then continue tightening ONE FULL turn.
  • Page 38 LOCATING HOLES When pre-drilled tubes have been inserted into the wing and tail covers, find the holes as instructed in each sequence. Locate them with your finger nail then mark the location with a Pencil. The location distance is typically called out during assembly. Always heat seal a hole with a hot knife.

  • Page 39: Stand-Off Assembly

    STAND-OFF ASSEMBLY This is an anti-vibration assembly used to isolate fuel lines, throttle cables, choke cables, push/pull control cables, brake cables, and some electrical cables/wires throughout the aircraft. The exact locations and numbers used are detailed in the relevant assembly sequence. All tie wraps and fuel lines must be replaced in accordance with the progressive maintenance schedules.
  • Page 40 NICO GAUGE The Nico Sleeve Gauge, Quicksilver Part Number (P/N) 20447, supplied with the aircraft kit is used during the initial parts inventory to verify the accuracy of the cable compression sleeves on ALL cables. NOTE: The Nico Sleeve is one particular brand of cable compression sleeve.
  • Page 41 TYPICAL ABBREVIATIONS In certain instances, abbreviations must be used in this assembly manual. The following are typical abbreviations which may be 'called out': ABBREVIATION SIGNIFICANCE ABBREVIATION SIGNIFICANCE Adjuster Grade (as in Grade 5 Bolt) Aileron Guard Aluminum Inbd Inboard Alum Aluminum L.E.
  • Page 42 BASIC TOOLS & SUPPLIES REQUIRED FOR AIRFRAME ASSEMBLY Angle Finder (can be digital ie. phone) Protective Material (carpet or bed sheets, etc.) Bench Vise Center Punch Rivet Tool (Gun)(for 1/8" & 3/16" Clamp(s) (C type) Rivets) Cord (Nylon Leech Line, Rope, or String) Sandpaper (medium grit) Deburring Tool (Hand) Scales: 3, each w/ 250 Ibs (113 kg)
  • Page 43 RUDDER ASSEMBLY.......2-2 ELEVATOR ASSEMBLY....2-12 STABILIZER ASSEMBLY....2-13 TAIL TUBE ASSEMBLY....2-15 TAIL SKID ASSEMBLY....2-17 TAIL BOOM & BRACE ASSEMBLY..2-18 Section 2 Air-Tech, Inc...
  • Page 44 40333 Section 2 Air-Tech, Inc...
  • Page 45 RUDDER COVER AND RUDDER LEADING EDGE Section 2 Air-Tech, Inc...
  • Page 46 RUDDER LEADING EDGE AND CONTROL ARM Section 2 Air-Tech, Inc...
  • Page 47 RUDDER LEADING EDGE AND CONTROL ARM Section 2 Air-Tech, Inc...
  • Page 48 Section 2 Air-Tech, Inc...
  • Page 49 Section 2 Air-Tech, Inc...
  • Page 50 Section 2 Air-Tech, Inc...
  • Page 51 RUDDER BALANCE STRUT Section 2 Air-Tech, Inc...
  • Page 52 Section 2 Air-Tech, Inc...
  • Page 53 RUDDER HINGE BOLT Section 2 Air-Tech, Inc...
  • Page 54 BLANK PAGE Section 2 Air-Tech, Inc...
  • Page 55 sections Locknuts- 10510 Washers- 10560 Heat cut slits TEMPLATE Page 12-3 (70130) bolt AN3-14A (10035) TOP VIEW Section 2 (10500) Air-Tech, Inc...
  • Page 56 (40275) Section 2 Air-Tech, Inc...
  • Page 57 STABILIZER LEADING EDGE ASSEMBLY Section 2 Air-Tech, Inc...
  • Page 58 TAIL MOUNT / RUDDER BRACE Slide the two pieces of Flex Sleeve (20397) onto the Tail Mount (40172). The exact location will be determined later in the assembly. Refer to DETAIL ‘A’ on the correct orientation of the Rudder Brace Tube (40181) and the Tail Mount Tube (40172) The Holes in the illustration are drilled at an Angle.

  • Page 59: Side View

    TAIL MOUNT RUDDER BRACE SEE PAGE 2-18 FLEX SLEEVE (20397) Installation HOLES DRILLED AT AN ANGLE TO MATCH TAIL SKID DETAIL ‘A’ SIDE VIEW DETAIL ‘B’ DETAIL ‘C’ DETAIL ‘C’ #14 Bolt may seem to long. Add washers under the nut (#8) to take up space.
  • Page 60 TAIL SKID HINGE FORKS 1/4” LOCKNUT (10510) 1/4” WASHER (10560) HINGE FORK (10390) AN4-27a (10250) 1” X 1/8” SADDLE (20270) AN4-25a (10220) FLEX SLEEVE (20397) FLEX SLEEVE (20397) 1-1/8” SADDLE (20285 41150 CLEVIS PIN (10440) SAFETY RING (20310)
  • Page 61 BLANK PAGE Section 2 Air-Tech, Inc...
  • Page 62 TAIL BOOM / TAIL BRACE ASSEMBLY This will complete the assembly of the Tail Group. There are many different size Saddles on this page. Be careful to install the Saddles only as shown. DO NOT Over tighten the bolts through the saddles as this will (in time) develop cracks in the saddles.
  • Page 63 TAIL BOOMS TAIL BRACES DETAIL ‘B’ DETAIL ‘A’ DETAIL ‘C’ DETAIL ‘C’ Section 2 Air-Tech, Inc...
  • Page 64 This Section is provided to illustrate the Wing Spar Channels to the Root Tube. Some builders will attached the Root Tube to the top of a wood saw horse to facilitae the assembly of the Wings. Installation of the Hirth F-23 engine, installs the engine mount angles between the rear Channels and the Root T T ube.
  • Page 65 ROOT TUBE The Hirth F-23 will mount to the AFT part of the Root Tube. See the Engine Install Instructions for clarification. The aft Channels are in the F-23 engine mount kit. AN5-25a (10312) AN4-30a (10270) 5/16” Washer (10570) as needed Tri Bar Nose Wire Assy.
  • Page 66 Section 3 Air-Tech, Inc...
  • Page 67 SECTION 5 AILERONS TRAILING EDGE ASSY ......2 NUTPLATE & COMPRESSION STRUTS..3 LEADING EDGE ASSEMBLY...... 4 COMP STRUT INSTALL ......5 FABRIC INSTALL ........6 EYEBOLT / HORH ATTACH ....... 7...
  • Page 68 Section 5 Air-Tech, Inc...
  • Page 69 Section 5 Air-Tech, Inc...
  • Page 70 Section 5 Air-Tech, Inc...
  • Page 71 Section 5 Air-Tech, Inc...
  • Page 72 YOU TUBE SEARCH: QUICKSILVER AILERON INSTALL Section 5 Air-Tech, Inc...
  • Page 73 Section 5 Air-Tech, Inc...
  • Page 74 SECTION 6 TRIKE SUB ASSEMBLIES NOTES..........2 GENERAL ARRANGEMENT......3 TIRE WHEEL ASSEMBLY......5 NOSE GEAR........... 6 RUDDER PEDALS & CABLES ....7 RUDDER PEDAL STOP......8 TRI BAR ASSEMBLY........ 10 LANDING GEAR DOWN TUBE / MAIN AXLE 11 AFT RUDDER CABLE PULLY...... 12 Section 6 Air-Tech, Inc...
  • Page 75 TRIKE ASSEMBLY NOTES Plastic bushings 70250 (page 6-6) are installed into the Foot Pedals. It is important that the bushing fit smoothly into the 1” hole in the Pedal and over the Pedal Mount Tube (40430). If necessary open up the hole in the pedal with a round file or use sandpaper. Once assembled, the pedals should rotate freely on the tube.
  • Page 76 TRIKE GENERAL ARRANGEMENT Section 6 Air-Tech, Inc...
  • Page 77 6-3b BLANK PAGE Section 6 Air-Tech, Inc...
  • Page 78 Section 6 Air-Tech, Inc...
  • Page 79 Section 6 Air-Tech, Inc...
  • Page 80 FOOT PEDAL & RUDDER CABLE ASSEMBLY Safety Ring (20310) Foot Pedal (70231) 1/4” Locknut (10510) Clevis Pin (10440) Clevis Pin (10440) thru this 3/16” hole to attach to top of Spring (91115) See Note on page 6-5 Drill 1/4” (6.3mm) using dimensions below After Pedals are installed, a TIE WRAP (30480) used as spacer between pedals bushings.
  • Page 81 Section 6 Air-Tech, Inc...
  • Page 82 RUDDER PEDAL STOP SET AN4-15a (10270) 1/4” Washers (10560) Once assembly from previous page is complete, the Rudder Pedal Stop Bolts (10270) will be installed. The Stop Bolt sets the AFT limit for the Rudder Pedals. During Final Assembly the adjustment of this bolt will limit the travel of the Rudder. Proper adjustment will not allow the Rudder to contact the Elevator.
  • Page 83 TRI BAR ASSEMBLY Lubricate and install Tri Bar Down Tubes into Crosstube. Grease is best. Be sure lower hole in Down Tube aligns with hole in Crosstube. Nose Wire attaches to front of Root Tube. 20331 Shackle is shown for reference only. See Page 3-2 for upper attachment of the TRI BAR NOSE WIRE (20602) For HIRTH F-23 this bolt...
  • Page 84 RIGHT SIDE SHOWN Section 6 Air-Tech, Inc...
  • Page 85 5/16” LOCKNUT 10540) 5/16” WASHER (10570) 1“ X 1/8” SADDLE (20270) 20-1/2” 1/4” LOCKNUT AXLE STRUT (10510) (40381) Left Side Shown 1/4” WASHER (10650) AN4-16a Bolt (10140) TRI-BAR CROSSTUBE Left Side Shown Section 6 Air-Tech, Inc...
  • Page 86 Section 6 Air-Tech, Inc...
  • Page 87 NOSE STRUT 40365 TENSION STRUT (41300) AXLE INBOARD TENSION STRUT (41300) NOSE STRUT 40365 FILE AND DEBURR ANY INTERERENCE ON NOSE STRUT & AXLE STRUT Section 6 Air-Tech, Inc...
  • Page 88 SECTION 8 SEAT MOUNT CONTROLS SEAT MOUNT & SUPPORT TUBE ....2 THROTTLE ASSEMBLY......3 SEAT ATTACH........4 CONTROL STICK ........5 AILERON CABLE GUARD ......6 ELEVATOR CONTROL ......8 ROOT TUBE BELLCRANK ......10 FUEL TANK..........12 Section 8 Air-Tech, Inc...
  • Page 89 Drill to 5/16” Section 8 Air-Tech, Inc...
  • Page 90 THROTTLE ASSEMBLY Assemble the Lever 90202) to the Mount (90201). The Throttle Cable will be installed during Engine install. The Forward Shoulder Bolt (90300) sets the Forward STOP for the Throttle Lever. IDEALLY ATTACH THIS ASSEMBLY TO SEAT AFTER STEPS ON PAGE 8-9. In some instance there is interference with the Push Pull interference with the Push Pull Tube (40177) Sould be mounted as low as possible on seat.
  • Page 91 SEAT MOUNT ASSEMBLY AN4-17a (10150) 2 places rear AN4-15a (10120) Section 8 Air-Tech, Inc...
  • Page 92 Section 8 Air-Tech, Inc...
  • Page 93 AILERON CONTROL CABLE GUARD ATTACH VERTICAL 70389 40337 91111. . Control Cable...
  • Page 95 AN3-16a 10045...
  • Page 96 FINAL ASSEMBLY MAY REQUIRE A NEW HOLE BE DRILLED AN4-15a (10120) NOTE: #11 is a Nylon Washer This bolt gets Castle Nut...
  • Page 97 Section 8 Air-Tech, Inc...
  • Page 98 Final adjsutment to the Aileron Bellcrank will be performed in Section 10 Be certain that LOCKRIB (#14) is in GROOVE of Control Cable Lock Jam Nut (#7) onto #4 AFTER Final Assembly. USE LOCTITE Route CABLE with SMOOTH bends using ty-raps and stand offs CABLE Actions must be SMOOTH and...
  • Page 99 Prior to installing the Fuel Tank be sure the inside is clean and holes are De-Burred RUBBER FUEL TANK BUSHING (30290) Install Bushing then Fittings. Grip Fittings with Vise Grips Use oil on bushings and Fittings Some Fuel Caps do not Require this hole be Drilled.
  • Page 100 SECTION 9 WING & TAIL ATTACH WINGS TO TRIKE........2 KINGPOST ASSEMBLY ......3 ASSEMBLY NOTES........4 UPPER & LOWER WIRE ATTACH ....5 TAIL GROUP ATTACH......6 Section 9 Air-Tech, Inc...
  • Page 101 REFFER TO SECTION 4 PAGE 8 THE INSTALLED ENGINE MAY PREVENT THE WING TIPS FROM RESTING ON THE GROUND USE OUTBOARD COMPRESSION STRUTS TO RAISE WINGS Section 9 Air-Tech, Inc...
  • Page 102 KING POST ASSEMBLY FWD King Post (40205) Section 9 Air-Tech, Inc...
  • Page 103 WING ATTACH / UPPER & LOWER WIRES / KINGPOST REFER TO DETAIL ON FOLLOWING PAGE. Understand this entire procedure before starting. This begins the final assembly of the kit. Additional help is almost required but can be done solo. Put weight on top of the nose wheel to hold the nose wheel on the ground.
  • Page 104 UPPER & LOWER WIRES KING POST INSTALL LEFT UPPER WIRES 20586 RIGHT UPPER WIRES 20587 CLEVIS PIN AFT KING POST FWD KING POST SAFETY RING (3 PLACES) T HANDLE PIN (2 PLACES) 20547 REF PAGE 6-11 20546 FOR BOLT SIZE TRI BAR CROSS TUBE 20534...
  • Page 105 TAIL GROUP TO AXLE & WINGS LANDING GEAR SIDE WIRE (20616) 1/4” LOCKNUT (10510) WASHER LOWER BOOM TUBE (40421) AN4-20a (10170) BOTH ASSEMBLIES USE THE SAME HARDWARE UPPER BOOM TUBE (40179) CHANNEL (20090) TAIL BRACE TUBE (40425) At this point, both wings are attached to the Trike and the Trike is sitting on all three wheels. First step is to set the Tail Skid on blocks (chair) and attach the Upper Tail Booms to the Channels on the Wings.
  • Page 106 SECTION 10 CONTROL SURFACES ATTACH & ADJUST SURFACES INSTALL / ADJUST NOTES..2 CONTROL STICK SET......3 AILERON CABLE ATTACH ......4 AILERON TO WING......... 5 AILERON PUSH ROD....... 6 AILERON ADJUST........7 SYSTEM CHECK ........8 ELEVATOR PUSH / PULL TUBE ....9 TAIL INCIDENCE ........
  • Page 107 CONTROL SURFACE INSTALL AND ADJUST Once the Control Surfaces are installed they will need to be checked and adjusted Ideally the Ailerons can be installed and adjusted prior to installing the Tail Section. AILERONS: First step is to assure the Root Tube Bellcrank is PARALLEL to the Root Tube.
  • Page 108 Tie Control Stick in “NEUTRAL” Position. LOCTITE JAM NUT (10495) ROOT TUBE BELLCRANK (42002) Adjust to LOCK Cable onto MUST BE PARALLEL TO ROOT TUBE. Rod End Bearing. Ideally- Equal threads Top & Bottom. LANDING GEAR DOWN TUBE (40291) Section 10 Air-Tech, Inc...
  • Page 109 TOP VIEW Section 10 Air-Tech, Inc...
  • Page 110 Section 10 Air-Tech, Inc...
  • Page 111 AILERON INSTALTION (CONT’D PUSH ROD Inboard hole = Less Effort Less Travel Outboard hole = More Effort and More Travel Section 10 Air-Tech, Inc...
  • Page 112 With Control Stick in NEUTRAL Position, Adjust Control Rods till Ailerons align with Straight Edge along Bottom of Wing. Same for BOTH Wings. Location of Straight Edge should be near Aileron Horn. ONCE ADJUSTMENTS ARE COMPLETE APPLY LOCTITE TO JAM NUTS Section 10 Air-Tech, Inc...
  • Page 113 Section 10 Air-Tech, Inc...
  • Page 114 ELEVATOR AFT PUSH PULL TUBE ATTACH ELEV HORN (70070) 1/4” CASTLE NUT (10521) 3/16” LOCKNUT CASTLE NUT (10550) (10571) 70600 70190 10550 COTTER PIN ( 10635) AFT PUSH PULL TUBE (40178) WASHER (10550) AN4-14 (10110) AN3-14a (10035) AN3-16 (10130) AN4-15a (10120) 40178 ELEVATOR PUSH PULL TUBE IS ATTACHED AS SHOWN...
  • Page 115 HORIZONTAL STABILIZER INCIDENCE This step Checks the Anglular difference between the Wing and the Horizontal Stabilizer Surface. 1. Establish ROOT TUBE is in Level Position. 2. Place Straight Edge with Level on top of Leading and Trailing Edge of Stabilizer Frame near the center but not on the “Sleeve”...
  • Page 116 CONTROL STICK NEUTRAL / VERTICLE STRAIGHT UP >>This Step is with reference to Page 9 in Section 8 and DETAIL “B” >>The Angle of the seat should be in its Final position. >>The For Aft adjustment of the Seat Mount Assy should be complete. 1.
  • Page 117 Wing Washout is the angular differance between the Root Cord (Root Tube) and the Tip of the Wing. This difference is establish during the engineering of the aircraft is set by the pre made Wire Lengths. Theres no practicle way for you (the builder) to change or adjust this setting BUT it MUST be checked to determine the Wings were assembled correctly.
  • Page 118 DOCUMENT / LABEL PLACEMENT CLEAN & DEGREASE AREA, APPLY LABEL, REMOVE AIR BUBBLES NOSE STRUT DOC#846-1C DOC#886-01 DOC#846-17 DOC#846-21 DOC#846-19 AXLE STRUT DOC # 50420-05 POSITION LABEL TO BE EASILY SEEN BY ANYONE APPROCHING THE AREA NEAR OR AROUND THE PROPELLER ONE LABLE FOR EACH SIDE Section 11 Air-Tech, Inc...
  • Page 119 Section 11 Air-Tech, Inc...
  • Page 120 LEADING EDGE OUTBOARD WIRE RUDDER & ELEVATOR #1 THRU # 4 RIB END CUT-OUT WING COMPRESSION STRUTS Section 12 Air-Tech, Inc...
  • Page 121 Section 12 Air-Tech, Inc...
  • Page 122 TEMPLATES #1 THRU # 4 TEMPLATE FOR RUDDER TOP ALIGN TO ZIG ZAG STITCHING CUT OUT ON SOLID LINE ALIGN THIS LINE TO CENTER OF COMPRESSION STRUT TUBE TEMPLATE FOR RUDDER AND ELEVATOR # 2, 3, 4 FOR TEMPLATE #2 & 4 PLACE ZIG ZAG ON TUBE CENTER LINE ALIGN TO ZIG ZAG STITCHING Section 12...

  • Page 123: Cut Out Template

    RIB END CUT OUT TEMPLATE CUT OUT SLITS CUT OUT TEMPLATE EDGE OF RIB POCKET Section 12 Air-Tech, Inc...
  • Page 124 TEMPLATE WING COMPRESSION STRUT SLOT LINE UP FOR TRAILING EDGE CUT OUT CUT TEMPLATE FROM SUITABLE MATERIAL NOTE: PRINTED LENGTH OF ILLUSTRATION IS NOT CORRECT. SEE DIMENSIONS ON SIDE OF TEMPLATE FINISH LENGTH IS 16” LINE UP FOR LEADING EDGE CUT OUT Section 12 Air-Tech, Inc...

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