INSTALLATION INSTRUCTIONS
AVIAT HUSKY A-1C-200 · Maintenance Manual
Overview
This document provides installation instructions for aluminum lift struts for the Aviat A-1 series aircraft, specifically the A-1C-200 model. It includes details on the removal of existing steel struts, installation of new aluminum struts, and necessary adjustments for proper aircraft rigging.
- The manual is proprietary to Airframes Alaska, LLC.
- Installation requires two people for safety.
- Aluminum struts are lighter and resistant to corrosion compared to steel.
- Proper aileron cable tension is critical at 30 lb. +15 lb. -0 lb.
- Old jury struts must be reused with new clamps.
- Powder coating of aluminum struts is not acceptable.
- Weight reduction of 7.2 lbs. when replacing OEM struts with aluminum.
- Struts are located 23 inches aft of the wing leading edge datum.
Document
Source
Originally published by alaskagearcompany.com. Sprinkle hosts a reference copy with an added summary, specifications and searchable full text.
Document details
- Type ·
- Maintenance Manual
- Year ·
- 2023
- File size ·
- 543 KB
- Publisher ·
- alaskagearcompany.com
- Language ·
- en
Specifications & performance
Extracted from this document.
Specifications
- Oem rear strut weight (lb) ·
- 6.88
- Oem front strut weight (lb) ·
- 11.15
- Replacement rear strut weight (lb) ·
- 5.56
- Replacement front strut weight (lb) ·
- 8.85
Performance
- Strut location inch ·
- 23
- Weight reduction (lb) ·
- 7.2
What is the INSTALLATION INSTRUCTIONS?
The INSTALLATION INSTRUCTIONS is a maintenance manual for the AVIAT HUSKY A-1C-200, dated 2023.
Where does the INSTALLATION INSTRUCTIONS come from?
This copy of the INSTALLATION INSTRUCTIONS was originally published by alaskagearcompany.com and is hosted on Sprinkle as a free, searchable reference copy.
What year was the INSTALLATION INSTRUCTIONS published?
The INSTALLATION INSTRUCTIONS — the AVIAT HUSKY A-1C-200 maintenance manual on file — is dated 2023.
Most owners only have the POH. Here's the essential set for the AVIAT HUSKY A-1C-200.
- Pilot's Operating Handbook / AFM
- Checklist
- Maintenance Manual
- Parts Catalog (IPC)
- Systems & Wiring
- Service Bulletins on file
- Type Certificate (TCDS)
More AVIAT HUSKY A-1C-200manuals & documents
In this document
Background
This section describes the benefits of using lightweight aluminum replacement lift struts, highlighting their corrosion resistance compared to steel.
Installation Instructions
Detailed steps for removing steel lift struts and installing new aluminum struts, including necessary precautions and adjustments.
Weight and Balance
Information on the weight differences between OEM and replacement struts, emphasizing the need for weight and balance adjustments post-installation.
Trouble Shooting
This section will be updated with common problems and corrections as they arise during field installations.
Documents and Drawings
A list of related documents and drawings necessary for installation and continued airworthiness.
Engineering Changes and Amendments
Details on how Airframes Alaska will notify owners of any changes affecting airworthiness.
Safety notes
- Caution: Powder coating of heat-treated aluminum struts could alter their strength.
- Ensure proper aileron cable tension to avoid control issues.
- Use care when handling and installing struts to prevent damage.
- Mark jury struts to ensure correct reinstallation.
- Always check for proper aileron movement after installation.
Full document text
1 INSTALLATION INSTRUCTIONS Aircraft: Aviat A-1, A-1A, A-1B, A-1C-180, A-1C-200 ALUMINUM LIFT STRUTS Release Number: A Release Date: 03/1/2023 THIS MANUAL INCLUDES INFORMATION PROPRIETY TO AIRFRAMES ALASKA AND SHALL NOT BE USED TO MANUFACTURE OR REPRODUCE ANY PART OR ASSEMBLY WITHOUT THE PRIOR WRITTERN PERMISSION OF AIRFRAMES ALASKA. 907.331.4480 // AIRFRAMESALASKA.COM // 81 E. COMMERCIAL DRIVE, PALMER, AK, 99645 2 THIS MANUAL INCLUDES INFORMATION PROPRIETY TO AIRFRAMES ALASKA, LLC. AND SHALL NOT BE USED TO MANUFACTURE OR REPRODUCE ANY PART OR ASSEMBLY WITHOUT THE PRIOR WRITTERN PERMISSION OF AIRFRAMES ALASKA, LLC. This Page Intentionally Left Blank 3 THIS MANUAL INCLUDES INFORMATION PROPRIETY TO AIRFRAMES ALASKA, LLC. AND SHALL NOT BE USED TO MANUFACTURE OR REPRODUCE ANY PART OR ASSEMBLY WITHOUT THE PRIOR WRITTERN PERMISSION OF AIRFRAMES ALASKA, LLC. Record of Revisions Rev Level Date Page Author Explanation of Revisions IR 7/5/2022 - Jon Earl Initial Release A 3/1/2023 6 Jon Earl Aileron cable tension updated to 30 lb. +15 lb. -0 lb. Distribution of Changes A current copy of this manual will be maintained on the Airframes Alaska, LLC. website. 4 THIS MANUAL INCLUDES INFORMATION PROPRIETY TO AIRFRAMES ALASKA, LLC. AND SHALL NOT BE USED TO MANUFACTURE OR REPRODUCE ANY PART OR ASSEMBLY WITHOUT THE PRIOR WRITTERN PERMISSION OF AIRFRAMES ALASKA, LLC. Table of Contents 1 Background .............................................................................................................. 5 2 Installation Instructions ............................................................................................. 5 3 Weight and Balance ..................................................................................... ...........7 4 Trouble Shooting ...................................................................................................... 7 5 Documents and Drawings .........................................................................................8 6 Engineering Changes and Amendments ..................................................................9 5 THIS MANUAL INCLUDES INFORMATION PROPRIETY TO AIRFRAMES ALASKA, LLC. AND SHALL NOT BE USED TO MANUFACTURE OR REPRODUCE ANY PART OR ASSEMBLY WITHOUT THE PRIOR WRITTERN PERMISSION OF AIRFRAMES ALASKA, LLC. 1 Background This lightweight aluminum replacement lift strut utilizes an aluminum extrusion with open ends. Corrosion will not be an issue as with the non-sealed OEM steel struts. 2 Installation Instructions (to accomplish lift strut removal and installation properly, two people will be required) If the aircraft has steel lift struts in place, they need to be removed as outlined below: 1. Remove the fuselage body panels covering the aileron pulleys and aileron cable attachment to the torque tube. 2. Remove the two aileron pulleys and then disconnect the aileron cables from the torque tube. 3. Pull the aileron cables through the top of the strut fairleads and secure them away from the struts. 4. Remove the 6 front strut fairlead phenolics and C clips. They will be able to be reused on the replacement aluminum struts if they are in good condition. 5. Remove the jury struts from the aircraft, they will be reused with the new aluminum struts so do not damage them and mark which one goes on the front strut, and which one go on the rear strut. 6. Remove the front and rear strut fasteners from the fuselage by removing the bolts, washers, and nuts at the lower end of each strut. 7. With one person at the wing tip holding the wing tip up. Disconnect the rear lift strut from the wing panel by removing the bolt, washer, and nut. 8. Pull the rear strut off the fuselage and place it out of the way in a safe location. 9. While one person is still holding the wing tip up, disconnect the front lift strut from the wing panel by removing the bolt, washer, nut, spacer, and pulley housing. 10. Pull the front strut off the fuselage and place it out of the way in a safe location. 11. It may be necessary to prop the wing tip up with a stand if the new aluminum struts are not prepared and immediately ready for installation. 6 THIS MANUAL INCLUDES INFORMATION PROPRIETY TO AIRFRAMES ALASKA, LLC. AND SHALL NOT BE USED TO MANUFACTURE OR REPRODUCE ANY PART OR ASSEMBLY WITHOUT THE PRIOR WRITTERN PERMISSION OF AIRFRAMES ALASKA, LLC. Installation of the new aluminum lift struts (if the aircraft flew straight and level and was properly rigged prior to removal of the steel struts, adjust the new aluminum forks exactly like the forks on the steel struts. Note: there must not be more than 15 threads showing external to the strut.) Caution: Powder coating of heat-treated Aluminum struts could alter their strength; therefore powder coating is not acceptable. These aluminum struts must be finished with conventional liquid paint or left in their bare aluminum state only. 1. With one person at the wing tip holding up the wing, install the new aluminum front strut to the wing panel. Note: The new aluminum front and rear lift struts are interchangeable so there is not a dedicated left-hand or right-hand strut. Use the same bolt, nut, washer, spacer, and pulley housing that was removed from the front steel strut. Secure the nut onto the bolt. 2. The person holding up the tip will need to raise the tip up so that the split end of the front strut can be guided and aligned to the front strut hole on the fuselage strut fitting (be careful not to damage the strut during the installation process). 3. Once the new front strut is in place, install the fuselage strut bolt, washer, and nut to secure it in place at the fuselage strut fitting. The wing will now be stable and the person holding up the tip can release it without fear of the wing panel dropping. 4. Mount the new aluminum rear strut to the rear hole on the fuselage strut fitting. 5. With one person holding the wing tip trialing edge, mount the rear strut to the
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wing panel. The person holding the wing tip trailing edge will likely have to either raise or lower the tip to mate the rear strut to the wing panel. 6. Reinstall using the same bolts, nuts, and washers removed from the steel strut. If the aircraft flew straight and level and was properly rigged prior to removal of the steel struts and the fork positions were replicated proceed to the next step. If not, the aircraft will need to be properly rigged. 7. Install the old jury struts using the new front and rear jury strut clamps. 8. Install and secure three cable fairlead assemblies to each of the front struts. 9. Route the free aileron cable through the front strut cable fairleads, through the pulley at the lower front strut, and through the belly to the torque tube. 10. Reinstall and secure the fuselage aileron pulleys using new cotter pins. Reinstall the aileron cable to the torque tube using new cotter pins. 11. Reinstall all fuselage body panels. 12. Ensure proper aileron cable tension (30 lb. +15 lb, -0 lb). 13. Check for proper aileron movement. Move the control stick to the left, the left aileron should raise, and the right aileron should lower. Move the control stick to the right, the right aileron should raise, and the left aileron should lower. Check cables for interference or chafing. 7 THIS MANUAL INCLUDES INFORMATION PROPRIETY TO AIRFRAMES ALASKA, LLC. AND SHALL NOT BE USED TO MANUFACTURE OR REPRODUCE ANY PART OR ASSEMBLY WITHOUT THE PRIOR WRITTERN PERMISSION OF AIRFRAMES ALASKA, LLC. 3 Weight and Balance The replacement Aviat Husky aluminum lift strut exchange weight is significant and will require changes to the aircraft Weight and Balance after installing this STC. If replacing OEM Aviat Husky Struts, the aircraft weight is reduced by: 7.2 Lbs. OEM Aviat Husky Front Strut Weight: 11.15 lbs. OEM Aviat Husky Rear Strut Weight: 6.88 lbs. Airframes Alaska Replacement Aluminum Front Strut Weight: 8.85 lbs. Airframes Alaska Replacement Aluminum Rear Strut Weight: 5.56 lbs. The struts are located 23” aft of the wing leading edge datum 4 Trouble Shooting To be updated with common Problems and Corrections, if necessary, when and if they arise when more kits are installed in the field. 8 THIS MANUAL INCLUDES INFORMATION PROPRIETY TO AIRFRAMES ALASKA, LLC. AND SHALL NOT BE USED TO MANUFACTURE OR REPRODUCE ANY PART OR ASSEMBLY WITHOUT THE PRIOR WRITTERN PERMISSION OF AIRFRAMES ALASKA, LLC. 5 Documents and Drawings Descriptive Data List Document Title Document Number Revision Level Pages Date Instructions for Continued Airworthiness ICA - 6/17/2022 Aviat Husky Aluminum Front Lift Strut Assembly Drawing AF51653 - 2/17/2021 Aviat Husky Aluminum Rear Lift Strut Assembly Drawing AF51654 - 2/17/2021 9 THIS MANUAL INCLUDES INFORMATION PROPRIETY TO AIRFRAMES ALASKA, LLC. AND SHALL NOT BE USED TO MANUFACTURE OR REPRODUCE ANY PART OR ASSEMBLY WITHOUT THE PRIOR WRITTERN PERMISSION OF AIRFRAMES ALASKA, LLC. 6 Engineering Changes and Amendments In the event that a change or amendment is made to the design, components, or procedures contained within this manual or STC that affect airworthiness of the installation; Airframes Alaska, LLC. will notify the recorded owners in writing of the affected element(s) and provide the necessary data for compliance. 907.331.4480 // AIRFRAMESALASKA.COM // 81 E. COMMERCIAL DRIVE, PALMER, AK, 99645