Cessna Flap Gap Seals 100/200 Series STC#SA2382NM

OF WING SKETCH C SIDE VIEW FLAP GAP SEAL AFT Cessna Flap Gap Seals 100/200 Series STC#SA2382NM Manual: CFGS Rev C Knots 2U, Ltd. 709 Airport Road Burlington, WI 53105 Ph: 262 763-5100 fax 262 763-5125 1.5 Attaching Gap Seals P/N C-IFS And C-OFS (Left Wing) Hold the seals in their proper location and drill two holes (#40 hole size) through the seal and attach brackets per figure 1 detail 2. Cleco the seals to the attach brackets as you go. With the seals temporarily attached to the brackets locate 7 or 8 points along the leading edge of the seal inboard seal, 4 along the leading edge of the outboard seal, and drill #40 holes through seal into trailing edge of wing skin per sketch B page 1. Look for areas in the seal that are not tight to the bottom of wing skin, more locations can be used if appropriate. Cleco seals as you go. Remove seals and enlarge the holes in the attach brackets and bottom of wing skin to a #12 holes size, de-burr holes and corrosion proof with Alodine or equivalent. Install P/N A6K-75 rivnuts in each location. Enlarge the holes in the seals to a #20 hole size and install seals using AN526C-632R8 screws and AN960C- 6L washers. Check to make sure air cannot get between the leading edge of the seal and the bottom wing skin. If areas are found that can allow air to get between the seal and the bottom wing skin the seal can be bent further upward or extra rivnuts and screws added to the leading edge. After gap seals are secured, apply 3M Tape P/N 8672 to the joint where the leading edge of the seal meets the bottom of the wing per 3M directions. The joint between the seal and the bottom of the wing must be completely sealsed to prevent airflow between the seal and wing. 1.6 Installing Seals On The Right Wing. Repeat Steps 1.1 thru 1.5 on right wing. 1.7 Paperwork Complete form 337, logbook entry, and weight & balance. Place copy of Supplemental Type Certificate and Maintenance manual with aircraft logs. Flap Seals with hardware ………… 3.15 lbs. Arm…………………………………... Per appropriate Cessna Service Manual 1.8 Parts List Part No. Qty. Description C-IFS 2 Inboard Flap Gap Seal C-OFS 2 Outboard Flap Gap Seal C-BRACK 8 Attach Bracket C-SHIM 8 Shim C-TAB 2 End Attach Tab CR3243-4-2 32 Roundhead Cherry-max Rivet CR3243-4-3 6 Roundhead Cherry-max Rivet AN526C-632R8 56 Stainless Steel # 6 Screw AN960C-6L 56 Stainless Steel # 6 Washer (Thin Profile) A6K-75 56 # 6 Keyed Rivnut 3M 8672 X 1” Wide 162” 3M Polyurethane Protective Tape Page –2- FIGURE #1 PAGE 3 FLAP INSTALLATION DETAIL #1 SIDE VIEW CESSNA 100/200 SERIES FLAP GAP SEAL INSTALLATION LEADING EDGE ATTACHMENT (4 LOCATIONS MIN) EXACT LOCATIONS MAY VARY DUE TO AIRFRAME VARIATIONS. o o o o o o CENTER LINE o o o o o o .50 .50 o o .50 TYP C-BRACK HOLE PATTERN DETAIL #2 INBOARD AND CENTER BRACKETS SPLICE BRACKETS DRAWING # CESSNA 100/200 SERIES CESSNA MODELS (EXCLUDES MODELS 150/152) 01/04/2000 NOT TO SCALE DRAWN BY: JMB C100/200FGS KNOTS 2U, LTD. 709 AIRPORT DRIVE, BURLINGTON, WI 53105 BRACKET #1 LOCATE AS FAR INBOARD AS POSSIBLE. INSTALL UNDER INSPECTION PANEL AND INBOARD FAIRING IF NECESSARY. BRACKET #2 BRACKET #3 (SPLICE) EXACT LOCATION DETERMINED BY LENGTH OF P/N C-IFS BRACKET #4 CENTER OUTBOARD P/N C-BRACK BETWEEN #3 SPLICE BRACKET AND END OF FLAP WELL SEAL IS TRIMMED TO FIT UNDER FAIRING AND NOTCHED AROUND SCREWS. REMOVE (2) RIVETS, INSTALL P/N C-TAB BETWEEN SKINS AND RE-RIVET. (SOME A/C USE SCREWS AT THIS LOCATION INSTEAD OF RIVETS) o o o o SHIM P/N C-SHIM MAY BE INSTALLED AT TOP OR BOTTOM TO MAKE P/N C-BRACK PARALLEL WITH BOTTOM OF WING CR3243-4-2 CHERRY MAX RIVET (4) PER BRACKET REQUIRED AN960C-6L AN526C-632R8 AFT P/N C-BRACK FLAP GAP SEAL CESSNA FLAP WELL A6K-75 REV # DATE EFFECT A 08/22/00 Replaced fiberlock nut with rivnuts. Added attachment to leading edge of flap seal. o 0 o o o o o o B 12-26-01 Moved location of inboard attach bracket APPLY 3M TAPE AT LEADING EDGE OF GAP SEAL C 04-18-14 Added 3M tape to leading edge of gap seal. Cessna Flap Gap Seals 100/200 Series STC#SA2382NM Manual: CFGS Rev C Knots 2U, Ltd. 709 Airport Road Burlington, WI 53105 Ph: 262 763-5100 fax 262 763-5125 This manual describes the installation of flap gap seals on Cessna 100 & 200 series aircraft. All aluminum parts are treated with a Zinc Chromate primer and ready to paint. To finish simply scuff the surface lightly, clean, and paint with desired color. The parts may be painted before or after installation. For optimum performance of this modification it is desirable to check the flap rigging per the appropriate Cessna Manual before the installation of the gap seals. Section 2.0 Installing Flap Gap Seal Kit on 206 Models. 2.1 Locating Outboard Flap Seal P/N C-206-LOF (Left Wing) Locate the outboard seal P/N C-206-LOF flush with the end of the flap well area, notch the flange on the trailing edge of the seal where it interferes with the flap track (see Sketch A). Make sure to radius all corners of notches to prevent cracking. On some models the flap access panels may need to be trimmed slightly at the bottom to prevent interference with the gap seals. On models with a screw at the bottom of the access panel, the bottom screw may be removed. 2.2 Locating Center Flap Seal P/N C-206-CFS (Left Wing) With the outboard flap seal P/N C-206-LOF properly located, mark a line on the bottom of the wing at the most inboard point of the seal. This line will represent the location for the outboard edge of the center seal P/N C-206-CFS. With the center seal P/N C-206-CFS properly located, notch the flange on the trailing edge of the seal where it interferes with the flap track (see Sketch A). Make sure to radius all corners of notches to prevent cracking. 2.3 Locating and Trimming Inboard Flap Seal P/N C-206-IFS. (Left Wing) With the center flap seal P/N C-206-CFS properly located, mark a line on the bottom of the wing at the most inboard point of the seal. This line will represent the location for the outboard edge of the center seal P/N C-206-IFS. Trim the Inboard flap gap seal P/N C-206-IFS to length, also trim the seal to match the contour of the fuselage for the particular aircraft. Per Figure 2 Page 6, place the inboard end of P/N C-206-IFS 1/16” from fuselage. Mark the location of the two screws holding the existing fairing around the wing to fuselage junction. Seal P/N C-206-IFS should be notched so it can be slid between fairings and around screws. Also notch the flange on the trailing edge of the seal where it interferes with the flap track (see Sketch A). Make sure to radius the corners of the notches to prevent cracking. 2.4 Locating and Riveting Attach Brackets P/N C-BRACK (Left Wing) (To aid in the placement of the attach brackets, 2 sided tape may be used to temporarily hold them in position.) Referring to Figure 2 Page 6, mark the attach bracket locations on wing. These marks represent the center of each bracket. The bracket locations shown are recommended locations, however they may be moved if interference is found with existing rivet heads, flap tracks, or inspection panels. If it is required to move attach brackets, confirm they are located no further than 24” from each other or the end of the flaps. Due to variations in airframes, shims P/N C-SHIM may be used to achieve correct angle along bottom of brackets (figure 2 detail 1). With all brackets temporarily held in place check for proper fit of gap seals. Drill #27 holes through brackets, flap well skin and shims if necessary. De-burr holes and corrosion proof with Alodine or equivalent. Rivet the brackets in place using (4) CR3243-4-2 rivets per bracket. Page –4- SKETCH-A NOTCHING DETAIL .125” Min. Radius Corners SEAL MUST FIT TIGHTLY AGAINST BOTTOM OF WING HERE END VIEW OF WING SKETCH B SIDE FLAP GAP AFT Cessna Flap Gap Seals 100/200 Series STC#SA2382NM Manual: CFGS Rev C Knots 2U, Ltd. 709 Airport Road Burlington, WI 53105 Ph: 262 763-5100 fax 262 763-5125 2.5 Attaching Gap Seals P/N C-206-IFS, C-206-CFS and C-206-LOF (Left Wing) Hold the seals in their proper location and drill two holes (#40 hole size) through the seal and attach brackets per figure 2 detail 2. Cleco the seals to the attach brackets as you go. With the seals temporarily attached to the brackets locate 5 or 6 points along the leading edge of each seal and drill #40 holes through seal into trailing edge of wing skin per sketch B page 4. Look for areas in the seal that are not tight to the bottom of wing skin, more locations can be used if appropriate. Cleco seals as you go. Remove seals and enlarge the holes in the attach brackets and bottom of wing skin to a #12 holes size, de-burr holes and corrosion proof with Alodine or equivalent. Install P/N A6K-75 rivnuts in each location. Enlarge the holes in the seals to a #20 hole size and attach the seals using AN526C-632R8 screws and AN960C-6L washers. Check to make sure air cannot get between the leading edge of the seal and the bottom wing skin. If areas are found that can allow air to get between the seal and the bottom wing skin the seal can be bent further upward or extra rivnuts and screws added to the leading edge. After gap seals are secured, apply 3M Tape P/N 8672 to the joint where the leading edge of the seal meets the bottom of the wing per 3M directions. The joint between the seal and the bottom of the wing must be completely sealsed to prevent airflow between the seal and wing. 2.6 Installing Seals On The Right Wing. Repeat Steps 2.1 thru 2.5 on right wing. 2.7 Paperwork Complete form 337, logbook entry, and weight & balance. Place copy of Supplemental Type Certificate and Maintenance manual with aircraft logs. Flap Seals with hardware ………… 3.95 lbs. Arm……………………………………Per appropriate Cessna Service Manual 2.8 Parts List Part No. Qty. Description C-206-IFS 2 Inboard Flap Gap Seal C-206-CFS 2 Outboard Flap Gap Seal C-206-LOF 1 Left Outboard Flap Gap Seal C-206-ROF 1 Right Outboard Flap Gap Seal C-BRACK 14 Attach Bracket C-SHIM 14 Shim CR3243-4-2 56 Roundhead Cherry-max Rivet AN526C-632R8 72 Stainless Steel # 6 Screw AN960C-6L 72 Stainless Steel # 6 Washer (Thin Profile) A6K-75 72 # 6 Keyed Rivnut 3M 8672 X 1” Wide 238” 3M Polyurethane Protective Tape Page –5- CESSNA 206 SERIES FLAP 'GAP SEAL INSTALLATION BRACKET#7 BRACKET#6 BRACKET#5 (SPLICE) EXACT LOCATION DETERMINED BY LENGTH OF PIN C-206-CFS LOCATE BRACKET AT MOST OlJTBOARO POINT CENTER BEoWEEN BRACKET # 5AND#7 APPROVED JAN 2 2 2002 MAr A-c.t. _,, "c..... HIG,4GO AIRCRAFT CtRTIFICATION OFFICE ri::�tTAAJ Rf:GION LEADING EDGE ATTACHMENT(4LOCATIONS MIN.) EXACT LOCATIONS MAY VARY DUE TOAIRFRAME VARIATIONS FIGURE #2 PAGE 6 •·· PIN C206-LOF ,..//.-· 7 BRACKET#4 CENTER BE1WEEN BRACKET # 3AND#5 LEADING EDGE ATTACHMENT(5LOCATIONS MIN.) EXACT LOCATIONS MAY VARY DUE TO AIRFRAME VARIATIONS LEADING EDGE ATTACHMENT(4 LOCATIONS MIN.) EXACT LOCATIONS MAY VARY DUE TOAIRFRAME VARIATIONS FLAP INSTALLATION DETAIL #1 SIDE VIEW I C-BRACK HOLE PATTERN DETAIL #2 CESSNA FLAP WELL� SHIM P/N C-SHIM MAY BE INSTALLED AT TOP OR BOTTOM OF C-BRACK AFT 0 /;<: � /fig\ CR3243-4-2 CHERRY MAX , , , �RIVET PIN C-BRACK ; l \ <E (4) PER BRACKET REQUIRED L...� �r- 75 ! ! \ FLAP GAP� t -+- ...;....«;-- AN960C-6L SEAL b ! !, <E-- AN526C-632RB , . INBOARD AND CENTER SPLICE BRACKETS BRACKETS .50 k....[J] .1 r: :::c :=:: :q:_! :i ....,._! 50 ' T'I? CENTER JLINE BRACKET#3 (SPLICE) EXACT LOCATION BRACKET#2 DETERMINED BY LENGTH CENTER BRACKET OF PIN C-206-IFS r BE1WEEN BRACKET #1 AND#3 ..... ...... BRACKET#! LOCATE AS FAR INBOARD AS POSSIBLE. INSTALL UNDER INSPECTION PANEL AND INBOARD FAIRING IF NECESSARY. SEAL IS TRIMMED TO FIT UNDER FAIRING AND NOTCHED AROUND SCREWS. REV# I DATE EFFECT KNOTS 2U, LTD.703 AIRPORT DRIVE. BURUNGTON. WI 53105 DRAWING# C-206FGS CESSNA 206 MODELS 12/26/01 NOT TO SCALE I DRAWN BY: JMB .:... _ . ....... - - ... .. . -- ~ I ------------i . ····- ___:_:=J;) ~j ~ Cessna Flap Gap Seals 100/200 Series STC#SA2382NM Manual: CFGS Rev C Knots 2U, Ltd. 709 Airport Road Burlington, WI 53105 Ph: 262 763-5100 fax 262 763-5125 Section 3.0 Installing Flap Gap Seal Kit on 207 Models. This Section Left Blank Intentionally. Page –7- Cessna Flap Gap Seals 100/200 Series STC#SA2382NM Manual: CFGS Rev C Knots 2U, Ltd. 709 Airport Road Burlington, WI 53105 Ph: 262 763-5100 fax 262 763-5125 Knots 2U, Ltd. 709 Airport Road Burlington, WI 53105 Phone: 262 763-5100 Fax: 262 763-5125 For the current copy of this manual please contact Knots 2U, Ltd. at 262 763-5100 or via email at technical@knots2u.com. The Airworthiness Limitations section is FAA approved and specifies maintenance required under Secs. 43.16 and 91.403 of the Federal Aviation Regulations unless an alternative program has been FAA approved. Section 4.0 Instructions for Continued Airworthiness. PART A. INSPECTION 1. Daily inspection at preflight to ensure there is no bent, cracked or broken seals and that all attachment hardware is tight. 2. Daily inspection at preflight to ensure that the polyurethane protective tape at the leading edge of the flap gap seals is in proper condition and is not coming loose or missing. 3. When aircraft has been stored outside during snow or freezing conditions, a careful inspection should be made of the areas between the seals and flaps for ice accumulations. If ice is found, which cannot be removed by careful brushing, the aircraft should be de-iced. 4. 100 hour inspections are suggested to check for any bent or cracked seals and that all attachment hardware is in good condition. PART B. CRACKING, DEFECTS, LOOSE RIVETS, LOOSE TAPE. 1. If cracks are found in a Gap Seal, stop drill the crack. If there is more than 1 crack in a gap seal, the seal must be replaced. 2. If polyurethane protective tape is found loose or missing from the leading edge of the gap seal it should be replaced. The product may be purchased from various aviation sources or from Knots 2U, Ltd. The tape is 3M part number 8672 and is 1” wide. 3. If there are excessive bends or kinks in the seal, and the airflow over the control surface is disturbed, the seal must be replaced. 4. If seal rivets become loose you may drill the rivets and replace with the next size rivet or replace the appropriate screws as required. 5. If a flap seal is replaced, the 3M tape must be replaced on that seal. Page –8-