Tail Cone Reinforcement Kit: Installation Instructions for Cessna 180, Early 182, and 185 Aircraft

Baldwin City, KS 66006 www.mcfarlaneaviation.com sales@mcfarlaneaviation.com Tail Cone Reinforcement Splice Installation Instructions ST02171AK-A INSTALL, Rev D Page 7 2. Starting on the l e ft - h a n d side of the a i r c r a ft, drill out the far aft ( 4 ) AN426AD-4 ( s m a l l flush) r i v e t s of the ta i l cone reinforcement angle w i t h a #30 drill bit. Be c a r e f u l not to oblong the rivet h o l es . You may want to start out w i t h a smaller #40 d r i l l bit and then work your way up to a #30 d r i l l bit. The aircraft should now l o o k l i k e Figure 8. Figure 8: Aft four AN426AD-4 rivets drilled out McFarlane Aviation, LLC. 785-594-2741 696 E 1700 RD 785-594-3922 Fax Baldwin City, KS 66006 www.mcfarlaneaviation.com sales@mcfarlaneaviation.com Tail Cone Reinforcement Splice Installation Instructions ST02171AK-A INSTALL, Rev D Page 8 3. Drill out the far aft (2) AN470AD-4 (large universal head) rivets of the tail cone reinforcement angle with a #30 drill bit. Agai n, be careful not to oblong the rivet holes. You may want to start out with a smaller #40 drill bit and then work your way up to a #30 drill bit. See Figure 9. Figure 9: Drill out aft two AN470AD-4 rivets McFarlane Aviation, LLC. 785-594-2741 696 E 1700 RD 785-594-3922 Fax Baldwin City, KS 66006 www.mcfarlaneaviation.com sales@mcfarlaneaviation.com Tail Cone Reinforcement Splice Installation Instructions ST02171AK-A INSTALL, Rev D Page 9 4. Slip the supplied guard between the fuselage outer skin and the tail cone reinforcement angle as shown below so as to prevent cutting the outer fuselage skin. See Figure 10. Figure 10: Insert Guard between fuselage skin and reinforcement angle McFarlane Aviation, LLC. 785-594-2741 696 E 1700 RD 785-594-3922 Fax Baldwin City, KS 66006 www.mcfarlaneaviation.com sales@mcfarlaneaviation.com Tail Cone Reinforcement Splice Installation Instructions ST02171AK-A INSTALL, Rev D Page 10 5. Using the hacksaw blade that i s i n s e rt e d in to the hacksaw h a n d l e , cut the aft p o rt i o n of the t a i l cone reinforcement angle o ff . Make the cut flush w i t h the forward opening i n the top plate as shown in Figure 11. Figure 11: Cutting Reinforcement Angle McFarlane Aviation, LLC. 785-594-2741 696 E 1700 RD 785-594-3922 Fax Baldwin City, KS 66006 www.mcfarlaneaviation.com sales@mcfarlaneaviation.com Tail Cone Reinforcement Splice Installation Instructions ST02171AK-A INSTALL, Rev D Page 11 6. Remove the cut portion of the tail cone reinforcement angle as shown in Figure 12. Figure 12: Remove cut off portion of reinforcement angle McFarlane Aviation, LLC. 785-594-2741 696 E 1700 RD 785-594-3922 Fax Baldwin City, KS 66006 www.mcfarlaneaviation.com sales@mcfarlaneaviation.com Tail Cone Reinforcement Splice Installation Instructions ST02171AK-A INSTALL, Rev D Page 12 7. After you complete the cut, your aircraft should look like Figure 13. Figure 13: After removing reinforcement angle cutoff McFarlane Aviation, LLC. 785-594-2741 696 E 1700 RD 785-594-3922 Fax Baldwin City, KS 66006 www.mcfarlaneaviation.com sales@mcfarlaneaviation.com Tail Cone Reinforcement Splice Installation Instructions ST02171AK-A INSTALL, Rev D Page 13 3.4 Reinforcement Angle Splice Installation 1. Remove the guard and insert the LH tail cone reinforcement splice (P/N QMI-0712048- 7R). Figure 14: Reinforcement Splice Placement Diagram 2. Install drill guide assembly over the pivot hole and insert a drill bit or pin as shown in Figure 15 to mark the center of the hole. Check the mark to ensure the hole is centered over the flat section of the offset face of the splice. Slide the splice forward or aft as needed to ensure hole is center to the face. Figure 15: Drill Guide Assembly w/ Marking Pin McFarlane Aviation, LLC. 785-594-2741 696 E 1700 RD 785-594-3922 Fax Baldwin City, KS 66006 www.mcfarlaneaviation.com sales@mcfarlaneaviation.com Tail Cone Reinforcement Splice Installation Instructions ST02171AK-A INSTALL, Rev D Page 14 3. Clamp the bracket in locations shown in Figure 16 and mark all the hole locations. Figure 16: Hole Marking Diagram 4. Remove the clamps and bracket from the aircraft. Ensure the marks are clear and will give adequate edge distance for rivet installation. Reposition and repeat marking as necessary. 5. Clamp the reinforcement splice in its proper position and drill the rivet holes with a #40 (Ø0.098”) drill bit. Figure 17: Match Drill Diagram - #40 Bit McFarlane Aviation, LLC. 785-594-2741 696 E 1700 RD 785-594-3922 Fax Baldwin City, KS 66006 www.mcfarlaneaviation.com sales@mcfarlaneaviation.com Tail Cone Reinforcement Splice Installation Instructions ST02171AK-A INSTALL, Rev D Page 15 6. After drilling the holes, use clecos to secure the reinforcement splice part to the aircraft as shown in Figure 18. Figure 18: Cleco Reinforcement Angle Splice onto aircraft 7. Use two clamps to secure the aft portion of the ta i l cone reinforcement s p l i c e for match drilling. Figure 19: Clamp aft end of Splice to aircraft McFarlane Aviation, LLC. 785-594-2741 696 E 1700 RD 785-594-3922 Fax Baldwin City, KS 66006 www.mcfarlaneaviation.com sales@mcfarlaneaviation.com Tail Cone Reinforcement Splice Installation Instructions ST02171AK-A INSTALL, Rev D Page 16 8. Using a #30 drill bit , match drill the aft hole in the t ail cone reinforce ment spli ce. After match drilling wit h a #30 drill bit. Run the supplied #19 drill bit through the aft hole as shown in Figure 21. Figure 20: Match Drill Diagram – Most Aft Hole Figure 21: Drill aft tail cone reinforcement hole McFarlane Aviation, LLC. 785-594-2741 696 E 1700 RD 785-594-3922 Fax Baldwin City, KS 66006 www.mcfarlaneaviation.com sales@mcfarlaneaviation.com Tail Cone Reinforcement Splice Installation Instructions ST02171AK-A INSTALL, Rev D Page 17 9. Enlarge the second hole from the aft end from a #30 hole to a number # 2 1 hole using the supplied # 2 1 d r i l l bit and install cleco. Figure 22: Match Drill Diagram – Second Aft Hole 10. Enlarge the most aft counter sunk #40 hole in steps, first using the supplied #30 drill bit and then the supplied #19 bit. Install cleco to secure. Figure 23: Match Drill Diagram – Third Aft Hole 11. Drill countersunk rivet hole in reinforcer splice. One at a time, remove clecos from remaining forward three holes and drill with the #30 supplied drill bit. Replacing clecos as you go. Figure 24: Match Drill Diagram – Countersunk Rivet Holes McFarlane Aviation, LLC. 785-594-2741 696 E 1700 RD 785-594-3922 Fax Baldwin City, KS 66006 www.mcfarlaneaviation.com sales@mcfarlaneaviation.com Tail Cone Reinforcement Splice Installation Instructions ST02171AK-A INSTALL, Rev D Page 18 12. Remove the tail cone reinforcement angle splice and deburr all the holes as shown in Figure 25. Figure 25: Deburr Angle Splice Holes McFarlane Aviation, LLC. 785-594-2741 696 E 1700 RD 785-594-3922 Fax Baldwin City, KS 66006 www.mcfarlaneaviation.com sales@mcfarlaneaviation.com Tail Cone Reinforcement Splice Installation Instructions ST02171AK-A INSTALL, Rev D Page 19 13. Reinsert the tail cone reinforcement angle splice and temporally secure with clecos. Wet coat holes and fasteners with a corrosion preventative primer before installing fasteners. Insert an AN525-832R8 bolt (the shorter one) into the far aft tail cone reinforcement angle hole along with an AN960-8 washer and a MS21043-08 nut. Tighten the nut securely. Insert an MS20470AD5-7 rivet* into the second from the aft rivet hole and secure it with a pneumatic rivet gun and appropriate bucking bar as shown in Figure 26. *For 1961 C180/185 and later use an MS20470AD5-8 Figure 26: Rivet Reinforcement Angle Splice AN525-832R8 bolt AN470AD-5-7 rivet McFarlane Aviation, LLC. 785-594-2741 696 E 1700 RD 785-594-3922 Fax Baldwin City, KS 66006 www.mcfarlaneaviation.com sales@mcfarlaneaviation.com Tail Cone Reinforcement Splice Installation Instructions ST02171AK-A INSTALL, Rev D Page 20 14. Your aircraft should now look like Figure 27. Figure 27: View after AN525-832R8 bolt and MS20470AD5-7 rivet installed McFarlane Aviation, LLC. 785-594-2741 696 E 1700 RD 785-594-3922 Fax Baldwin City, KS 66006 www.mcfarlaneaviation.com sales@mcfarlaneaviation.com Tail Cone Reinforcement Splice Installation Instructions ST02171AK-A INSTALL, Rev D Page 21 15. Remove the cleco from the most aft countersunk hole, and insert an AN525-832R10 bolt (the long one) in the hole. This is the hole you just opened up with the #19 drill bit in step 10. Insert an AN960-8 washer and a MS21043-08 onto the back side of the bolt and tighten until secure. 16. For the last three rivet holes, proceeding one at a time, remove cleco, insert an appropriately sized MS20426AD4-6, -7, or -8 flush head rivet (all supplied in kit) into the rivet hole, and secure with a pneumatic rivet gun and appropriate bucking bar. Repeat for remaining two holes. Your aircraft should now look like the image in Figure 28. Figure 28: View after installing AN525-832R10 bolt and three MS20426AD4 flush head rivets McFarlane Aviation, LLC. 785-594-2741 696 E 1700 RD 785-594-3922 Fax Baldwin City, KS 66006 www.mcfarlaneaviation.com sales@mcfarlaneaviation.com Tail Cone Reinforcement Splice Installation Instructions ST02171AK-A INSTALL, Rev D Page 22 17. Now it is time to drill a pilot hole in the tail cone reinforcement angle splice for the horizontal stabilizer rear pivot with the supplied drill guide assembly. Insert the drill guide assembly as shown in Figure 29. Figure 29: Insert drill guide assembly McFarlane Aviation, LLC. 785-594-2741 696 E 1700 RD 785-594-3922 Fax Baldwin City, KS 66006 www.mcfarlaneaviation.com sales@mcfarlaneaviation.com Tail Cone Reinforcement Splice Installation Instructions ST02171AK-A INSTALL, Rev D Page 23 18. Using the supplied hex key and box wrench, insert the drill guide shoulder bolt into the drill guide assembly from inside the tail cone through the existing horizontal stabilizer pivot hole as shown in Figure 30. Figure 30: Insert drill guide shoulder bolt McFarlane Aviation, LLC. 785-594-2741 696 E 1700 RD 785-594-3922 Fax Baldwin City, KS 66006 www.mcfarlaneaviation.com sales@mcfarlaneaviation.com Tail Cone Reinforcement Splice Installation Instructions ST02171AK-A INSTALL, Rev D Page 24 19. Using a #40 drill bit, drill a pilot hole through the tail cone reinforcement angle splice using the installed drill guide fixture as shown in Figure 31. Figure 31: Drill pilot hole through reinforcement splice McFarlane Aviation, LLC. 785-594-2741 696 E 1700 RD 785-594-3922 Fax Baldwin City, KS 66006 www.mcfarlaneaviation.com sales@mcfarlaneaviation.com Tail Cone Reinforcement Splice Installation Instructions ST02171AK-A INSTALL, Rev D Page 25 20. Remove the drill guide fixture and open up the pilot hole with the supplied 15/64" diameter drill bit as shown in Figure 32. Align the drill bit to be perpendicular to the inner bracket. Figure 32: Open up pilot hole McFarlane Aviation, LLC. 785-594-2741 696 E 1700 RD 785-594-3922 Fax Baldwin City, KS 66006 www.mcfarlaneaviation.com sales@mcfarlaneaviation.com Tail Cone Reinforcement Splice Installation Instructions ST02171AK-A INSTALL, Rev D Page 26 21. Using the supplied ¼” diameter reamer, ream the 15/64” hole as shown in Figure 33. Figure 33: Ream Pivot Hole McFarlane Aviation, LLC. 785-594-2741 696 E 1700 RD 785-594-3922 Fax Baldwin City, KS 66006 www.mcfarlaneaviation.com sales@mcfarlaneaviation.com Tail Cone Reinforcement Splice Installation Instructions ST02171AK-A INSTALL, Rev D Page 27 22. Using the ¼” diameter reamer continue to ream through the inboard horizontal stabilizer pivot hole as shown in Figure 34. Figure 34: Ream inboard stabilizer pivot hole McFarlane Aviation, LLC. 785-594-2741 696 E 1700 RD 785-594-3922 Fax Baldwin City, KS 66006 www.mcfarlaneaviation.com sales@mcfarlaneaviation.com Tail Cone Reinforcement Splice Installation Instructions ST02171AK-A INSTALL, Rev D Page 28 23. Your aircraft should now look like Figure 35. Figure 35: View of finished Reinforcement Splice Installation 24. Repeat all the steps in sections 3.3 and 3.4 on the opposite RH side of the aircraft so that both sides have the t ai l cone reinforcement angle splice i n s t a ll e d . 25. Reinstall the h o r i z o n t a l stabilizer and elevator using ne w ha rdwa re as ne eded . 26. Reconnect the elevator bell crank tube to the elevator p y l o n . 27. R e in s t a l l the v e rt i c a l stabilizer and rudder using the same hardware used when i t was r e m o v ed . 28. Reconnect the rudder c o n t ro l cables to the rudder b e l l c ran k . 29. Reinstall all fin and h o r i z o n t a l stabilizer t a i l f a i r i n g as n e e d ed . 30. Reconnect e l e c t r i c a l power to the a i r c r a ft . McFarlane Aviation, LLC. 785-594-2741 696 E 1700 RD 785-594-3922 Fax Baldwin City, KS 66006 www.mcfarlaneaviation.com sales@mcfarlaneaviation.com Tail Cone Reinforcement Splice Installation Instructions ST02171AK-A INSTALL, Rev D Page 29 31. Fill out a 337 form for the aircraft log book documenting the installation of this STC. 32. All assembly, rigging, and testing for proper operation must be done in accordance with the appropriate Cessna Service Manual. 4 Weight and Balance The Tail Cone Reinforcement Angel Splice STC exchange weight is negligible therefore no changes to the aircraft Weight and Balance is required after installing this STC. 5 Trouble Shooting Section to be updated with common Problems and Corrections if necessary when and if arise when more kits are installed in the field.