Installation Instructions – Corrugated Control Skin

mark (see step 3) adheres to AC65-15A and/or AC43.13-1B for proper rivet spacing edge distance requirements. a. Verify all holes on both sides of spar b. If spacing is NOT acceptable i. Make slight adjustments to skin leading edge location to increase edge to hole distance ii. Remark positioning line, as required 9. Using the lines marked in step 3, align the top McFarlane skin longitudinally and laterally to the control surface spar. Clamp skin to structure when aligned. 10. Inspect skin placement; verify that no rivet head will contact any part of any of the corrugations. a. If spacing is NOT acceptable i. Make slight lateral adjustments to skin position to increase edge to hole distances and re-clamp. ii. Repair or replace control surface spar if adjustments are greater than .13 inches 11. Match drill all mounting holes in the leading edge of McFarlane skin. a. Refer to AC65-15A and/or AC43.13-1B for proper match drilling procedures b. Match drill all appropriate rivet holes with an appropriate diameter drill bit c. Attach properly sized cleco into newly drilled rivet hole before proceeding to match drilling of a successive rivet hole; leave clecos installed. Note: Continuously check for control surface flatness and proper lofting of the trailing edge of the aileron. 12. Mate and Install sub structure ribs to McFarlane skin a. Square the sub structure ribs to the control spar and the McFarlane skin b. Clamp skin and rib together and match drill. c. After each hole is drilled, attach cleco and leave installed Installation Instructions – Corrugated Control Skin Drawing: 6755 McFarlane Aviation, Inc. 07-JAN-2014 3 13. Flip control structure over, and align trailing edge of lower skin to upper skin. a. While keeping trailing edges aligned, align the corrugations of the lower skin to the upper skin. b. Clamp both skins together; Take care not to damage or buckle skins when clamping. c. If installing skin with cutout for tab, verify alignment of cutouts. 14. Drill skin trailing edges between corrugations a. Drill three rivet holes between each parallel corrugation i. Refer to AC65-15A and/or AC43.13-1B for proper rivet spacing edge distance requirements ii. No holes will be drilled into any corrugation iii. #40 drill bit diameter will be the MINIMUM acceptable diameter of rivet hole along the trailing edge b. Attach properly sized cleco into newly drilled rivet hole before proceeding to next successive rivet hole; leave clecos installed 15. Drill spar mounting holes in the leading edge of lower skin a. Match drill all appropriate rivet holes with an appropriate diameter drill bit i. Refer to AC65-15A and/or AC43.13-1B for proper match drilling procedures b. Attach properly sized cleco into newly drilled rivet hole before proceeding to match drilling of a successive rivet hole; leave clecos installed 16. For rudder assembly only, drill for rudder tab installation a. Place appropriate rudder tab in correct orientation and location along the trailing edge b. Clamp in position; Take care not to damage, or buckle, skins when clamping. c. Drill appropriate holes with a #40 drill bit diameter i. Refer to AC65-15A and/or AC43.13-1B for proper hole drilling d. Attach properly sized cleco into newly drilled rivet hole before proceeding to match drilling of a successive rivet hole; leave clecos installed 17. For Elevator with trim tab only, drill for elevator tab installation a. Place appropriate elevator tab in correct orientation and location along the trailing edge b. Clamp in position; Take care not to damage, or buckle, skins when clamping. c. Drill appropriate holes with to a #40 drill bit diameter i. Refer to AC65-15A and/or AC43.13-1B for proper hole drilling d. Attach properly sized cleco into newly drilled rivet hole before proceeding to match drilling of a successive rivet hole; leave clecos installed 18. Disassemble the control assembly a. Remove all clecos b. Remove McFarlane skins and deburr all holes created, per procedures stated in AC65-15A for proper drilled hole procedures 19. Reassemble the control assembly a. Place McFarlane skins back in the appropriate location and orientation on the sub structure b. Reattach all appropriate clecos 20. Rivet Control assembly together a. Use appropriate sized MS20470AD rivets i. Refer to AC65-15A and/or AC43.13-1B for proper rivet shank length requirements b. Refer to AC65-15A and/or AC43.13-1B for proper riveting procedures 21. Finish control surface as required to match aircraft a. Follow finish instructions provided by aircraft manufacturer in the appropriate maintenance manual b. Refer to the Refer to AC65-15A and/or AC43.13-1B for additional information on proper aircraft painting and finishing procedures 22. Balance control surface, as required, by the Cessna published instructions a. Refer to Cessna Service Newsletter SNL 86-44 and/or applicable maintenance manual for proper control surface balancing data and procedures TROUBLE SHOOTING Refer to the applicable Cessna 100 Series 1962 and Prior Model Service Manual for general guidance only troubleshooting instructions and the applicable Cessna Illustrated Parts Catalog for component part numbers. PLACARDS None applicable Installation Instructions – Corrugated Control Skin Drawing: 6755 McFarlane Aviation, Inc. 07-JAN-2014 4 DATA All information to support the continued airworthiness of this replacement part is as defined herein and contained in: • Relevant Cessna Model Illustrated Parts Catalog • Relevant AC65-15A Airframe and Powerplant Mechanics Airframe Handbook • Relevant AC43.13-1B Acceptable Methods, Techniques, and Practices-Aircraft Inspection and Repair • Relevant FAA Regulations • Relevant Cessna 100 Series 1962 and Prior Model Service Manual (general guidance only) INSPECTION Installation of McFarlane skins does not alter the existing inspection requirements or intervals, as stated by current FAA regulations. RECOMMENDED OVERHAUL PERIODS No additional overhaul time limitations exist with the use of these parts. AIRWORTHINESS LIMITATIONS The Airworthiness Limitations section is FAA approved and specifies maintenance required under Sec. 43.16 and 91.403 of the Federal Aviation Regulations unless an alternative program has been FAA approved. No additional airworthiness limitations exist. ASSISTANCE AND REVISIONS Revisions to these instructions shall be made available on the McFarlane website, www.mcfarlaneaviation.com/Reference. For questions or assistance regarding these instructions, contact McFarlane Aviation, Inc via email or phone. Email: engineering@mcfarlaneaviation.com Phone: 1-800-544-8594 (within the US) or 1-785-594-2741.