Kitfox Super Sport Wing Assembly Manual

FIBERGLASS WING TANK REAR MAIN SPAR (6061-T6 ALUMINUM TUBE) ALUMINUM DRAG/ANTI-DRAG TUBES WELDED 4130 STEEL LIFT STRUT WELDED 4130 STEEL JURY STRUT LOWER LIFT STRUT ATTACH POINT FRONT WING ATTACH FITTINGS REAR WING ATTACH FITTINGS LEADING EDGE EXTRUSION FRONT MAIN SPAR (6061-T6 ALUMINUM TUBE) UPPER FALSE RIBS AND STRINGER (LOWER FALSE RIBS REMOVED FOR CLARITY) OPTIONAL LOWER FALSE RIBS AND STRINGER (UPPER FALSE RIBS REMOVED FOR CLARITY) FWD 6061-T6 ALUMINUM SPAR INSERT (SPAR REMOVED FOR CLARITY) PRE-ASSEMBLED BIRCH PLYWOOD WING RIBS END RIB FABRIC BRACING END RIB FABRIC BRACING OPTIONAL LOWER FALSE RIBS AND STRINGER #2 #3 #4 #5 #6 #7 #8 #9 #10 #1 OPTIONAL WINGTIPS OPTIONAL STROBE SYSTEM PAGE DATE REV. MODEL CHAPTER SS SECTION 6 D 10/17 Kitfox Aircraft LLC Kitfox Aircraft LLC ©2008 - 2018 Section B. Wing Parts Inspection Section B. Wing Parts Inspection 1. Carefully inspect the spar tubes to ensure that they have not been scraped, gouged, or dented during shipping. Check the two wing root, or #1, ribs (P/N: 27001.000) for capstrip-to-web squareness. Sight down the rib from the tail end and visually inspect the ribs. The rib capstrips should be perpendicular (90°) to the rib web (See Figure B-1). The rib capstrips must be square for the proper align- ment of the flaperon brackets and hinges. Inspect the rib capstrips to make sure that they have been properly bonded to the rib web. Do this by carefully rocking the capstrip back and forth on the rib web. If the capstrip feels as though it may be loose, apply a small fillet of structural adhesive between the rib capstrip and web to strengthen the joint. 2. Sand the wing root ribs and false ribs with 220-grit sandpaper. Smooth all the sharp edges, including the routed, inner edges and remove any splinters or burrs. Remove, or carefully tap in, any staples in the rib capstrips that protrude above the capstrip surfaces. (The staples are used by the factory to temporarily hold the capstrips on the ribs while the adhesive cures.) Completion Date _______________ 7 PAGE DATE REV. MODEL CHAPTER SS SECTION D 10/17 Kitfox Super Sport Kitfox Aircraft LLC ©2008 - 2018 BOTTOM CAPSTRIP 90° TOP CAPSTRIP GOOD RIB BAD RIB ± 1/32" (1 mm) RIB CAPSTRIP LOWER STRINGER NOTCH (OPTIONAL BOTTOM FALSE RIB INSTALLATION) DRAG TUBE SLOT UPPER STRINGER NOTCH FWD ROOT (#1) RIB Figure B-1 Capstrip Inspection Figure B-2 Wing Rib Detail Section B. Wing Parts Inspection PAGE DATE REV. MODEL CHAPTER SS SECTION 8 D 10/17 Kitfox Aircraft LLC Kitfox Aircraft LLC ©2008 - 2018 Section C. Wing Installation Preparation CAUTION The center holes in each bracket are factory tooling holes. DO NOT drill through the center holes in the REAR brackets. The center holes in the FRONT brackets only will be used for installing rivets. 4. The lift brackets are pre-drilled. Ream the lift strut mounting holes in the ears of the brackets to .2500". Ream the holes in the lock back tabs of the rear brackets to .1875". See Figure D-8 for drilling instructions. Completion Date _______________ 9 PAGE DATE REV. MODEL CHAPTER SS SECTION D 10/17 Kitfox Super Sport Kitfox Aircraft LLC ©2008 - 2018 FRONT LIFT STRUT BRACKET #30 (x 44) .2500" REAR LIFT STRUT BRACKET (RT SHOWN, LT OPPOSITE) .2500" 1 DRILL LATER THIS HOLE IS DRILLED AT THE FACTORY (DO NOT USE) #30 (x 42) .1875 WING LOCK-BACK BRACE TAB FACES TO REAR OF AIRCRAFT LTR DESCRIPTION PART NO QTY A FRONT LIFT STRUT BRACKET 23005.000 2 B REAR LIFT STRUT BRACKET, RT 23006.000 1 C REAR LIFT STRUT BRACKET, LT 23007.000 1 A C B (LEFT) (RIGHT) OR Figure C-1 Lift Strut Bracket Rivet Pattern PAGE DATE REV. MODEL CHAPTER SS SECTION 10 D 10/17 Kitfox Aircraft LLC Kitfox Aircraft LLC ©2008 - 2018 NOTE If you purchased the optional Pre-Fab Kit (P/N: 64829.000), you will receive the parts instead of the raw stock. Skip step 5. NOTE The spar reinforcement fittings will be bonded and riveted to the spars in Section D. If the fittings are not powder coated, the mating surface of the fittings can be masked-off when applying epoxy primer so that the adhesive will bond directly to the metal, thereby creating a stronger installation. 5. Fabricate the spar reinforcement fittings as shown in Figure C-2. Deburr the holes, clean with alcohol, and apply epoxy primer. Completion Date _______________ Section C. Wing Installation Preparation 11 PAGE DATE REV. MODEL CHAPTER SS SECTION D 10/17 Kitfox Super Sport Kitfox Aircraft LLC ©2008 - 2018 R 1/4 TYP 3-7/8" 3-1/8" 7/8" R 1/4" TYP DRILL 19/64" REAM TO .3115 ø 3/32" (x 7) 5 3-7/8" 2-5/8" 1-7/8" 1-1/16" 1/4" 1/4" 1/4" 7/8" 11/16" 1-7/16" 2-1/4" 3-1/8" FABRICATE FROM P/N: 22002.000 8 REQUIRED INNER OUTER FABRICATE FROM P/N: 22002.000 8 REQUIRED DRILL 19/64" REAM TO .3115 RAW STOCK PRE-FAB DESCRIPTION PART NO PART NO QTY SPAR REINFORCMENT FITTING, INNER 22002.000 12044.102 8 SPAR REINFORCMENT FITTING, OUTER 22002.000 12044.104 8 AFT OUTBOARD FRONT SPAR VERTICAL C OF SPAR LINE MADE BY DRAGGING STRAIGHT EDGE ACROSS SPARS 9/16" PARALLEL LINE DRAWN 26° AFT OF CENTERLINE 7 6 Figure C-2 Spar Reinforcement Fittings Figure C-3 Front Spar Lift Strut Attach Bracket Alignment Section C. Wing Installation Preparation PAGE DATE REV. MODEL CHAPTER SS SECTION 12 D 10/17 Kitfox Aircraft LLC Kitfox Aircraft LLC ©2008 - 2018 NOTE If you ordered your wing with the factory pre-rigging option, you may skip steps 6 and 7. Carefully place the appropriate lift strut brackets onto the spars at the locations marked on the spars. Clamp the brackets to the spars with a pair of hose clamps, using small strips of rubber or cardboard under the hose clamp bands where they contact the spars to protect the spars from damage. 6. Set each wing upside down on sawhorses. Place a long, smooth straight edge across the front and rear spars in between ribs #6 and #7 and gently drag it back and forth to create a faint wear mark on the spars. This mark represents the vertical centerline of the spars. Carefully slip the appropriate lift strut bracket over the rear spars (the wing lock-back brace tab on the brackets must be oriented toward the trailing edge). Position the rear brackets so that the center tooling hole in each bracket lines up with the wear line on the rear spar. Adjust the brackets along the spars until the center of the lift strut mounting holes is 94-1/2 " outboard from the root end. Clamp the brackets to the spars with a pair of hose clamps, using small strips of rubber or cardboard under the hose clamp bands where they contact the spars to protect the spars from damage. 7. On each of the front spars, measure back 9 /16" from the vertical cen- terline and draw a parallel line, as shown in Figure C-3. Slip the front lift strut brackets onto the front spars with the center of the lift strut mounting holes 95" outboard from the root end. Rotate the brackets until the new line just drawn is centered in the tooling hole. Clamp the brackets to the spars in the same manner as the rear brackets. Completion Date _______________ Section C. Wing Installation Preparation 13 PAGE DATE REV. MODEL CHAPTER SS SECTION D 10/17 Kitfox Super Sport Kitfox Aircraft LLC ©2008 - 2018 FRONT SPAR P/N 23005.000 FRONT LIFT STRUT ATTACH BRACKET 95.0" 94-1/2" ROOT END REAR SPAR P/N 23006.000 (RIGHT) P/N 23007.000 (LEFT) REAR LIFT STRUT ATTACH BRACKET 7 6 Reference Reference Figure C-4 Lift Strut Bracket Placement Section C. Wing Installation Preparation PAGE DATE REV. MODEL CHAPTER SS SECTION 14 D 10/17 Kitfox Aircraft LLC Kitfox Aircraft LLC ©2008 - 2018 CAUTION Do not let the lift struts swing up or down while they are bolted to the lift strut brackets in the following step. The rod ends or lift struts could be damaged by excessive movement of the lift strut. 8. Fabricate a temporary lift strut brace which is approximately 36-1 /2" long from a 2x4 board or similar material. Thread two check nuts and rod ends on each lift strut. Adjust each rod end so that 1 /4 " of thread appears outboard of the check nut, as shown in Figure C-5. Connect the lift struts to the wings with bolts, washers, and nuts. Install the temporary lift strut brace between the lift strut and wing with clamps or tape to hold the lift strut in place while you install the wing on the fuselage. NOTE Use an thin washer on one or both sides of the lift strut rod end bearings to take up any slack between the lift strut and the rod end (See Figure C-5). Completion Date _______________ Section C. Wing Installation Preparation 15 PAGE DATE REV. MODEL CHAPTER SS SECTION D 10/17 Kitfox Super Sport Kitfox Aircraft LLC ©2008 - 2018 REAR SPAR TUBE (P/N 21007.000) REAR LIFT STRUT BRACKET (P/N: 23006.000 OR 23007.000) (x 2) FWD LTR DESCRIPTION PART NO QTY A LIFT STRUT, LT 52004.201 1 B LIFT STRUT, RT 52004.202 1 C ROD END, 1/4" x 3/8" 90072.000 4 D BOLT, NAS6204-16 90147.000 4 E NUT AN316-6 90071.000 4 F NUT MS21042-4 90046.000 4 G WASHER AN960-416 91137.000 4 H WASHER AN960-416L 91138.000 8 D B A (LEFT) (RIGHT) OR C E F G H Figure C-5 Lift Strut/Bracket Installation Section C. Wing Installation Preparation PAGE DATE REV. MODEL CHAPTER SS SECTION 16 D 10/17 Kitfox Aircraft LLC Kitfox Aircraft LLC ©2008 - 2018 Section D. Wing Installation 1. At this point in the wing assembly process you need to decide what particular engine you are going to install. The weight of the engine installation may require you to sweep your wings forward in order to obtain an acceptable center-of-gravity range. You must, therefore, select the engine before you can proceed with the wing installation procedures outlined below. Aircraft using the Rotax 912, 912S, or 914 engines WILL NOT require a wing sweep. Aircraft using the Continental O-200 or IO-240 or the Lycoming O-235 engines WILL require a 1° forward wing sweep. NOTE If you ordered your wing with the factory pre-rigging option, you may skip steps 2 and 3. 2. Set the fuselage on a low sawhorse or on jack stands placed under the lift strut attach fittings on the fuselage and under the tail (weight will need to be added to the tail to prevent the fuselage from tipping forward). Using the underside of the fuselage as a datum, level the fuselage front to back. Tape two equally-sized shims onto the ends of a 48" level (to clear the stands under the fuselage). Hold one end up against the lift strut carry-through tube and the other end up against the bottom tube of the front bulkhead. Also level the fuselage side to side. When you have the fuselage level in both directions, weight it down with sandbags or other heavy items so it will not tip over when you install one wing. 3. The following measurements are critical for the proper installation and rigging of the wings, so be as accurate as possible. Mark the top center of the forward fuselage carry-through tube. Measure the dis- tance from this mark to the center of each of the forward spar attach lugs (approximately 18-1/2", as shown in Figure D-1). Measure the distance from the center of the lugs in the rear fuselage carry-through attach lugs to the center of the forward spar attach lugs (approximately 27- 1 /2 "). Record these measurements for later reference below. Right Measurements: ________ / ________ Left Measurements: ________ / _________ Section D. Wing Installation Completion Date _______________ 17 PAGE DATE REV. MODEL CHAPTER SS SECTION D 10/17 Kitfox Super Sport Kitfox Aircraft LLC ©2008 - 2018 FORWARD FUSELAGE CARRY-THROUGH TUBE RIB #1 ROOT RIB (REFERENCE ONLY) » 18-1/2" » 18-1/2" » 27-1/2" FORWARD SPAR ATTACH LUG REAR SPAR ATTACH LUG REAR FUSELAGE CARRY-THROUGH TUBE FigureD-1 Fuselage Reference Dimensions Section D. Wing Installation PAGE DATE REV. MODEL CHAPTER SS SECTION 18 D 10/17 Kitfox Aircraft LLC Kitfox Aircraft LLC ©2008 - 2018 4. Ream the powdercoating out of all four spar attach lugs on the fuse- lage. Using a file, contour the top and bottom of each lug to match the inside radius of the wing spars. One way of doing this is to make a 2-3 /8 " hole in a piece of scrap wood or metal and use it as a contour template. 5. Ream the holes in the "fish mouth" on the lower end of the lift struts and the hole in the lift strut attach fittings on the lower end of the fuselage to .3750". 6. For wings being installed with a forward sweep, you will need to trim a portion of the root end of the front spars to allow the wings to sweep forward. Measure 37- 1 /4" from the center of rib #3 inboard. Make a mark at this location around the entire circumference of the front spar. Remove the spar material inboard of this mark. Refer to Figure D-2. NOTE You will need two people to safely perform this next step. 7. Temporarily secure rib #1 into position on the spars with strapping tape or bungee cords. Have someone hold up the tip end of the wing while you position the root end of the rear spar over the rear spar attach lug (use of an adjustable stand, if available, will help with this procedure). Drop an AN5-31 bolt though the spar and into the attach lug to secure the rear spar to the wing. Position the front spar over the forward spar attach lug. Attach the lower lift strut fitting to the fuselage with an AN6-12 bolt. Avoid any wing movement while the wing is being held on the fuselage without the bolts. Tape or clamp the front spar to the fuselage to prevent the wing from swinging backwards. Install the opposite wing in the same manner. NOTE If you ordered your wing with the factory pre-rigging option, you may skip ahead to step 12. Completion Date _______________ Section D. Wing Installation 19 PAGE DATE REV. MODEL CHAPTER SS SECTION D 10/17 Kitfox Super Sport Kitfox Aircraft LLC ©2008 - 2018 FORWARD FUSELAGE CARRY-THROUGH TUBE RIB #1 ROOT RIB (TEMPORARY) FORWARD SPAR ATTACH LUG REAR SPAR ATTACH LUG REAR FUSELAGE CARRY-THROUGH TUBE RIB #3 REAM .3125 (x 4) CENTER OF #3 RIB CUT THIS PIECE OFF ONLY FOR FORWARD SWEPT WING INSTALLATIONS 6 4 35 1/2" LTR DESCRIPTION PART NO QTY A LIFT STRUT, LEFT 52004.201 1 B LIFT STRUT, RIGHT 52004.202 1 C BOLT, AN5-31 90081.000 2 D BOLT, AN6-12 94173.000 2 E CLEVIS PIN, AN395-89 98027.000 2 F NUT, SHEAR,AN320-5 90047.000 2 G NUT, CASTLE, AN310-6 91052.000 2 H WASHER, AN960-516 91141.000 2 J WASHER, AN960-616 91144.000 2 K COTTER PIN, AN380-2-3 91073.000 2 L COTTER PIN, AN380-3-3 91074.000 2 M SAFETY PIN, AN416-1 91098.000 2 7 J G D A B OR 7 C 37-1/4" (946mm) (THIS PROCEDURE IS ONLY FOR FORWARD-SWEPT INSTALLATIONS) L 7 E H F K M� Figure D-2 Initial Wing Installation Section D. Wing Installation PAGE DATE REV. MODEL CHAPTER SS SECTION 20 D 10/17 Kitfox Aircraft LLC Kitfox Aircraft LLC ©2008 - 2018 CAUTION There are two positions that you can set your wing - no sweep and 1° forward sweep. Refer to Step 1 to determine the correct wing sweep for your aircraft. The following steps explain the procedures for installing the wings with or without wing sweep. Refer to Step 8 for aircraft with no wing sweep and Step 9 for aircraft with for- ward-swept wings. 8. NO WING SWEEP With the aircraft still leveled, tape a 1" block at the tip of each wing on the leading edge. Make a mark 120" out from the rear spar attach lug on the rear spar of each wing. A. Run a length of fishing line from the right leading edge block to the left leading edge block. Put a small weight on the line, centered in the middle. This should allow the center of the line to be level with the forward fuselage carry-through tube. B. Measure the distance from the leading edge of each wing spar root to the line. This measurement should be 1" for the proper wing position. Loosen the clamped (or taped) front spars and adjust the wings fore and aft as required to obtain this distance. Secure the front spars again. C. Measure from the end of the middle rod end bushing (center rudder attachment point) on the vertical stabilizer tailpost to the mark on the right and left rear spars. Loosen the clamped (or taped) front spars and adjust the position of the wings as required until these two distances are within 1/4 " of being equal. NOTE Repeat steps B and C until the proper measurements are achieved. Completion Date _______________ Section D. Wing Installation 21 PAGE DATE REV. MODEL CHAPTER SS SECTION D 10/17 Kitfox Super Sport Kitfox Aircraft LLC ©2008 - 2018 CENTER OF MIDDLE ROD END BUSHING DISTANCE BETWEEN STRING AND FRONT END OF SPAR SHOULD BE 1" ON EACH WING 1" BLOCK TAPED TO LEADING EDGE OF BOTH WINGS STRING ADD WEIGHT ON STRING TO BRING IT EVEN WITH MIDDLE OF CARRY-THROUGH TUBE 120" DISTANCE MEASURED FROM OUTBOARD EDGE OF ATTACH LUG ALONG CENTERLINE OF SPAR DIAGONAL MEASUREMENTS MUST BE WITHIN 1/4" OF EACH OTHER 8 Figure D-3 Wing Installation - No Wing Sweep (0°) Section D. Wing Installation PAGE DATE REV. MODEL CHAPTER SS SECTION 22 D 10/17 Kitfox Aircraft LLC Kitfox Aircraft LLC ©2008 - 2018 9. 1° FORWARD WING SWEEP While the aircraft is still leveled, measure outboard 120" from the outer edge of the front spar attach lug out to the front spar leading edge on each wing. Tape a 1" block in place at each of these locations. Make a similar mark 120" out from the rear spar attach lugs on the rear spars (no block is required for the rear spars). A. Run a length of fishing line from the right leading edge block to the left leading edge block. Place a small weight on the line, centered in the middle. This should allow the center of the line to be level with the forward fuselage carry-through tube. B. Measure the distance from the leading edge of each wing spar root to the line. This measurement should be 3-3 /16" for the proper wing position. Loosen the clamped (or taped) front spars and adjust the wings fore and aft as required to obtain this distance. Secure the front spars again. C. Measure from the end of the middle rod end bushing (center rudder attachment point) on the vertical stabilizer tailpost to the mark on the right and left rear spars. Loosen the clamped (or taped) front spars and adjust the position of the wings as required until these two distances are within 1 /4" of being equal. NOTE Repeat steps B and C until the proper measurements are achieved. Completion Date _______________ Section D. Wing Installation 23 PAGE DATE REV. MODEL CHAPTER SS SECTION D 10/17 Kitfox Super Sport Kitfox Aircraft LLC ©2008 - 2018 1" BLOCK TAPED TO LEADING EDGE OF BOTH WINGS DISTANCE BETWEEN STRING AND FRONT END OF SPAR SHOULD BE 3-3/16" ON EACH WING FOR PROPER SWEEP STRING 120" ADD WEIGHT ON STRING TO BRING IT EVEN WITH MIDDLE OF CARRY-THROUGH TUBE 120" DISTANCE MEASURED FROM OUTBOARD EDGE OF ATTACH LUG ALONG CENTERLINE OF SPAR DIAGONAL MEASUREMENTS MUST BE WITHIN 1/4" OF EACH OTHER CENTER OF MIDDLE ROD END BUSHING 9 Figure D-4 Wing Installation- 1° Forward Wing Sweep Section D. Wing Installation PAGE DATE REV. MODEL CHAPTER SS SECTION 24 D 10/17 Kitfox Aircraft LLC Kitfox Aircraft LLC ©2008 - 2018 10. Make certain the aircraft is still leveled both longitudinally and later- ally. Place a 48" level along the front spar near the wing root. Pivot the level on its inboard end until the bubble is centered. Measure the distance between the top of the outboard end of the level and the bottom of the front spar (Refer to Figure D-5). The correct dihedral of 1° is equal to 13/16" (± 1/16") at the outboard end of the 48" level. Loosen the clamps on the lift strut brackets and move the brackets inboard (increasing the dihedral) or outboard (decreasing the dihedral) until the correct measurements are achieved. Make sure to move the front and rear lift strut brackets equal amounts. Tighten the clamps on the lift strut brackets to secure them once again. 11. Next, the twist, or "washout", of each wing must be adjusted. Make a mark on the bottom of each rear spar at 3" and 159" from the root end. Place a level across the bottom of the spars just outboard of the root rib. Clamp a straight edge or steel ruler perpendicular to the lev- el so it will contact the rear spar at its center (see Figure D-6). With the level resting against the bottom of the front spar, adjust the ruler until the bubble indicates level and clamp the ruler in place. Move the level to the 159" mark and, with the level resting against the rear spar, insert a 1/2"-thick block between the rear spar and the ruler. The bubble again should indicate level. If it does not, adjust the rear lift strut attach bracket position by loosening the clamps and moving it until the bubble indicates level. 12. In Step 3 you recorded the measurements from the center of the forward fuselage carry-through tube to the center of the forward spar attach lugs and from the center of the rear attach lug to the front. Using these dimensions, mark the location of the center of the forward spar attach lugs on to the top of the front spars. These locations are already marked with a pilot hole if you ordered factory pre-rigged wings; the inboard hole is for wings with no sweep and the outboard hole is for 1° forward sweep. Drill through the upper surface of the front spars with a 3 /16 " drill. If the holes appear to be centered over the lugs, drill them out to 1/4". Next, use a small “rattail” file to take the hole out to just under 5 /16". Finally, ream the holes to match the lug hole. Insert an AN395-89 clevis pin into the spar. WARNING Check the positions of the lift strut brackets relative to their original outline on the spars. If they have moved inboard or outboard, check to make sure that they are not positioned over any spar insert rivets. If their clocking has changed, verify that you will maintain 1/4" from the center of the lift strut bracket rivet hole and the edge of the spar insert. Completion Date _______________ Section D. Wing Installation 25 PAGE DATE REV. MODEL CHAPTER SS SECTION D 10/17 Kitfox Super Sport Kitfox Aircraft LLC ©2008 - 2018 Section D. Wing Installation PAGE DATE REV. MODEL CHAPTER SS SECTION 26 D 10/17 Kitfox Aircraft LLC Kitfox Aircraft LLC ©2008 - 2018 CAUTION Use a 5 /16 " drill bit with 2-1 /4" flutes or less. Drilling with flutes any longer than this could result in the top attach holes of the spars being oversized. 13. Remove the AN5-30 bolts from the rear spars. Using the spar attach lugs as a drill guide, drill down through the hole in the top of the rear spars and through the bottom of the spars. Replace the bolts. Drill the bottom holes in the front spars in the same manner. Secure the check nuts on the lift strut rod ends and remove the wings from the fuselage. NOTE Use a sharp drill bit to prevent elongation of the holes in the spar rein- forcement fittings and spars in the following steps. CAUTION Mark, tape, number, or safety wire the pairs of spar reinforcement fittings together as you remove them from the spars. DO NOT mis- match the fittings. 14. Place a pair of spar reinforcement fittings (inner and outer) on the upper surface of each of the spars. The outer fittings already have the 3 /32 " holes drilled in them. Line the fittings up with the attach holes already drilled into the spars and insert the appropriate hardware (clevis pin or bolt) through the holes. Clamp the fittings to the spars and match-drill through the outboard holes in the fittings with a 3 /32 " drill, clecoing the inside fittings, spar, and outside fittings together as you proceed. Once the holes are drilled, enlarge each of the holes with a #30 drill, again clecoing the parts together as you proceed. Repeat this procedure for the reinforcement fittings on the bottom of each of the spars. Mark the outline of the fittings on the spars with a fine point marking pen. Remove the fittings from the spars, making sure to keep the pairs together. Deburr all the rivet holes in the fittings and spars. 15. Prepare the mating surfaces of the fittings and spars with Scotch-Brite and clean with denatured alcohol. Install one pair of fittings at a time. Apply structural adhesive mixed with microballoons to the fittings and spar and cleco the fittings in place. Place the appropriate bolt or clevis pin into the mounting holes to make sure the holes are aligned. Install the spar attach fittings with the rivets shown in Figure D-7. Remove the bolt or pin and clecos and clean them with denatured alcohol. Remove any excess adhesive that has squeezed out from under the fittings with denatured alcohol. Repeat this procedure for the remaining pairs of fittings. Completion Date _______________ Section D. Wing Installation 27 PAGE DATE REV. MODEL CHAPTER SS SECTION D 10/17 Kitfox Super Sport Kitfox Aircraft LLC ©2008 - 2018 SPAR TUBE DRILL OUTBOARD HOLE FIRST ROOT END DRILL OUTBOARD HOLE FIRST SPAR REINFORCEMENT FITTINGS (TWO OUTER AND TWO INNER PER SPAR) SPAR TUBE SPAR ATTACH LUG CENTERLINE (x 7) A LTR DESCRIPTION PART NO QTY A RIVET, 1/8" x 1/4" SS 95004.000 56 Figure D-7 Front Spar Attach Reinforcement Fittings Installation Section D. Wing Installation PAGE DATE REV. MODEL CHAPTER SS SECTION 28 D 10/17 Kitfox Aircraft LLC Kitfox Aircraft LLC ©2008 - 2018 16. Make sure the lift strut attach brackets are securely attached to the spars with hose clamps. Match-drill through the brackets into the spars with a #30 drill. Start at the center of each bracket, installing a cleco in each new hole as you work toward the ends. Remove the clamps so you can drill all the rivet holes in the bracket. Drill the four rivet holes on the rear lift strut attach brackets (refer to Flag 1 "Drill Later" shown in Figure C-1). These holes should line up with the spar insert rivet pattern. Locate the four flagged holes so they do not interfere with the welds on the bracket. Be careful not to drill into the web of the spar insert (refer to Figure D-8). Remove the brackets and deburr the holes in the spar. 17. Bond prep the mating surfaces of the lift strut attach brackets and the spars with Scotch-Brite and clean with denatured alcohol. Mix enough structural adhesive to coat the inner surface of one lift strut attach bracket. Coat the inner surface of the bracket with adhesive and cleco it in place on the spar. Use 1/8 " x 1 /8 " SS rivets to attach the bracket to the spar, and 1/8" x 3/8 " SS rivets to attach the bracket to the spar and spar insert. Refer to Figure D-8 for the required rivet locations. For hard to reach rivets, fabricate a spacer (or several small flat washers) that can fit over the shaft of the rivet and provide some space between the rivet and the rivet gun tip. Clean the clecos with denatured alcohol before the adhesive cures. Remove any excess adhesive that has squeezed out from under the bracket with denatured alcohol. Repeat this procedure for the remaining brackets. 18. Install rib #1 on each wing. Notch the ribs so they will slip over the spar attach fittings. Bond prep the spars where the ribs will be installed with Scotch-Brite and clean with denatured alcohol. Slide the ribs onto the wing spars and reattach the wing to the fuselage. Apply a small amount of structural adhesive to the spars where the ribs will attach and slide the ribs into place. Adjust the ribs until they are in the proper position (see Figure D-2) and apply a fillet of structural adhesive thickened with cotton flox. Hold the rib securely to the front spar and let the adhesive set up overnight before continuing. 19. After the adhesive has cured, recheck the wing sweep, dihedral and twist. Make any minor adjustments by turning the lift strut rod ends in or out as required and secure the check nuts. After the wing has been checked for proper rigging, proceed to Section E while the wings are still attached to the fuselage. Completion Date _______________ Section D. Wing Installation 29 PAGE DATE REV. MODEL CHAPTER SS SECTION D 10/17 Kitfox Super Sport Kitfox Aircraft LLC ©2008 - 2018 26° TYPICAL LTR DESCRIPTION PART NO QTY A RIVET, 1/8" x 1/8" SS 95002.000 74 B RIVET, 1/8" x 3/8" SS 95005.000 14 B B A A A A 12 RIVET ROW 8 RIVET ROW A 8 RIVET ROW A 12 RIVET ROW 1 OR 2 RIVET ROW THIS ROW MUST BE IN LINE WITH THE SPAR INSERT RIVET ROW 1 OR 2 RIVET ROW THIS ROW MUST BE IN LINE WITH THE SPAR INSERT RIVET ROW 1 RIVET 1 RIVET REAR LIFT STRUT BRACKET LEFT OR RIGHT A 12 RIVET ROW A 8 RIVET ROW FRONT LIFT STRUT BRACKET B 2 RIVET ROW THIS ROW MUST BE IN LINE WITH THE SPAR INSERT RIVET ROW A 12 RIVET ROW B 8 RIVET ROW THIS ROW MUST BE IN LINE WITH THE SPAR INSERT RIVET ROW DO NOT DRILL ! FRONT SPAR REAR SPAR Figure D-8 Lift Strut Attach Bracket Installation Section D. Wing Installation PAGE DATE REV. MODEL CHAPTER SS SECTION 30 D 10/17 Kitfox Aircraft LLC Kitfox Aircraft LLC ©2008 - 2018 Section E. Butt Rib Installation NOTE The wings must be mounted on the fuselage in order to install the butt ribs. 1. Drill two #30 holes in each butt rib bracket approximately 1" apart, on opposite sides of the tube, and in-line with the tabs. Drill one #30 hole in each bracket tab, centered so the hole clears the weld. Slide the brackets into place on the tubes welded to the fuselage headrack. You may have to ream the butt rib brackets so they fit over the tubes on the headrack. See Figure E-1. 2. Position the P/N: 27003.000 (left) and P/N: 27004.000 (right) butt ribs next to the #1 ribs on the wings. The flanges on the butt ribs should be oriented outboard toward the #1 ribs. Install temporary 1/16 " shims between the butt ribs and the #1 ribs. These will compensate for the thickness of the fabric on the ribs. The butt ribs should line up with the root ribs fore and aft. 3. Slide the brackets out against the butt ribs and match-drill through the bracket tabs into the ribs with a #30 drill and cleco. Match-drill with a #30 drill at both tube holes on each bracket and cleco. Label each bracket so they can be correctly relocated later. Remove the brackets and deburr all holes. 4. Trim the P/N: 22908.000 aluminum backing strips to fit on the un- derside of each upper butt rib capstrip. Position the backing strip as close to the butt rib web as possible. This aluminum strip will provide reinforcement for the windshield installation. Bond prep the strips and clean with denatured alcohol. Bond the strips to the underside of the upper butt rib capstrips. Use small spring clamps to hold the strips in position. Remove any excess adhesive with denatured alcohol. NOTE Apply two or three coats of epoxy varnish to the butt ribs before they are attached to the fuselage. 5. With the butt rib clecoed in place on the fuselage, mark and trim off any excess fuselage butt rib mounting tab material that protrudes outboard of the butt ribs. Bend the fuselage tabs upward or down- ward so they fit evenly against the bottom face of the lower butt rib capstrip. Layout two evenly spaced rivet holes in each fuselage tab. Drill through the tab and the butt rib capstrip with a #30 drill and cleco. Rivet the butt rib brackets to the headrack tubes with 1/8" x 1/8" SS pop rivets, the butt rib brackets to the butt ribs with 1 /8" x 3 /8" SS pop rivets, and the butt ribs to the fuselage tabs with 1/8" x 1 /4 " SS pop rivets and backup washers. Completion Date _______________ Section E. Butt Rib Installation 31 PAGE DATE REV. MODEL CHAPTER SS SECTION D 10/17 Kitfox Super Sport Kitfox Aircraft LLC ©2008 - 2018 (TYPICAL 4 PLACES) BUTT RIB TAB (TRIM FLUSH WITH OUTBOARD EDGE OF BUTT RIB) (TYPICAL 8 PLACES) (TYPICAL 4 PLACES) FORWARD FUSELAGE CARRY-THROUGH TUBE (x 8) DRILL #30 (4 PLACES PER BRACKET) #30 (TYPICAL 4 PLACES) 1 5 LTR DESCRIPTION PART NO QTY A BUTT RIB, LEFT 27003.000 1 B BUTT RIB, RIGHT 27004.000 1 C BUTT RIB BRACKET 51036.705 8 D WASHER, ALUMINUM 90039.000 8 E RIVET, 1/8" x 1/8" SS 95002.000 16 F RIVET, 1/8" x 1/4" SS 95004.000 8 G RIVET, 1/8" x 3/8" SS 95005.000 16 H AL BACKING STRIP 22908.000 2 B D RIGHT SIDE SHOWN LEFT SIDE OPPOSITE G (TYPICAL 4 PLACES) C F E 5 H UNDER CAP STRIP 4 Figure E-1 Butt Rib Installation Section E. Butt Rib Installation PAGE DATE REV. MODEL CHAPTER SS SECTION 32 D 10/17 Kitfox Aircraft LLC Kitfox Aircraft LLC ©2008 - 2018 Section F. Jury Strut Installation NOTE If you purchased the optional Pre-Fab Kit (P/N: 64829.000), skip step 1. Otherwise, manufacture the brackets and skip step 2. NOTE The jury strut brackets will be bonded and riveted to the spars in the next installation sequence. The mating surface of the brackets can be masked off when applying epoxy primer so that the adhesive will bond directly to the metal, thereby creating a stronger installation. 1. Make eight jury strut attach brackets from the P/N: 23011.000 bracket material (see Figure F-1). The 90° bends can be made in a vise using a piece of aluminum or a light sheet metal doubler to provide a greater radius in the bend. Drill and deburr the holes in the brackets. File and sand smooth any rough edges, clean with denatured alcohol, and apply epoxy primer to the brackets before installation. 2. Modify the four pre-fab brackets as shown in Figure-F-1. 3. Ream the bolt holes in the brackets to .1875". Section F. Jury Strut Installation Completion Date _______________ 33 PAGE DATE REV. MODEL CHAPTER SS SECTION D 10/17 Kitfox Super Sport Kitfox Aircraft LLC ©2008 - 2018 1/4" 1/4" 1/2" 1/2" 1/4" #30 (x 2) 1/8" 1/8" 1/8" 1/4" .1875" 1/2" 1" FABRICATE EIGHT JURY STRUT BRACKETS FROM P/N: 23011.000 MATERIAL #30 (x 2) 3/16" 3/16" .1875" PRE-FAB JURY STRUT BRACKET P/N: 52012.301 3 3 FULL RADIUS FULL RADIUS 1 2 Figure F-1 Jury Strut Bracket Fabrication Section F. Jury Strut Installation PAGE DATE REV. MODEL CHAPTER SS SECTION 34 D 10/17 Kitfox Aircraft LLC Kitfox Aircraft LLC ©2008 - 2018 NOTE The wings must be installed on the fuselage in order to properly position and install the jury struts. 3. Match-drill the flanges of each P/N: 22911.000 clamp with a #13 drill and ream to .1875". Bolt the jury strut brackets onto the upper end of each jury strut. The pre-fab brackets are positioned on the outboard side of the jury strut. (see Figure F-2, Detail "A"). Position the jury struts approximately 53" outboard from the root end of the rear spar and perpendicular to the front spars (as viewed from the front of the aircraft). Use large hose clamps to hold the jury strut brackets to the spars. Wrap pieces of masking tape around the lift struts to prevent the clamps from scratching the powder coating when fitting the jury struts. Slip a jury strut clamp onto each lift strut and bolt the lower ends of the jury struts to the clamps (see Figure F-2, Detail "B"). CAUTION The jury struts must position the lift strut tubes so they are absolutely straight. Hold a length of string along the lift strut tubes to verify that the jury struts do not cause them to bow up or down, fore or aft. The aft, vertical tube of the jury struts must be aligned with the center of the rear spar tube and the center of the aft lift strut tube. The forward tube in the jury struts must be aligned with the center of the front spar tube and the center of the front lift strut tube. 4. Adjust the jury struts until they are perpendicular with the floor of the fuselage. One method of aligning them is to level the fuselage longitudinally and laterally, hang a plumb bob from the spar in front of the jury struts, and visually align the jury struts with the string. It may be necessary to move the upper and lower ends of the jury struts inboard or outboard to properly position them. When you are satisfied with their position, drill through the jury strut brackets into the spars, installing clecos as you proceed. Remove the jury strut brackets and deburr all the holes. Bond prep the brackets and the wing spars using Scotch-Brite and clean with denatured alcohol. Bond the jury strut brackets in place with a structural adhesive/microballoons mixture and rivet as shown in Figure F-2, Detail "A". 5. Carefully measure and record the positions of the jury strut clamps on the lift struts for reassembly later. Completion Date _______________ Section F. Jury Strut Installation 35 PAGE DATE REV. MODEL CHAPTER SS SECTION D 10/17 Kitfox Super Sport Kitfox Aircraft LLC ©2008 - 2018 FWD A B DETAIL "B" LOWER JURY STRUT ATTACH REAR SPAR FRONT SPAR JURY STRUT FORWARD LIFT STRUT TUBE REAR LIFT STRUT TUBE JURY STRUT LTR DESCRIPTION PART NO QTY A CLAMP 22911.000 4 B BOLT, AN3-4A 91030.000 8 C NUT, AN364-1032 91064.000 8 D WASHER, AN960-10 91147.000 8 E RIVET 1/8" x 1/8" SS 95002.000 16 D A B C (x 4) (x 2) DETAIL "A" UPPER JURY STRUT ATTACH BUILDER MADE BRACKETS JURY STRUT B D C E JURY STRUT PRE-FAB BRACKETS B E C D Figure F-2 Jury Strut Installation Section F. Jury Strut Installation PAGE DATE REV. MODEL CHAPTER SS SECTION 36 D 10/17 Kitfox Aircraft LLC Kitfox Aircraft LLC ©2008 - 2018 Section G. False Rib Installation As part of the standard quick-build wing that is included in your wing kit, the top false ribs are installed at the factory, with the exception of those between ribs #6 and #7. Those false ribs were not installed to facilitate the installation of the lift strut attach brackets. Once the lift strut attach brackets are installed, then those top false ribs can be installed. CAUTION Do not use pencil lead to mark the false rib locations on the wing spars. The graphite in the pencil lead can promote corrosion. 1. Use a fine point marking pen to make three marks on the stringers and front spars, equally spaced between the wing ribs. 2. Prep the front spar at each false rib location with Scotch-Brite and clean the spars with denatured alcohol. Finish sand the false ribs with 220-grit sandpaper. 3. Position the false ribs on the spar and stringer, making sure that the tops of the false ribs are even with the upper contour of the wing rib capstrips (you can tem- porarily secure the false ribs in place on the stringer with a small amount of super glue). When all the false ribs are in position, bond them to the spars and stringers with a fillet of structural adhesive/flox mixture. If you are installing the optional bottom false ribs, install only two false ribs between ribs #6 and #7, spaced evenly, adjacent to the lift strut bracket. NOTE If installing the optional bottom false ribs, install the bottom stringer per the instruc- tions in Step 4, then repeat Steps 1 through 3 to install the bottom false ribs. 4. Slide the stringer through the slot in the wing rib webs leaving 6" inboard of the #3 rib and extend it 1 /4"- 3 /8" past the #10 rib web. Lightly clamp or tape the stringer against the bottom capstrip. Apply a small amount of structural adhesive in the rib web slots where it will mate with the stringer, then unclamp the stringer and push it into the round portion of the slots (towards the top capstrip). Use masking tape to hold the stringer in position. Apply a small fillet of adhesive around the stringers where they intersect the ribs and let the adhesive cure. NOTE A very shallow notch filed on the false rib at the stringer allows a slight vertical ad- justment of the false ribs to match the contour of the wing ribs, if necessary. 5. Lightly sand all the wood parts to prepare them for varnish, along with smoothing any sharp edges on the capstrips and false ribs where they will touch the fabric covering. Apply two or three coats of epoxy varnish to all the wood parts on the wings. Section G. False Rib Installation Completion Date _______________ 37 PAGE DATE REV. MODEL CHAPTER SS SECTION D 10/17 Kitfox Super Sport Kitfox Aircraft LLC ©2008 - 2018 TOP STRINGER FWD NOTCH FALSE RIBS AT THE STRINGER (IF REQUIRED) 4 3 + FLOX + FLOX 3 P PREP + FLOX LTR DESCRIPTION PART NO QTY A ALUMINUM, 3/8 X .035 WALL 21902.000 B TOP FALSE RIBS 24006.000 C BOTTOM FALSE RIBS 24022.000 C A B Figure G-1 Stringer and False Rib Installation Section G. False Rib Installation PAGE DATE REV. MODEL CHAPTER SS SECTION 38 D 10/17 Kitfox Aircraft LLC Kitfox Aircraft LLC ©2008 - 2018 Section H. Fuel Tank Installation This section of the wing manual describes the assembly and installation of the 13-gallon wing tanks. Note that the main difference between the left and right tank installations is that the right wing tank has an additional fitting for the header tank vent line. CAUTION The wing tanks should not be installed until the wings have been rigged for sweep, dihedral, washout, and the #1 ribs are installed. 1. Visually inspect the wing tanks for any damage. Gently press on the flanged areas and check for any cracks or delaminations in the fiberglass. Temporarily install the vent line fitting and a length of Tygon tubing onto the tank, and use packaging tape to seal all of the remaining holes (including the filler neck). Using LUNG POWER ONLY, blow into the Tygon tubing until the tape sealing the filler neck becomes crowned. Pinch off the Tygon tubing by folding it in half and clamping it together with a spring clamp (see Figure H-1). Spray all of the tank surfaces and seams with soapy water and visually inspect the tank for leaks. Gently press on the flanges again and look for any bubbles in the soap which might indicate a leak. If any leaks are detected in the tank, call Kitfox’s Customer Service Department. CAUTION Tapping the tapered NPT fitting holes in the wing tanks too deeply can result in a hole that is oversized, which will not allow the fittings to seal properly. 2. Use a 1/8" NPT tap to carefully clean the vent, drain, and sight gauge holes. Use a 3/8 " NPT tap to clean the fuel line fitting hole in the wing tank. Tape over all openings in the tank except the fuel filler open- ing with strapping tape. Fill the tank with a minimum one-quart of clean acetone and slosh it around inside the tank. Drain the acetone out through a paint filter and inspect the filter for any contaminants. Repeat the procedure with clean acetone until no contaminants are present and the acetone drains clear. Remove the tape and allow the tank to dry thoroughly. Tape over the openings in the tank until the it is ready to be installed. Cut a small slit in the filler cap tape to allow the pressure to vent. Section H. Fuel Tank Installation Completion Date _______________ 39 PAGE DATE REV. MODEL CHAPTER SS SECTION D 10/17 Kitfox Super Sport Kitfox Aircraft LLC ©2008 - 2018 BLOW INTO VENT TUBE UNTIL TAPE SEALING FILLER NECK CROWNS PRESSURIZE FUEL TANK (LUNG POWER ONLY) SEAL FUEL FITTING HOLES WITH STRAPPING TAPE TYGON TUBING SOAPY WATER MIXTURE OVER ALL SURFACES 1 Figure H-1 Fuel Tank Pressure Test Section H. Fuel Tank Installation PAGE DATE REV. MODEL CHAPTER SS SECTION 40 D 10/17 Kitfox Aircraft LLC Kitfox Aircraft LLC ©2008 - 2018 CAUTION Use a quality thread sealant that is impervious to gasoline on all fittings being threaded into the fiberglass wing tanks. 3. Thread the sight gauge fittings and the vent line fitting (right tank only) into the wing tank. The vent line fitting is installed in the forward-most hole in the right wing tank (see Figure H-2). Thread the finger strainer fitting into the 3 /8 " hole in the tank and install the fuel line fitting into the finger strainer. Make sure to use thread sealant on all of the fittings. Only tighten the fittings until they are snug- overtightening can damage the threads in the tank! NOTE The quick-drain fitting will be installed in the bottom of the wing tanks AFTER the wings have been covered with fabric and painted. 4. Notch rib #1 to allow adequate clearance for the 5/16" fuel lines and clamps near the rear spar. (The butt rib may also need to be notched for the fuel lines.) A 3 /8 " sanding drum on a Dremel tool will work well for this step. NOTE Varnish the inboard side of the #3 rib and the outboard side of the #1 rib proir to installing the fuel tank CAUTION Use only the alcohol-based silicone adhesive provided with the kit to install the wing tanks. Ammonia-based silicone adhesives can promote corrosion on the aluminum spars. 6. Bond prep the spars and wing tanks at their mating surfaces using Scotch-Brite on the spars and 220-grit sandpaper on the tanks and clean with denatured alcohol. Run a bead (approximately 3 /8 " diameter) of the silicone adhesive on the wing tank where the tank mates with the front and rear spars. Use a wavy, or zigzag, bead pattern. DO NOT run the beads spanwise along the tank -the wavy silicon bead allows air to flow into the cavity and cure the silicon. Slide the tank onto the front spar first, then rotate the tank down onto the rear spar. Lightly clamp the tank to the spars and allow the adhesive to cure overnight. 7. Apply structural adhesive between the top cap strip and wing tank edge for the #1 and #3 rib. Completion Date _______________ Section H. Fuel Tank Installation