KITFOX AIRCRAFT
KITFOX SUPER SPORT · Maintenance Manual
Overview
This document is a maintenance manual for the Kitfox Super Sport aircraft, specifically focusing on the horizontal tail assembly and installation. It provides detailed instructions for constructing and installing the horizontal stabilizer and elevator, as well as the trim control system.
- The horizontal tail is constructed using shaped wooden ribs bonded into a welded tube structure.
- Pitch trim is controlled by pivoting the horizontal stabilizer about its trailing edge.
- Installation involves precise reaming of various components to specific diameters.
- Ribs must be aligned for proper finish during the fabric covering process.
- Adhesive and flox mixtures are used for bonding ribs and stiffeners.
- Wood components should be varnished with epoxy varnish.
- Bearings must be pressed into hinge bushings during installation.
- Slider blocks are fabricated and installed for stabilizer attachment.
Document
Source
Originally published by kitfoxaircraft.com. Sprinkle hosts a reference copy with an added summary, specifications and searchable full text.
Document details
- Type ·
- Maintenance Manual
- Year ·
- 2023
- File size ·
- 752 KB
- Publisher ·
- kitfoxaircraft.com
- Language ·
- en
What is the KITFOX AIRCRAFT?
The KITFOX AIRCRAFT is a maintenance manual for the KITFOX SUPER SPORT, dated 2023.
Where does the KITFOX AIRCRAFT come from?
This copy of the KITFOX AIRCRAFT was originally published by kitfoxaircraft.com and is hosted on Sprinkle as a free, searchable reference copy.
What year was the KITFOX AIRCRAFT published?
The KITFOX AIRCRAFT — the KITFOX SUPER SPORT maintenance manual on file — is dated 2023.
Most owners only have the POH. Here's the essential set for the KITFOX SUPER SPORT.
- Pilot's Operating Handbook / AFM
- Checklist
- Maintenance Manual
- Parts Catalog (IPC)
- Systems & Wiring
- Service Bulletins on file
- Type Certificate (TCDS)
More KITFOX SUPER SPORTmanuals & documents
In this document
Introduction
This section introduces the construction of the horizontal stabilizer and elevator, detailing the materials and methods used.
Horizontal Tail Assembly
This section outlines the preparation and reaming processes required for the horizontal stabilizer and elevator components.
Horizontal Tail Installation
This section describes the steps for installing the horizontal tail onto the fuselage, including the attachment of braces and bearings.
Safety notes
- Ensure all reaming is performed to the specified diameters to avoid fit issues.
- Use caution when sanding bushings to prevent excessive material removal.
- Adhesive should be cleaned up to save weight and ensure a neat finish.
Full document text
1PAGE DATE REV. MODEL CHAPTER SS SECTION D 1/23 Kitfox Super Sport Kitfox Aircraft LLC ©2008 - 2023 EXAMPLE SUPER SPORT CHAPTER IV HORIZONTAL TAIL ASSEMBLY KITFOX AIRCRAFT PAGE DATE REV. MODEL CHAPTER SS SECTION2 D 1/23 Kitfox Aircraft LLC Kitfox Aircraft LLC ©2008 - 2023 EXAMPLE Contents Section A. Introduction ........................................................................................................................... 3 Section B. Horizontal Tail Assembly ...................................................................................................... 4 Section C. Horizontal Tail Installation .................................................................................................. 10 Section D. Trim Actuator Installation ................................................................................................... 16 Section E. Trim Control System ........................................................................................................... 22 3PAGE DATE REV. MODEL CHAPTER SS SECTION D 1/23 Kitfox Super Sport Kitfox Aircraft LLC ©2008 - 2023 EXAMPLE Section A. Introduction CHAPTER IV. HORIZONTAL TAIL ASSEMBLY Section A. Introduction In this chapter you will construct your horizontal stabilizer and elevator, and install them in the fuselage. The tail of the Kitfox is fully airfoiled by shaped wooden ribs that are bonded into the welded tube structure. Stiffeners are used on some of the ribs to increase their resistance to deflection. End caps are employed to give the surfaces a smoothly rounded and finished tip. Pitch trim is handled by pivoting the horizontal stabilizer about its trailing edge with a pilot controlled trim system. This provides the ability to trim the aircraft throughout its entire operating envelope. PAGE DATE REV. MODEL CHAPTER SS SECTION4 D 1/23 Kitfox Aircraft LLC Kitfox Aircraft LLC ©2008 - 2023 EXAMPLE Section B. Horizontal Tail Assembly Completion Date _______________ Section B. Horizontal Tail Assembly Prepare the horizontal stabilizer and elevator weldments by performing the following reams. For the difficult reams that are close to other weldments, you will find that using a vise grip or similar tool to turn the ream is the best technique. 1. Ream the tabs in the elevator control horn to .1875". 2. Ream all six pairs of elevator hinge tabs to .1875". 3. Ream the horizontal tail hinge bushings to .4375" at all seven locations. 4. Ream the horizontal tail brace bushings, both left and right, to .1875". The following reams are all performed on the fuselage. 5. Ream the horizontal tail rear pivot mount to .1875". 6. Ream the horizontal tail brace tabs to .1875". 7. Ream the trim actuator mounting tabs to .1875". 5PAGE DATE REV. MODEL CHAPTER SS SECTION D 1/23 Kitfox Super Sport Kitfox Aircraft LLC ©2008 - 2023 EXAMPLE Figure HTA-2 Horizontal Tail Weldment Preparation Section B. Horizontal Tail Assembly 2 4 .1875" (x 2) .1875" (x 12) 1 .1875" HORIZONTAL TAIL BRACE BUSHING ELEVATOR CONTROL HORN ELEVATOR HINGE TAB HORIZONTAL TAIL REAR PIVOT MOUNT 5 .1875" 3 .4375" (x 7) HORIZONTAL TAIL HINGE BUSHING LTR DESCRIPTION PART NO QTY A STABILIZER WELDMENT 51051.101 1 B ELEVATOR WELDMENT 51096.101 1 A B .1875" (x 2) 6 HORIZONTAL TAIL BRACE TABS .1875" (x 2) 7 TRIM ACTUATOR MOUNTING TABS PAGE DATE REV. MODEL CHAPTER SS SECTION6 D 1/23 Kitfox Aircraft LLC Kitfox Aircraft LLC ©2008 - 2023 EXAMPLE Section B. Horizontal Tail Assembly Completion Date _______________ NOTE During the installation of the airfoil ribs, keep in mind that the layout dimen- sions are +/- 1/8" tolerance. In particular, the P/N -308 ribs in the horizontal stabilizer can be moved outboard as required to position them against the metal ribs. This will require slight extra trimming of the ribs to make them fit. It is a good idea to align the elevator ribs with the stabilizer ribs. This will help to keep your finish tapes aligned when covering. 8. Trim the ribs for the elevator so that they fit in the locations shown. Ribs that fit over the welded structure are slit to allow the rib to be twisted over the tube, (see Detail "A". When the ribs fit properly, prep them for bonding by sanding the bonding areas with 220 grit sandpaper. Prep the tubes for bonding by cleaning the surfaces with solvent, followed by a scotch brite roughening, and a second solvent wipe. 9. When the ribs are properly fitted to their layout locations and prepped, bond the ribs in place with a adhesive/flox mixture. TIP: Use a touch of modelers glue and a quick dry accelerator to hold the ribs in place while bonding. 10. Cut rib stiffeners as needed for the ribs. Remember the stiffeners are only to keep the ribs from bowing and only need to be installed on ribs you feel need the support. Prep the stiffeners and ribs for bonding by sanding them with 220 grit sandpaper, and then bond the stiffeners to the ribs with a mixture of adhesive and flox. Clean up any adhesive that oozes out to save weight, and clamp the parts until the adhesive has cured. 11. On the aft ends of the center two metal ribs of the horizontal stabilizer you will find two holes approximately 9/16" in diameter. These holes allow for the proper reaming of the stabilizer hinge bushing, and for the removal and replacement of the stabilizer pivot bearing. Match drill the two -310 ribs installed adjacent to the metal ribs with a 1/2" drill and finish the holes with a round file. 12. All wood should be varnished with an Epoxy Varnish. Poly Fiber EV- 400 Epoxy Varnish and EV-410 Epoxy Varnish Catalist is recommended. 7PAGE DATE REV. MODEL CHAPTER SS SECTION D 1/23 Kitfox Super Sport Kitfox Aircraft LLC ©2008 - 2023 EXAMPLE Figure HTA-3 Stabilizer and Elevator Rib Installation Section B. Horizontal Tail Assembly 7-1/4" P PREP + FLOX 12-5/8" 18" 23-3/8" 29-1/8" 34-1/2" 40-5/8" 46-7/8" P PREP + FLOX 220 GRIT 8 220 GRIT Dimensional information for reference.
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After placement of stabilizer ribs, align elevator ribs to match. This allows for the finish tapes to match during the fabric covering process. A DETAIL "A" P PREP + FLOX J K L M N P Q R S B C D E F G H LTR DESCRIPTION PART NO QTY A RIB, ELEVATOR 11036.201 2 B RIB, ELEVATOR 11036.202 2 C RIB, ELEVATOR 11036.203 2 D RIB, ELEVATOR 11036.204 2 E RIB, ELEVATOR 11036.205 2 F RIB, ELEVATOR 11036.206 2 G RIB, ELEVATOR 11036.207 2 H RIB, ELEVATOR 11036.208 2 J RIB, HORZ STAB 11070.301 2 K RIB, HORZ STAB 11070.303 2 L RIB, HORZ STAB 11070.304 2 M RIB, HORZ STAB 11070.305 2 N RIB, HORZ STAB 11070.306 2 P RIB, HORZ STAB 11070.307 2 Q RIB, HORZ STAB 11070.308 2 R RIB, HORZ STAB 11070.309 2 S RIB, HORZ STAB 11070.310 2 T PLYWOOD, BIRCH 14016.000 * 9 "B" "A" 8 11 DETAIL "B" RIB STIFFENER STABILIZER RIB 10 P PREP + FLOX PLYWOOD STIFFENER T ALIGN THESE TWO RIBS WITH THE METAL RIBS, NOT PARALLEL TO THE OTHER RIBS (TYP) PAGE DATE REV. MODEL CHAPTER SS SECTION8 D 1/23 Kitfox Aircraft LLC Kitfox Aircraft LLC ©2008 - 2023 EXAMPLE Section B. Horizontal Tail Assembly 13. Cut and shape the foam blocks for the horizontal and elevator end caps to fit the tubing. Bond the pieces in and let the adhesive cure. Balsa wood blocks (not supplied) may be used in place of the foam. 14. Shape the end caps for a pleasing contour with the surrounding tail surfaces, using sandpaper and a file. When you are satisfied with the final shape of the end caps, coat the exposed surfaces of the foam or balsa with a thin layer of structural adhesive. Completion Date _______________ 9PAGE DATE REV. MODEL CHAPTER SS SECTION D 1/23 Kitfox Super Sport Kitfox Aircraft LLC ©2008 - 2023 EXAMPLE HORIZONTAL STABILIZER ASSEMBLY P/N 24018.000 FOAM BLOCK AS REQUIRED ELEVATOR ASSEMBLY PPREP 14 13 Figure HTA-5 Foam End Cap Installation Section B. Horizontal Tail Assembly PAGE DATE REV. MODEL CHAPTER SS SECTION10 D 1/23 Kitfox Aircraft LLC Kitfox Aircraft LLC ©2008 - 2023 EXAMPLE Section C. Horizontal Tail Installation Completion Date _______________ Section C. Horizontal Tail Installation 15. Press the bearings into the elevator hinge mounting bushings, six places. 16. Press the bearing into the aft center elevator hinge. 17. Attach the stabilizer to the fuselage using the hardware shown in detail “A”. NOTE The P/N 11500.000 bushing can vary in outside diameter by as much as .0025". If the bushing will not slide into the pressed bearing, sand down the outside of the bushing with 220 grit sandpaper initially; then finish the surface with 400 grit. Chucking the bushing into a drill motor or drill press can speed the process. 18. Attach the braces to the fuselage with the hardware shown in detail “B”. 19. Attach the left and right stabilizer braces to the stabilizer using the rod ends and hardware shown in detail “C”. Start by assembling the left hand brace and rod end onto the fuselage and horizontal tail first, and then adjust the length of the right side brace so that it slips into place without any bending of the horizontal tail. Refer to paragraph 26 of this section for the final rigging and adjustment of the horizontal tail. 20. Reserved. 11PAGE DATE REV. MODEL CHAPTER SS SECTION D 1/23 Kitfox Super Sport Kitfox Aircraft LLC ©2008 - 2023 EXAMPLE Figure HTA-6 Horizontal Tail Installation Section C. Horizontal Tail Installation HORIZONTAL STABILIZER BRACE LOWER MOUNTING TABS (x 6) ELEVATOR HINGE MOUNT LIQUID BEARING LOCK "C" LTR DESCRIPTION PART NO QTY A STRUT, HORZ STABILIZER 51041.101 2 A1 OPTIONAL STRMLINE STRUT 15160.000 2 B ROD END 93002.000 2 C BUSHING 11500.000 7 D BEARING 93021.000 7 E BOLT AN3-4A 91030.000 2 F BOLT AN3-13A 90030.000 1 G BOLT AN3-25A 91267.000 2 H NUT AN316-4 91055.000 2 J NUT AN365-1032 91069.000 5 K BUSHING, STANDOFF 11501.000 2 L WASHER AN960-10 91147.000 5 M WASHER AN970-3 91151.000 2 A B C D G L H J REAR STABILIZER PIVOT MOUNT (FUSELAGE) HORIZONTAL STABILIZER LIQUID BEARING LOCK STABILIZER SPAR STABILIZER BRACE DETAIL "C" UPPER BRACE ATTACH 19 DETAIL "A" REAR STABILIZER ATTACH 17 16 15 18 DETAIL "B" LOWER BRACE ATTACH E M K L J L J F D "A" B PAGE DATE REV. MODEL CHAPTER SS SECTION12 D 1/23 Kitfox Aircraft LLC Kitfox Aircraft LLC ©2008 - 2023 EXAMPLE Section C. Horizontal Tail Installation 21. Drill four #34 holes at the locations shown in the TOP FACE ONLY of the stabilizer slider block brackets, and deburr the holes. 22. Fabricate two slider blocks out of the material provided. 23. Position the slider blocks in the slider block brackets so that the distance between each bracket and the square vertical slider tube on the fuselage are equal. With the slider blocks snug against the fuselage tube, back drill though the holes in the brackets, through the blocks and the bottom flanges of the brackets. Cleco as you go to keep the blocks up against the tube. Remove the blocks and deburr the holes. 24. Assemble the slider blocks with the hardware shown. 25. Reserved.Completion Date _______________ 13PAGE DATE REV. MODEL CHAPTER SS SECTION D 1/23 Kitfox Super Sport Kitfox Aircraft LLC ©2008 - 2023 EXAMPLE FWD TOP 1/4" (7mm) 3/4" (19mm) 1/4" (7mm) SLIDER BLOCK BRACKETS #34 (x 4) 21 5/8" (16mm) 22 (x 4) (x 2) #34 (x 4) 23 HORIZONTAL TAIL SLIDER BLOCK BRACKETS LTR DESCRIPTION PART NO QTY A SLIDER BLOCK MATERIAL 14017.000 1 B SCREW, AN526-440R12 91270.000 4 C NUT, AN365-440 91159.000 4 D WASHER, AN960-4 91269.000 4 B A (x 4) (x 4) C D 24 Figure HTA-7 Slider Block Installation Section C. Horizontal Tail Installation PAGE DATE REV. MODEL CHAPTER SS SECTION14 D 1/23 Kitfox Aircraft LLC Kitfox Aircraft LLC ©2008 - 2023 EXAMPLE Section C. Horizontal Tail Installation Completion Date _______________ 26. The horizontal tail should be installed so that it is perpendicular with the vertical tail of the aircraft. To properly adjust the position of the horizontal tail, disconnect the rod end from the right side of the stabilizer trailing edge. Measure from the outboard tip of each side of the horizontal stabilizer to the uppermost tip of the vertical tail. Adjust the length of the left hand stabilizer brace so that the two distances to the tip of the vertical tail are equal. When the stabilizer is in its proper position, tighten the check nut on the left hand brace. Adjust the length of the right hand brace so that the rod end and its bolt slip into the bushing on the stabilizer without any force. Tighten the check nut on the right hand brace when finished. NOTE It may be helpful to secure the horizontal stabilizer to the fuselage while the stabilizer is being adjusted. This can be accomplished by placing a clamp on the square vertical slider tube on the fuselage to prevent the horizontal tail from sliding down. Position the clamp so that the stabi- lizer is parallel to fuselage tube running fore and aft above the stabilizer. 27. Install the elevator assembly on to the stabilizer with the hardware shown in detail “A”. NOTE The P/N 11500.000 bushing can vary in outside diameter by as much as .0025". If the bushing will not slide into the pressed bearing, sand down the outside of the bushing with 220 grit sandpaper initially; then finish the surface with 400 grit. Chucking the bushing into a drill motor or drill press can speed the process. 28.-29. Reserved. 15PAGE DATE REV. MODEL CHAPTER SS SECTION D 1/23 Kitfox Super Sport Kitfox Aircraft LLC ©2008 - 2023 EXAMPLE ELEVATOR LEADING EDGE TUBE STABILIZER TRAILING EDGE TUBE "A" DETAIL "A" ELEVATOR HINGE INSTALLATION 27 D LTR DESCRIPTION PART NO QTY A BUSHING 11500.000 6 B BOLT, AN3-12A 91041.000 6 C NUT, AN365-1032 91069.000 6 D WASHER, AN960-10 91147.000 6 B A C ELEVATOR ASSEMBLY FUSELAGE WELDMENT "X" "X" 26 Figure HTA-8 Horizontal Tail Rigging and Elevator Installation Section C. Horizontal Tail Installation