Chapter 3: Wing Systems

E. Main Gear Doors ........................................................................................................ 3-7 Fitting the Gear Doors ........................................................................................................ 3-8 Gear Doors - Release Tape (Optional) ............................................................................... 3-9 Gear Doors - Outboard Hardware Mounting ....................................................................3-11 Gear Doors - Installing the Outboard Attachment Receptacles ........................................3-11 Installing the Inboard Gear Door ...................................................................................... 3-12 F. Main Gear Installation ................................................................................................ 3-15 G. Main Gear Wheels and Tires ...................................................................................... 3-21 H. Center Wing Section Hydraulics ................................................................................. 3-24 I. Aft Spar Transition Holes ........................................................................................... 3-31 J. Landing and Taxi Lights (Optional) ............................................................................. 3-32 K. Speed Brakes (Optional) ........................................................................................... 3-35 L. Fuel and Hydraulic Lines Schematics .......................................................................... 3-36 3-1 3/12-15-04 Chapter 3 REV. 0/02-15-02 WING SYSTEMS Lancair International Inc., Represented by Neico Aviation Inc., Copyright © 2000 , Redmond, OR 97756 # PART NO. (P/N) QTY DESCRIPTION OPTIONAL ITEM (not included with kit) MAIN GEAR DOORS Inboard Gear Doors (for both sides) 1) 4264-01 1 Inbd Gear Door, Left 2) 4264-02 1 Inbd Gear Door, Right 3) 4755 1 Assembly for Inboard Main Gear Door Hydraulic (Optional) 4714-01 1 Bracket, Inboard Gear Door, Left 4714-02 1 Bracket, Inboard Gear Door, Right 4726-01B 1 Bracket, Outboard Gear Door, Left 4726-02B 1 Bracket, Outboard Gear Door, Right 4787 2 Hydraulic Cylinder Actuator 13373 2 Hydraulic Cylinder Spring 4766 2 Hydraulic Cylinder Rod 4732 2 Bracket, Doubler Inboard Gear 4767 2 Spacer 4768 2 Spacer F34-14 2 Bearing Rod End, Female F34-15 2 Bearing Rod End, Female 4769 2 Spring Retainer AN316-4 2 Check nut AN3-20 2 Bolt AN3-22 2 Bolt MS24665-132 4 Cotter Pin AN310-3 4 Nut, Castle MS24694-S54 8 Screw, Machine AN3-5A 2 Bolt AN3-7A 2 Bolt AN3-10A 2 Bolt AN365-1032A 12 Nut, Nylock AN960-10 22 Washer, Flat 4) 4728 2 Hinge, Piano (Inboard Gear Door) 10” 5) AN3-5A 14 Bolt, Undrilled 6) MS24694-S5 26 Machine Screws (Structural) 7) AN365-832A 26 Nut, Lock (Metal) 8) K1000-3 14 Nut Plates 9) MSC-34 28 Pop Rivets, Flush Head 10) AN960-08L 28 Washer, Flat 11) AN960-10 14 Washer, Flat Outboard Gear Door (for both sides) 1) 4265-01 1 Outboard Gear Door, Left # PART NO. (P/N) QTY DESCRIPTION OPTIONAL ITEM (not included with kit) 2) 4265-02 1 Outboard Gear Door, Right 3) 4725 4 Bracket, Outboard Gear Door 4) 4727-01 2 Attachment, Outboard Gear Door 5) 4727-02 4 Receptacle 6) BJ-02 8 Ball Joint Assembly 7) AN315-3 8 Nut, Check 8) AN364-428 4 Nut, Nylock 9) AN365-1032A 12 Nut, Nylock 10) PH-125-3x3 2 Phenolic Blocks 11) GM321 4 Rod, Threaded 12) MS24694-S56 12 Screws, Machine (Structural) 13) AN960-10 12 Washer, Flat 14) AN960-4L 8 Washer, Flat MAIN GEAR INSTALLATION Main Landing Gear (for both sides) 1) 4702-01 1 Main Landing Gear (Left) 2) 4702-02 1 Main Landing Gear (Right) 3) 4707-01 8 .03” Shim 4) 4707-02 8 .06” Shim 5) 4710 2 Axle, Main Gear 6) 4711 4 Spacer, Axle 7) AN4-17A 8 Bolt, Undrilled Shank 8) AN5-14A 8 Bolt, Undrilled 9) AN5-22A 2 Bolt, Undrilled 10) MS24665-292 2 Cotter Pin 11) MS21025-20 2 Nut, Axle 12) AN365-428A 8 Nuts, Nylock 13) AN365-524A 10 Nut, Nylock 14) 075-00800 2 Torque Plate 15) AN960-516 10 Washer, Flat 16) AN960-416 8 Washers, Flat Over Center Link Attachment (for both sides) 1) 4705 4 Over Centerlink Attachment 2) 4706 2 Over Centerlink Reinforcement Plate 3) 4513 4 Over Center Link Backing Plate 4) AN4-15A14A 8 Bolts, Undrilled 5) AN365-428A 8 Nut, Nylock 6) AN960-416L 8 Washer, Flat Over Center Link (for both sides) 1) 4709-01 4 Shim 0.032” Note: Optional Parts available through : (*) Lancair Avionics (**) Kit Components, Inc. 1/09-18-02 6/08-10-07 3-2 Chapter 3 REV. 0/02-15-02 WING SYSTEMS Lancair International Inc., Represented by Neico Aviation Inc., Copyright © 2008 Redmond, OR 97756 # PART NO. (P/N) QTY DESCRIPTION OPTIONAL ITEM Over Center Link continued (for both sides) (not included with kit) 2) 4709-02 8 Shim 0.063” 3) 4712-407 2 Hydraulic Cylinder (Main Gear) 4) 4718 1 Left Over Center Link 5) 4720 1 Right Over Center Link 6) 4721 4 Over Center Link Arms 7) 4722 4 Bushing 8) 4723 2 Spacer 9) 4763 2 Main Gear Up Stop 10) JM-1 2 Actuator Arm for Micro Switch 11) F45-19 2 Bearings, Rod End 12) AN3-16A 4 Bolt, Undrilled 13) AN4-44A 2 Bolt, Undrilled 14) AN4-12A 2 Bolt, Undrilled 15) AN4-7A 2 Bolt, Undrilled 16) AN5-41A 2 Bolt, Undrilled 17) AN5-20A 4 Bolt, Undrilled 18) 110-0036 6381K103 4 Bushing 19) AN5-7 2 Bolt, Drilled 20) MS24665-140 4 Cotter Pin 21) 198-0004 9416K77 2 Clip, Safety 22) 198-0003 9416K71 2 End Fitting, Metal Ball Socket 23) 198-0005 9416K84 2 End Fitting, Metal Eyelet 24) AN816-4D 4 Fittings, Nipple 25) 160-0004 9416K24 2 Gas Strut 26) 1XE1-T 2 Main Gear Micro-switch 27) AN310-5 2 Nut, Castle 28) AN316-5 2 Nut, Check 29) AN365-524A 6 Nut, Nylock 30) AN365-428A 6 Nut, Nylock 31) AN365-1032A 4 Nut, Nylock 32) HC-05-A 4786 2 Sequence Valve 33) 198-0006 9512K73 2 Stud, Ball 34) AN960-516 16 Washer, Flat 35) AN960-416 12 Washer, Flat 36) AN960-10 8 Washer, Flat 37) 110-0002B 4 Bearing, Thrust, over-center link 38) 112-0034 4 Bushing for new actuator w/bearing & old over-center link w/AN5 bolt hole or 112-0050 4 Bushing for new actuator w/bearing & new over-center link w/AN3 bolt hole MAIN GEAR WHEELS & TIRES 1) AN4-23A 6 Bolt, Undrilled 2) TU-5.00-5 2 Inner Tube 5” 3) 57-1M 40-151 2 Main Wheel Assembly 4) AN365-428A 6 Nut, Nylock 5) TR-GY 5.00-5 2 Tire, Main Gear 6) AN960-416 12 Washers, Flat # PART NO. (P/N) QTY DESCRIPTION OPTIONAL ITEM CENTER WING SECTION HYDRAULICS (not included with kit) 1) AN3-13A 6 Bolt, Undrilled 2) AN3-10A 6 Bolt, Undrilled 3) MS219-DG4 6 Clamp 4) MS219-DG7 6 Clamp 5) AN804-4D 2 Fittings, Tee 6) AN818-4D 38 Fittings, Nut 7) AN819-4D 38 Fittings, Sleeve 8) AN822-4D 6 Fittings, Elbow 9) AN825-4D 2 Fittings, Tee 10) AN827-4D 2 Fitting, Cross 11) AN832-4D 6 Fittings, Union 12) AN833-4D 6 Fittings, Elbow 13) AN837-4D 7 Fittings, Elbow 14) AN924-4D 15 Fittings, Nut 15) BG03-4NJ 20 Hose Fittings 16) R703 130 in. Flexible Hydraulic Line 17) AN365-1032A 12 Nut, Nylock 18) PH-250 1 (1/4” x 3.5” x 1.5”) Phenolic Block 19) PH-250 2 (1/4” x 3” x 3”) Phenolic Block 20) 5052 240 in. 1/4” Tubing, Aluminum 21) AN960-10 12 Washer, Flat LANDING/TAXI LIGHTS 1) 4228 1 Landing/Taxi Light Mount **Yes 2) 4531 1 Landing/Taxi Light Lens **Yes 3) 4532 1 Gasket **Yes 4) MS35649-262 6 Nut, Check **Yes 5) MS24694-S52 8 Screw, Machine **Yes 6) 101-0127 91772A157 6 Screw, Machine 7) MS21069-06 6 Nut Plate 8) K1000-08 8 Nut Plate 9) 01-0770346-02 1 Landing Light **Yes 10) 01-0770346-04 1 Taxi Light **Yes 11) 3614 6 Spring **Yes 12) AN960-6 6 Washer **Yes 13) 800-0001 1 (pair) Main gear landing lights (12 volt) 14) 800-0002 1 (pair) Main gear landing lights (24 volt) SPEED BRAKES 1) 4530 2 Cover Plates (only used when **Yes 2) 4934-12 2 Precise Flight Speed Brakes, 12 Volt **Yes 3) 4934-24 2 Precise Flight Speed Brakes, 24 Volt **Yes 4) MS24694-S5 28 Screws, Machine (Structural) 3-3 8/09-01-14 Chapter 3 REV. 0/02-15-02 WING SYSTEMS Lancair International Inc., Represented by Neico Aviation Inc., Copyright © 2000 , Redmond, OR 97756 10’ Polyethelene Tubing 44-P (10 ft) 3. CONSTRUCTION PROCEDURES A. Pitot Tube (Optional) The pitot tube installs in the forward left access panel of the center wing section. A 1. Install in left forward access panel as shown: Mounting Pitot Tube Fig. 3:A:1 Pitot Tube Line & Wires Routing Fig. 3:A:2 A/C Up Fwd Outboard Machine Screw MS24694-S4 (4pcs) Mounting Screw MS35207-226 (4pcs) Lock Washer MS35388-41 (4 pcs) Pitot Tube AN5812-12-A (1 pc) Pitot Tube Mounting Flange, 4270 (1 pc) Note: Optional Parts available through Kit Components Inc. A/C Up Fwd Outboard Carefully bend the Pitot Tube exit line to point inboard (Use your hands). Install three (3) click bond tie downs, CB9151V5 . Install in the coreless area. Use epoxy/flox or clipbond adhesive. Use a tie wrap to hold the 44-P line and electrical wires to the click bond tie downs. Steel Fitting 6505-4x4 (1 pc) Plastic Fitting 266N-04x04 (1 pc) Line connects to airspeed indicator Center Main Spar 3-4 Chapter 3 REV. 0/02-15-02 WING SYSTEMS Lancair International Inc., Represented by Neico Aviation Inc., Copyright © 2000 , Redmond, OR 97756 C. Communications Antenna (Optional) The communications antenna installs in a joggle in the aft center of the center wing section. C 1. Drill the 5/8” hole for the antenna connector. Using the antenna as a template, drill the four mounting holes using a # 20 drill. Install the nutplates as shown using a # 40 Drill bit and a 100° countersink for the MSC-34 pop rivets. Mounting the Communications Antenna Fig. 3:C:1 Note: If you do not wish to install the marker beacon antenna (or the other antennas of the center wing section) apply three (3) BID to the joggled area and body work with micro. Optional Parts (Antenna) available through Lancair Avionics. B. Installing the Marker Beacon Antenna (Optional) The marker beacon mounts in a joggle in the front center of the center wing section. B 1. Drill holes to size as shown. Mount the marker beacon antenna with hardware as shown. Mounting the Marker Beacon Fig. 3:B:1 A/C UP FWD Adjuster Screw Bolt mounting holes Antenna Connector Marker Beacon Antenna CI-102 (1pc) Adjuster Screw hole 1/4” dia. Joggle in Center Wing Section Bolt holes 3/16” dia (4 places) Connector hole 5/8” dia. Bolt, AN3-3A (4pcs) Flat Washer AN960-10 (4pcs) MAIN SPAR A/C UP FWD Communicationssntenna CI-122C (1 pc) Nutplates K1000-08 (4 pcs) Machine screw MS24694-S7 (4 pcs) or MS24694-S5 as required Gasket (1 pc) Pop rivets, MSC-34 (8 pcs) Joggle in the center wing section 3-5 3/12-15-04 Chapter 3 REV. 0/02-15-02 WING SYSTEMS Lancair International Inc., Represented by Neico Aviation Inc., Copyright © 2000 , Redmond, OR 97756 D 3. Trim the fuel line transition hole of spar closeout to the scribe line. Fuel Line Transition Hole Spar Closeout Fig. 3:D:2 Prior to bonding in the center spar closeout we suggest creating the passage for the fuel lines. Center Main Spar Bonding the Spar Closeout to the Center Main Spar Fig. 3:D:3 Spar Closeout, 4214 Center Main Spar, 4212 D 4. Install spar closeout using epoxy & flox using proper bonding procedures. Center the spar closeout ± 1/8”. Align the center line for the Main Spar & Spar Close-out Install molded spar close-out to bottom of spar area. Fill the gap above close-out with flox. A/C Up Fwd A/C Up Fwd 2.75” 1.1875” Note that the holes are in the coreless area 3.125” 3.6” A/C Center Line 0.75” dia FWD FACE OF SPAR CLOSEOUT UPPER SPAR CAP 2.00” 1.70” 4.50” 7/8” radius Scribe line Center line LOWER SPAR CAP 0.375” dia Drill two .375” dia holes for brake lines. 0.5” from centerline 2.0” D. Spar Closeout D 1. Drill the holes for fuel supply (lower two holes) and Fuel return lines (upper) in the Center main spar as shown. D 2. Drill two holes (center two holes) for the brake lines. These two holes should be 0.375” diameter. The placement is approximately 2” from the bottom and 0.5” from the centerline. Note: If you are using a Lycoming engine it is not necessary to install fuel return lines. Fuel Supply/ Return Holes through Center Main Spar Fig. 3:D:1 2/06-30-04 3-6 1.125” dia Chapter 3 REV. 0/02-15-02 WING SYSTEMS Lancair International Inc., Represented by Neico Aviation Inc., Copyright © 2000 , Redmond, OR 97756 E. Main Gear Doors The main gear of the Legacy has two gear doors per side. The outboard gear door is mechanically actuated and the inboard gear door is actuated by a hydraulic cylinder. Inboard Gear Door 4264-01(1 pc) Machine Screw MS24694-S5 (13 pcs) Ball Joint Assembly, BJ-02 (4 pcs) Machine Screws MS24694-S56 (4 pcs) Check Nut, AN315-3 (4 pcs) Receptacle, 4727-02 (2 pcs) Outboard Gear Door 4265-01 (1 pcs) Threaded Rod, GM321 (2 pcs) Machine Screws MS24694-S56 (2 pcs) Metal Lock Nut AN365-832A (7 pcs) Flat Washer AN960-8L (7 pcs) Inboard Gear Door Hinge 4728 (1 pcs) Inboard Gear Door Bracket 4726-01(1 pc) Flat Washer, AN960-10 (2 pcs) Nylock Nut, AN365-1032A (2 pcs) MAIN GEAR, LEFT 4702-01 MAIN GEAR, RIGHT 4702-02 Nylock Nut AN365-1032A (4 pcs) Flat Washer AN960-10 (4 pcs) Flat Washer AN960-4L (4 pcs) Nylock Nut AN364-428 (2 pcs) Outbd Gear Door Attachment 4727-01 (1 pcs) Outbd Gear Door Bracket 4725 (2 pcs) A/C Up Outboard Fwd Note: Prior to installing the BJ-02 into gear leg, check for paint overspray in the threads. Tap if required. Parts shown & labeled are for left side only except as noted Metal Lock Nut AN365-832A (7 pcs) Note: some of the screws may be too short. Use MS24694-S7 where required. Flat Washer AN960-8L (7 pcs) Left Inboard & Outboard Gear Doors Fig. 3:E:1 3-7 1/09-18-02 Chapter 3 REV. 0/02-15-02 WING SYSTEMS Lancair International Inc., Represented by Neico Aviation Inc., Copyright © 2000 , Redmond, OR 97756 Mark and trim the outboard edge of the gear door. (You will trim aprox. 2 1/8 in. for reference). OUTBOARD GEAR DOOR 4265-01 Fitting the Gear Doors E 1. Lightly sand all edges of the gear doors with a sanding block. Be careful not to sand through the structural plies. E 2. Fit the inboard gear door by removing material off the inboard edge of the door to give 0.06 in. clearance all around. Fitting Gear Doors Fig. 3:E:2 E 3. Fit the outboard gear door. With the inboard gear door still in place, drop the outboard gear door in place as shown. From the inside, mark the trim line. Note that the bevelled edge of the gear door is outboard. Trimming Outboard Gear Door Fig. 3:E:3 Insert tongue depressors as shown on the inboard & outboard edges. Remove material off inboard end of gear door as required. Tongue Depressor 0.06”. A/C Up Fwd Outboard A/C Up Fwd Outboard INBOARD GEAR DOOR 4264-01 INBOARD GEAR DOOR 4264-01 Note: The outboard edge of the gear door is bevelled. This bevel is for identification purposes only. The door has two embedded hardpoints. 3/12-15-04 3-8 Chapter 3 REV. 0/02-15-02 WING SYSTEMS Lancair International Inc., Represented by Neico Aviation Inc., Copyright © 2000 , Redmond, OR 97756 E 4. Remove 3/16 of the exposed foam core from the inboard end of inboard gear door and the outboard end of outboard gear door. We suggest using a dremel. Fill with Epoxy/Micro mix. Micro Filling Gear Doors Fig. 3:E:4 VIEW AA INBOARD GEAR DOOR P/N: 4264-01 OUTBOARD GEAR DOOR P/N: 4265-01 VIEW BB Gear Doors - Release Tape (Optional) To get a perfect fit of the gear doors some body work may be required. The end result we are looking for is an even gap around the gear doors and that the gear doors transition nicely to the lower wing skin. This section describes one method for body working the gear doors. To get an even gear door gap we suggest using electrical tape (referred to as the release tape in this section) as a “spacer”. The release applying epoxy/micro with the electrical tape in place will form an even gap between the gear doors and the lower wing skin. Because of the shape of the gear door the doors tend to back lock during the release. Some force is required to remove the gear doors following the release. The correct shape is sanded by hand using the beveled sanding block shown in this section. Another method is to apply just one layer of a release tape and while the micro is curing, run a knife blade around the perimeter to create the even gap. Also some body work may be required to blend the gear doors to the lower wing skin. Inboard Gear Door Release Preparation Fig. 3:E:5 Outboard A/C Up Fwd Fill with Micro A A Fill with Micro B B Outboard A/C Up Fwd Inboard Gear Door P/N: 4264-01 Release tape Close out with 1 layer of electrical tape from the edge wrapping onto the upper surface Apply 4 layers of electrical tape to the edge wraping onto the lower surface Apply 1 layer of electrical tape to the upper surface. Inboard Gear Door Aircraft Up Inboard to close out the end of the gear door. 3-9 Chapter 3 REV. 0/02-15-02 WING SYSTEMS Lancair International Inc., Represented by Neico Aviation Inc., Copyright © 2000 , Redmond, OR 97756 Outboard Gear Door Outboard Gear Door Release Preparation Fig. 3:E:6 Aircraft Up Outboard Gear Door Apply 1 layer of electrical tape to the upper surface Apply 4 layers of electrical tape to the edge wrapping onto the lower surface Close out with 1 layer of electrical tape from the edge wrapping onto the upper surface. Gear Door Release Fig. 3:E:7 Outboard A/C Up Fwd Release tape Outbd Gear Door P/N: 4265-01 0.06 in. gap 0.06 in. gap Wood blocks superglued to the gear door. This sets the proper height. 0.06 in. gap Use shot bags as necessary to weigh the gear doors down. Apply weights as required Bevel (3°) one side of a 1”x 1”x 3” block of wood 3” 1” # 80 grit sandpaper Cut-out a 1/2” x 3” wood piece for a handle 1/2” A/C Up Fwd Outboard A/C Up After cure, clean edges up using a small sanding block as shown. Mound up micro as shown A/C Up gear door joggle 3-10 Chapter 3 REV. 0/02-15-02 WING SYSTEMS Lancair International Inc., Represented by Neico Aviation Inc., Copyright © 2000 , Redmond, OR 97756 Gear Doors - Installing the Outboard Attachment Receptacles E 7. Align the outboard gear door in the joggle. Temporarily secure in place using wood blocks and instant glue. Gear Door Alignment Fig. 3:E:9 E 8. From a 1/8 in. piece of phenolic, cut out four (4) pieces as shown below. Receptacle Support Fig. 3:E:10 11/32 “ 2 1/2 “ 3/4 ” Outboard A/C Up Fwd Receptacle must make contact with attachment. phenolic 3 BID Reinforcement 3/8 “ Hole 1 1/4 ” 45° Gear Doors - Outboard Hardware Mounting Outboard Gear Door Hardware Mounting Fig. 3:E:8 E 5. Install the outboard gear attachments as shown. Countersink the outside of the gear door for the screws. E 6. Install the outboard gear door bracket. Countersink the outside of the gear door for the screws. Outboard Machine Screw MS24694-S56 (6 pcs) 2 1/8 ” Flat Washer, AN960-10 (4 pcs) 10 1/2 ” Nylock Nut AN365-1032A (2 pcs.) Flat Washer AN960-10 (2 pcs.) Outboard Gear Door Attachment Bracket 4727-01 (1 pc) A/C Up Bracket, Outboard Gear Door 4725 (2 pcs) Note: For outboard gear doors that don’t have the hard-points for the outboard gear door attachment bracket screws, it is necessary to install hard-points. Drill the holes as explained above and visually determine if the hard-points are installed. They are identified as follows: No hard-point - There is foam between the holes. Hard-point - There is solid e-glass in the holes. Hard-points are installed as follows: (1) Mark screw locations on the inside of the gear door. (2) Draw a 5/8” dia. circle centered on the screw locations. (3) Remove the INSIDE LAMINATE ONLY of the circle you drew. (4) Remove 1/4” of the core around the hole and fill it with flox. Hardpoint Area 5/8 ” Nylock Nut, AN365-1032A (4 pcs) 3-11 Chapter 3 REV. 0/02-15-02 WING SYSTEMS Lancair International Inc., Represented by Neico Aviation Inc., Copyright © 2000 , Redmond, OR 97756 Final trim the BID tape after cure fora “clean look.” E 9. Prepare all bonding surfaces by sanding the inside of the stub wing, receptacle and phenolic. E 10. Install the receptacle and the phenolic with epoxy/flox. Receptacle Support Bonding Fig. 3:E:11 E 11. Secure with 3 BID using proper bonding procedures. Receptacle Support Reinforcement Fig. 3:E:12 Outboard A/C Up Fwd cut here as shown Pattern for Glassing 3” 3/4” 1 1/2” 3/4” 3/4” IMPORTANT: The receptacle must make contact with the attachment. form flox fillets form flox fillets Receptacle, 4727-02 (2 pcs) Fwd Outboard A/C Up Installing the Inboard Gear Door To complete this section the aft loads pad must be installed. Refer to chapter 10 for the aft load pad installa- tion. (The hinges for the inboard gear doors mount to the aft load pads). Prior to mounting the hinges the inboard gear door must be final trimmed. The inboard edge of the gear door becomes the reference for installing the hinge. Note the 3/16” notch in the inboard edge of the gear door. The notch is to accept the hinge. The .05” sets the gap between the inboard gear door and the joggle. While these dimensions may seem confusing at first we suggest that you study the parts and try to understand the installation process before getting started. Inboard Gear Door Hardware Mounting Fig. 3:E:13 E 12. Install hardware in inboard gear door. Outboard A/C Up Fwd Machine Screw, MS24694-S5 (6 pcs) Note: some of the screws may be too short. Use MS24694-S7 where re- quired. FWD 1” 10” The notch for the hinge is 3/16” deep. Align hinge 0.06” inboard of gear door. Flat Washer, AN960-10 (7 pcs) Metal Lock Nut, AN365-832A (6 pcs) 10” Bolt, AN3-5A (7 pcs) Pop Rivet, MSC-34, (14 pcs) Flat Washer, AN960-8L (6 pcs) Flat Washer, AN960-8L (7 pcs) Left Inboard Gear Shown Piano Hinge, 4728 (1 pc) Metal Lock Nut, AN365-832A (6 pcs) Bracket, Inboard Gear Door 4726-01B (1 pc) Nut Plates, K1000-3, (7 pcs) Machine Screw MS24694-S5 (6 pcs) (Countersink gear doors to accept screws) 1” 1/09-18-02 3/12-15-04 3-12 Chapter 3 REV. 0/02-15-02 WING SYSTEMS Lancair International Inc., Represented by Neico Aviation Inc., Copyright © 2000 , Redmond, OR 97756 E 19. Now assemble the parts for the other end of the cylinder actuator by sliding an AN3-20 bolt through the bracketdoubler (4732) and the remaining parts in the following order: rod end of the cylinder actuator, through the bracket (4726-01B), spacer (4767) rod end on the retainer spring, a flat washer (AN960-10), a castle nut (AN310-3) and secure with cotter pin MS24665-132. E 20. Finish bolting the two brackets together, 4732 to 4726-01B, using one each of bolts AN3-5A, AN3-7A and AN3-9A and three each of washers AN960-10 and nuts AN365-1032A. Inboard Gear Door Hydraulic Cylinder Mounting (part 2) Fig. 3:E:15 E 13. Identify the left indoor gear bracket (4714-01) using the figure below. The outboard edge of the bracket is a 90 deg. side, meaning the face of the bracket and the three bracket arms make a 90 deg. angle on the outboard side. Position the bracket with the two outboard holes over the the two existing holes in the fuselage that are approx. 10” from the cockpit closeout rib. Hold the bracket over the holes and mark the two inboard holes. Drill the inboard holes. E 14. Slide a flat washer, AN960-10, onto bolt AN3-22 then through the inboard gear door bracket, 4714-01, attaching the following in this order: cylinder actuator (4787), spacer (4768), hydraulic cylinder tube assembly (4765), and finish with another flat washer (AN960-10), a castle nut (AN310-3) and secure with cotter pin MS24665-132. Inboard Gear Door Hydraulic Cylinder Mounting (part 1) Fig. 3:E:14 3/12-15-04 3-13 See the previous page for locating and bolting the inboard gear door bracket to the inboard gear door. Note: The hydraulic cylinder operation is covered in chapter 16. Flat Washer AN960-10 (1 pc) Left Inboard Gear Door Bracket 4714-01 (1 pc) - outboard side Castle Nut AN310-3 (1 pc) Bolt, AN3-22 (1 pc) Hydraulic Cylinder Tube Assembly, 4765 (1 pc) Cylinder Actuator 4787 (1 pc) Cotter Pin MS24665-132 (1 pc) Spacer, 4768 (1 pc) Flat Washer AN960-10 (1 pc) Cylinder Spring 13373 (1 pc) E 15. Attach the Left Inboard Gear Door Bracket (4714-02) by aligning its holes with the outboard holes. Coun- tersink the holes in the center wing section for the four screws and install using machine screws, MS24694-S54, with washers, AN960-10L, and nuts AN365-1032A. E 16. Slide the cylinder spring (13373) onto the hydraulic cylinder tube assembly. E 17. Slide a retainer (4769) onto the tube assembly (4765). Then install and tighten a female rod end (F35-14) onto the assembly. E 18. Iinstall and tighten check nut (AN316-4) followed by a female rod end (F34-14) onto the cylinder actuator. Inboard side of the left Inboard Gear Door Bracket Flat Washer AN960-10 (1 pc) Cotter Pin MS24665-132 (1 pc) Cylinder Actuator 4787 (1 pc) Cylinder Spring 13373 (1 pc) Rod End-Female F35-14 (1 pc) Rod End- Female F34-14 (1 pc) Bolt, AN3-20 (1 pc) Rod for Hydraulic Cyl. 4766 ( 1 pc) Bracket Left Inboard Gear Door 4726-01B (1 pc) Retainer Spring 4769 ( 1 pc) Spacer, 4767 (1 pc) Bracket Doubler Inboard Gear Door 4732 (1 pc) Bolt, AN3-10A (1 pc) Bolt, AN3-7A (1 pc) Bolt, AN3-5A (1 pc) Check Nut AN316-4 (1 pc) Castle Nut AN310-3 (1 pc) Washer, AN960-10 (3 pcs) Nut, AN365-1032A (3 pcs) Chapter 3 REV. 0/02-15-02 WING SYSTEMS Lancair International Inc., Represented by Neico Aviation Inc., Copyright © 2000 , Redmond, OR 97756 3-13b Inboard Rib Nutplates, K1000-3 Pop Rivets, MSC-32 or use clicbond nutplates CN614CR3P Release rib as necessary Bolt, AN3-5A The rib is installed so that face is flush with outboard edge of joggle. Inboard Gear Door Hinge Mounting to Inboard Rib Fig. 3:E:16 Note: This step must be completed after the rib is aligned. Refer to Chapter 10, Figure 10:B:2. 3/12-15-04 Intentionally Left Blank Page added due to updates on prev. page for Rev. 3/12-15-04 Chapter 3 REV. 0/02-15-02 WING SYSTEMS Lancair International Inc., Represented by Neico Aviation Inc., Copyright © 2008 Redmond, OR 97756 F. Main Gear Installation F 1. Assemble the main gear legs as shown. Main Gear Aft Bearing Block 4704 (1 pc) Main Gear Fwd Bearing Block 4703 (1 pc) Main Landing Gear, 4702-01 (1 pc) Bolt, AN4-17A (4 pcs) Cotter Pin MS 24665-292 (1 pc) Torque Plate, 075-00800 (1 pc) Axle, 4710 (1 pc) Flat Washer AN 960-416 (4 pcs) Spacer, 4711 (1 pc) Axle Nut MS 21025-20 (1 pc) Spacer, Z02E471 (1 pc - supplied w/ landing gear) Bolt, AN5-22A (1 pc) Nylock Nut, AN365-524A (1 pc) Washer, AN960-516 (1 pc) Shims are installed between forward bearing block and spar at the factory. When installing the gear remove only the aft bearing block. Check that gear fits tight - there should be no play. If necessary add or remove shims. The shims are available through KCI at no charge. 0.03” shim P/N: 4707-01 0.06” shim P/N: 4707-02 Bushing Z02E973 Note: Tire not shown for clarity. Parts shown & labeled are for left side of the airplane only. Right hand is symmetrically opposite. Outboard A/C Up Fwd Main Landing Gear (Exploded View) Fig. 3:F:1 The Legacy landing gear is oleo pneumatic. The landing gear is pre-aligned at the factory however the angle of the gear leg itself must beset as shown later in this section. The first 50 Legacy kits were supplied with a style 1 landing gear and from then on a style 2 landing gear. To identify, style 1 is a one piece type fork as shown and style II has a collar that bolts to the fork as shown on the left. If you have a style 1 type of fork you must comply with service bulletin SB058. Main Landing Gear Style II Fig. 3:F:1:b Locknut,AN365-524A (4 pcs.) Washer, Flat AN960-516 (4 pcs.) Bolt, AN5-14A (4 pcs.) Nylock Nut AN365-428A (4 pcs) Main Gear Fork, Style One 3-14 Optional Landing Lights 12 volt 800-0001 24 volt 800-0002 (Sold by the pair) 7/09-05-08 Chapter 3 REV. 0/02-15-02 WING SYSTEMS Lancair International Inc., Represented by Neico Aviation Inc., Copyright © 2000 , Redmond, OR 97756 Over Center Link Support Assembly Fig. 3:F:3 F 2. Install the hardware at the center link rib as shown. A/C Up Fwd Outboard Torque Plate Positioning Fig. 3:F:2 Nylock Nut, AN365-428A (4 pcs) Flat Washer, AN960-416L (4 pcs) Over-center Link Backing Plate 4513 (2 pcs) MAIN SPAR AFT SPAR Over-center Link Reinforcement Plate 4706 (1 pc) Over-center Link Attachment 4705 (2 pcs) Bolt AN4-15A14A (4 pcs) (Bolt length varies depending on the number of shims needed) Over Center Link Ribs The shims installed between over-center link attachment and reinforcing plate are not shown. Refer to Fig. 3:F:4 Note: 4705 installed with long side down Note: Holes in 4706 are oversized Note: The over-center link backing plates do not come with the holes drilled. When aligning the plates install as high as possible to leave room for hydraulics fittings. It is acceptable to notch the plates to allow room for hydraulic fittings as required. Nylock Nut, AN365-428A (4 pcs) Torque Plate, 075-00800 (1 pc) Main Landing Gear, 4702-01 (1 pc) Fwd Note: Parts shown & labeled are for one side of the airplane only. Note: It may be necessary to remove material off this corner if part extends above the rib. 3-15 6/08-10-07 Chapter 3 REV. 0/02-15-02 WING SYSTEMS Lancair International Inc., Represented by Neico Aviation Inc., Copyright © 2008 Redmond, OR 97756 Over Center Link Assembly Fig. 3:F:4 Bolt, AN4-12A (1 pc) Check Nut, AN316-5 (1 pc) Flat Washer, AN960-416 (2 pcs) Nylock Nut, AN365-428A (1 pc) Nylock Nut AN365-428A (1 pc) Flat Washer, AN960-516 (6 pcs) Over-center Link, 4720 (1 pc) Bolt, AN5-7 (1 pc) or with new cylinder, use AN3-7 Nylock Nut AN365-524A (2 pcs) Nylock Nut, AN365-428A (4 pc) Over-center Link Reinforcement Plate 4706 (1 pc) Safety Clip 198-0003 9416K77 (1 pc) Rod End Bearing, 198-0003 9416K71 (1 pc) Rod End Bearing, 198-0005 9416K84 (1 pc) Flat Washer, AN960-416 (2 pcs) Bolt, AN4-7A (1 pc) Bolt, AN5-41A (1 pc) Flat Washer, AN960-516 (2 pcs) Over Center Link Arms, 4721 (2 pcs) Bolt, AN4-44A (1 pc) Flat Washer, AN960-416 (2 pcs) Nylock Nut, AN365-428A (1 pc) Ball Stud, 198-0006 9512K73 (1 pc) Flat Washer, AN960-416L (4 pcs) Bolt, AN4-15A14A (4 pcs) Bolt, AN5-20A (2 pcs) Over-center Link Attachment 4705 (2 pcs) Over-center Link Backing Plate 4513 (2 pcs) AVG: (1 pc) 0.032 T Shims, 4709-01 (A/R) (2 pcs) 0.063 T Shims, 4709-02 (A/R) Rod End Bearing, F45-19 (1 pc) Spacer (from ESCO) Included with the main gear Bushing 112-0036 6381K103 (2 pcs) Bushing, P/N 4722 Install from fwd side Gas Strut, 160-0004 9416K24 (1 pc) Install with Loctite Install from fwd side Install with Loctite Cotter Pin MS24665-140 (1 pc) Castle Nut, AN310-5 (1 pc) Install from fwd side Outboard Fwd A/C Up Note Install the ball stud, part number 198-0006 9512K73 with Loctite 242. FWD A/C Up 3-16 7/09-05-08 Note: The hydraulic cylinder should be installed such that the ports face forward. Install all bolts from forward to aft. Hydraulic Cylinder, 4712-407 (1 pc) with 4 bushings, 112-0050 REFER TO NEXT PAGE Spacer 4723 (1 pc) Nylock Nut, AN365-524A (1 pc) Chapter 3 REV. 0/02-15-02 WING SYSTEMS Lancair International Inc., Represented by Neico Aviation Inc., Copyright © 2000 , Redmond, OR 97756 Main Gear Down Switch Fig. 3:F:5 Fwd Ac/Up Main gear micro switch 1XE1-T This switch installs on the bottom. It can be installed on either side. Switch arm JM-1 Micro switch and switch arm are secured to the 4720 over center linkage with screws provided in the JM-1 packet. 2/06-30-04 This photograph is taken from beneath the main gear, looking up at the switch. 3-17 Chapter 3 REV. 0/02-15-02 WING SYSTEMS Lancair International Inc., Represented by Neico Aviation Inc., Copyright © 2008 Redmond, OR 97756 Final adjustment of up stop is explained in chapter 16. Sequence Valve/Gear Up Stop Fig. 3:F:7 Bolt, AN3-16A (2 pcs.) Washer, AN960-10 (2 pcs.) Sequence Valve HC-05-A 4786 (1pc.) Fitting Nipple, AN816-4D (2 pcs.) Main Gear Up Stop, 4763 Over Center Link Reinforcement Plate, 4706 Washer AN960-10 (2 pcs.) Locknut, AN365-1032A (2 pcs.) 2” 7/09-05-08 3-18 Chapter 3 REV. 0/02-15-02 WING SYSTEMS Lancair International Inc., Represented by Neico Aviation Inc., Copyright © 2000 , Redmond, OR 97756 Over Center Link Reinforcing Plate Shim Installation Looking Forward Fig. 3:F:8 SMART TOOL Install shims as required to set gear to 90° (or vertical). Install within 0.375” of top of box and drill 0.25” holes. Over center link backing plate 4513 (1 pc) Over center link rib Over center link reinforcement plate 4706 (1 pc) The number of shims are not necessarily the same on the front and the back (but should be very close). With the complete mechanism assembled visually inspect the Z02E973 bushing in the gear leg (Fig. 3:F:1) The bushing should be close to centered. Excessive friction (from binding) may be caused by such a mis- alignment. Notes: The aircraft must be level for this step. If the center wing section is bonded refer to Figure 10:A:5. If not, level the center wing section tip to tip. Shims: P/N 4709-01, 0.032” thick P/N 4709-02, 0.063” thick Typical amount required is between 2 and 3 thick shims. 3-19 Chapter 3 REV. 0/02-15-02 WING SYSTEMS Lancair International Inc., Represented by Neico Aviation Inc., Copyright © 2008 Redmond, OR 97756 G. Main Gear Wheels and Tires The main gear of the Legacy uses 5.00 x 5 wheels & tires. Cleveland wheels and brakes are standard in the kit. Installation of the brakes are in Chapter 18. Main Gear Wheels & Tires (Exploded View) Fig. 3:G:1 Note: Parts shown & labeled are for one side of the airplane only. Snap Ring, 155-00200 (Parker)/VH-237-S02 (Grove) Grease Seal Ring, 153-00800 (Parker)/011-001 (Grove) Felt Grease Seal, 154-00600 (Parker)/010-001 (Grove) Grease Seal Ring, 153-00800 (Parker)/011-001 (Grove) Cup Bearing and Cone, 214-00300 (Parker)/ Cup 028-004 and Cone 027-004 (Grove) Nylock Nut, AN365-428A (3 pcs) Flat Washer, AN960-416 (3 pcs) 5.00 x 5 tube, TU-5.00-5 5.00 x 5 Tire, TR-GY-5.00-5 Inner Wheel Half, 161-03100 (Parker)/015-001M (Grove) Brake Disc, 164-08500 (Parker)/018-003 (Grove) Outer Wheel Half, 162-02800 (Parker)/016-001M (Grove) Snap Ring, 155-00200 (Parker)/ VH-237-S02 (Grove) Felt Grease Seal, 154-00600 (Parker)/010-001 (Grove) Seal Ring, 153-00800 (Parker)/011-001 (Grove) Cup Bearing and Cone, 214-00300 (Parker)/ Cup 028-004 and Cone 027-004 (Grove) Grease Seal Ring, 153-00800 (Parker)/011-001 (Grove) Flat Washer, AN960-416 (3 pcs) Bolt, AN4-23A, (3 pcs) Main Wheel Assembly (1 set) 40-151 (Parker)/57-1M (Grove) WARNING: Bearings must be packed prior to flight. 3-20 8/09-01-14 Chapter 3 REV. 0/02-15-02 WING SYSTEMS Lancair International Inc., Represented by Neico Aviation Inc., Copyright © 2008 Redmond, OR 97756 G 1. Insert the 5.00 x 5 tube into the tire. Then inflate the tube with a very small amount of air (just enough to unfold it). This will make the assembly easier and prevent kinks. Wheel Assembly Fig. 3:G:2 Tube, TU-5.00 x 5 Tire, TR-GY-5.00 x 5 Outboard Rim (the half without the valve stem) 162-02800 (Parker)/016-001M (Grove) G 2. Place the tire and tube into the rim you have set on your bench. Push the tire down onto the rim, always avoid pinching the tube. You’ll not be able to push the tire all the way onto the rim, the tire will be fully seated with air pressure. G 3. Place the other half of the rim onto the tire, aligning the valve stem hole & the three (3) bolt holes. Pull the valve stem through the rim as you work the rim down. Here is where most people damage the tube. If you’re not careful when pushing the rims together, you can easily pinch the tube or stem between the rims. Instant leak! This problem can be avoided by just being careful & aware of the danger. Wheel Assembly Fig. 3:G:3 G 4. Before the two halves of a Cleveland rim can be secured together, the brake disc assembly must be placed onto the inboard face of the wheel (the side opposite the valve stem). The two rim halves & the brake disc are secured together with the manufacturer supplied bolts and nuts. G 5. Inflate the Goodyear tires 45 to 50 psi. It is a good idea to do this a few times before full inflation. This will help loosen any folds in the tube. Inboard Rim (with hole for stem) 161-03100 (Parker)/015-001M (Grove) Tire, tube & outer rim half Brake Disc, 164-08500 (Parker)/018-003 (Grove) Bolt, AN4-23A (3 pcs) Washer, AN960-416 (3 pcs) 3-21 8/09-01-14 Chapter 3 REV. 0/02-15-02 WING SYSTEMS Lancair International Inc., Represented by Neico Aviation Inc., Copyright © 2000 , Redmond, OR 97756 G 6. Grease the two wheel bearings with quality grease, making sure the grease penetrates the entire bearing. G 7. Place the bearings into the races of the wheel. On the Cleveland wheel, after the bearings are placed into the race, a seal consisting of two thin steel washers and a felt washer is secured with a retainer ring. The seals and the rings retain the bearings in the wheel. G 8. Now the wheels are ready to be mounted on the axles. Carefully slide the wheel onto the axle until the inboard bearing has been seated. Secure the wheel with an MS21025-20 axle nut. Tighten the nut until there is no slop in the wheel bearings. The axle nut should be tightened so when you spin the wheel it rotates approximately one turn. Then lock the axle nut into position with a MS24665-292 cotter pin. Securing Wheels to Axles Fig. 3:G:4 Axle, 4710 5.00 x 5 Tire & wheel with bearings installed Axle Spacer, 4711 Axle Nut, MS21025-20 (See step G8 for tightening guideline.) Cotter pin, MS 24665-292 Main Landing Gear 4702-01 Note: Parts shown & labeled are for one side of the airplane only. 2/06-30-04 INTENTIONALLY LEFT BLANK 3-22 Chapter 3 REV. 0/02-15-02 WING SYSTEMS Lancair International Inc., Represented by Neico Aviation Inc., Copyright © 2008 Redmond, OR 97756 H. Center Wing Section Hydraulics To view the schematics of all line layouts, see pages 3-35 through 3-37. Refer to Figure 3:H:2 for fitting at aft spar. Elbow fitting (90°), AN822-4D Bulkhead fitting, AN833-4D (2 pc) with checknut, AN924-4D Out FIREWALL AN822-4D Tee Fitting, AN804-4D HP LP Main Gear Hydraulic Cylinder 4712-407 (1 pc) Elbow Fitting (90°) AN833-4D Elbow Fitting (45°), AN837-4D Sequence Valve, HC-05-A (1 pc) w/ AN816-4D (Nipple) Fitting on both ends. Tee Fitting, AN825-4D Elbow Fitting (90°), AN822-4D Straight Bulkhead Fitting, AN832-4D In HP (UP) LP (DOWN) Hydraulic Pump, 637715 Has been relocated behind the co- pilot’s seat for c.g. reasons. High Pressure Switch PS 1000 Low Pressure Switch PS 550 Nipple Fitting AN816-4D Tee Fitting 2611- 4 x 2 x 2 (2 pcs) REF: FUSELAGE/CENTER WING SECTION JOINT Bulkhead Fitting, AN837-4D (3 pcs) with Nut Fitting, AN924-4D (3 pcs) MAIN SPAR Cross Fitting, AN827-4D Dump Valve, B-42xHF2-BKB Return Line Elbow Fitting (45°) AN837-4D Gear down Line, 4748 Gear up Line, 4749 Main Gear Hydraulic Cylinder 4712-407 Tee Fitting, AN825-4D Center Wing Section Hydraulic line Schematic drawing 3:H:1 Hydraulic Lines Low Pressure Line High Pressure Hydraulic Cylinder HC-03-A Hydraulic Cylinder HC-03-A Union Fitting, AN832-4D Union Fitting, AN832-4D Note: Installations aft of the aft spar and forward of the main spar installed in chapter 16. This is a schematic only. Refer to following pages for exact routing. Nose Gear Cylinder HC-08, (1 pc) REF: FUSELAGE/CENTER WING SECTION JOINT 7/09-05-08 HP (UP) LP (DOWN) Refer to this photo to review the shape of the hydraulic lines as they cross over the main spar. High Pressure Line Low Pressure Return Line Center console 3-23 Chapter 3 REV. 0/02-15-02 WING SYSTEMS Lancair International Inc., Represented by Neico Aviation Inc., Copyright © 2000 , Redmond, OR 97756 A/C Up Outboard Center Wing Section Hydraulic Lines Routing Fig. 3:H:2 Straight Bulkhead Fittings, AN832-4D with AN924-4D Check Nut Tee Fitting, AN825-4D Support Location of fuel return line 45° Bulkhead Fitting, AN837-4D with Check Nut, AN924-4D All 1/4” Lines with AN818-4D Nuts & AN819-4D Sleeves. Secure the line running from the cross fitting to the cylinder such that there is no move- ment of the aluminum lines when the cylinder is actuated. All flexible lines (shown in black) are R703 hose with BG03-04NJ fittings on both ends. Elbow Fitting, AN822-4D Cross Fitting, AN 827-4D (2 pcs) Phenolic Support 45° Bulkhead Fitting, AN837-4D with Check Nut, AN924-4D Fwd 3-24 3/12-15-04 LP HP Chapter 3 REV. 0/02-15-02 WING SYSTEMS Lancair International Inc., Represented by Neico Aviation Inc., Copyright © 2000 , Redmond, OR 97756 Positioning of Hydraulic lines Top View (Looking Down) Fig. 3:H:3 Return 10 3/4” Low Pressure 12 3/4” High Pressure 15 3/4” Forward AFT SPAR Hydraulic Line Support (phenolic) see Fig. 3:H:4 For hole dimensions see Fig. 3:H:5 Suggested Hydraulic Line Support (New layout) Fig. 3:H:4 1/2 ” Secure with 2 BID per side. 1/4” .44 Radius .13 Radius .13 Radius .28 2.5” 3/12-15-04 Fwd A/C Up Edge of console The first hole needs to be located 6” from the center line. 3-25 2” 2.5” Measurements are for reference only. Chapter 3 REV. 0/02-15-02 WING SYSTEMS Lancair International Inc., Represented by Neico Aviation Inc., Copyright © 2000 , Redmond, OR 97756 A/C Center Line Flap Motor Transition Hole AFT SPAR Aft Spar Hydraulic Line Transition Holes Fig. 3:H:5 Sequence Valve Installation Fig. 3:H:6 1234 1234 1234 12345678 12345678 12345678 12345678 12345678 1/4” Aluminum Line, 5052 w/ Sleeves, AN819-4D w/ Nuts, AN818-4D Sequence valve installed in section 3:F. See Fig. 3:F:6 H.P. L.P. Tee Bulkhead Fitting AN804-4D 45° Elbow Bulkhead Fitting, AN837-4D View AA A A Elbow Fitting AN822-4D (2 pcs) Main Gear Hydraulic Cylinder 90° Bulkhead Fitting AN833-4D Apply 4 BID reinforce- ment at the clamp location. Clamp should be approx. 5” outboard of rib. AFT SPAR A/C Up Fwd Outboard A/C Up Fwd 7/16 ” dia. holes Note: Parts shown & labeled are for one side of the airplane only. MS21919-DG8 clamp secured with screw, AN960-10 Washer AN365-1032A Nylock Nut Hose, R703 AN822-4D (2 per hose) 3/12-15-04 Drill three holes equal distance from each other. If the carbon layup was not completed by the factory, then you need to complete a 4-BID carbon layup as shown in the photo below. The decored area starts at 5.5” from the center line. The first hole needs to be located at 6” from the center line. Forward side of AFT Spar Console 3/4 ” 6” 3-26 Chapter 3 REV. 0/02-15-02 WING SYSTEMS Lancair International Inc., Represented by Neico Aviation Inc., Copyright © 2000 , Redmond, OR 97756 Sequence Valve Installation Continued Fig. 3:H:7 A/C Up Fwd Note: It is easier to install the AN816-4D fitting prior to mounting the sequence valve. Screw & check nut supplied with sequence valve. Forward Over Center Link Rib 1 7/8” 7/16” dia. (4 places) 1” 7/8” 1” 2 1/4” Prior to drilling each hole check the inboard side to ensure that the fitting is installed in a suitable location. It must clear the backing plate (p/n 4513) and mount on the flat surface. It is acceptable to trim a small amount of the backing plate to make room to install the fitting. 7/16” dia. holes (4 locations) 2/06-30-043-27 Chapter 3 REV. 0/02-15-02 WING SYSTEMS Lancair International Inc., Represented by Neico Aviation Inc., Copyright © 2000 , Redmond, OR 97756 Transition Holes for Aft Load Pad 19 Rib Fig. 3:H:8 VIEW LOOKING INBOARD Transition hole for push pull tube 3/4” dia. - fuel supply lines Transition hole for inboard gear door hydraulic cylinder. Locate and size as required. 7/16” dia. holes - hydraulic lines Flap torque tube access hole. Locate and size as required. A/C Up Fwd 3/8” dia. hole - brake line 7/16” dia. hole for fuel return line 3/8” dia. hole for seat belt attachment 7/16” dia. hole for hydraulic line Brake line 3-28 4/09-30-06 7/8” 3 1/8” 4 1/16” 5 3/8” (from center of hole to outside edge.) 1 3/4” 1 1/4” 1 1/8” 2” 7/8” 2 1/4” 1 1/2” Chapter 3 REV. 0/02-15-02 WING SYSTEMS Lancair International Inc., Represented by Neico Aviation Inc., Copyright © 2000 , Redmond, OR 97756 Hydraulic Line Routing through Gear Well Fig. 3:H:9 Elbow Bulkhead Fitting AN833-4D AFT SPAR MAIN SPAR Fuel Line 1/4” dia. Hydraulic Line (L.P.) 1/4” dia. Hydraulic Line (H.P.) 1/4” dia. 45O Elbow Bulkhead Fitting, AN837-4D Tee Bulkhead Fitting, AN804-4D Union Fitting AN832-4D 45° Elbow Fitting AN837-4D All lines must be kept clear of opening for the tire clearance. Secure the lines using one of the methods described in Chapter 1. The fuel and hydraulic lines on the aft side of the gear well must be kept clear of the flap torque tube. We suggest that you temporarily install the flap tube support brackets for reference. Refer to figure 21:A:1. Outbrd Fwd The fuel line is closest to the aft spar. 3/12-15-04 3-29 Chapter 3 REV. 0/02-15-02 WING SYSTEMS Lancair International Inc., Represented by Neico Aviation Inc., Copyright © 2000 , Redmond, OR 97756 I. Aft Spar Transition Holes While you have easy access to the aft spar flap actuating mechanism, it is the best time to cut the holes. We suggest using a dremel and final trimming with perma grit tools. Aft Spar Transition Holes Fig. 3:I:1 1 1/2” 2 1/2” Flap Hinge Bracket 4557-02 Flap Hinge Bracket 4557-01 1 1/2 ” UPPER CAP Fwd A/C Up AFT SPAR WARNING: DO NOT CUT INTO THE SPAR CAPS. 2” Spar Cap 2 1/2” Center Line 1.55 ” 1 1/4 ” .8” 1.2 ” Aft Face 3-30 Chapter 3 REV. 0/02-15-02 WING SYSTEMS Lancair International Inc., Represented by Neico Aviation Inc., Copyright © 2000 , Redmond, OR 97756 J. Landing and Taxi Lights (Optional) The landing/taxi light kits are available through KCI. They are available for both the left and the right side. Landing/Taxi Light Exploded View Fig. 3:J:1 J 1. Trim the landing/taxi light mount to the scribe lines. There are two sets of scribe lines: 1) Trim the mount flange to scribe line (flange width should be 1”). 2) Trim mount to scribe lines to accept the lights. J 2. Install the landing and taxi lights as shown in the light mount. Note: it isn’t necassary to install the adjustment system at this time. The adjustment mechanism consistsof the longer screws, washers & springs. This can be set anytime after closing the wing. The aircraft must be leveled for this step. See Chap- ter 7. Taxi Light: initially set to -4° Landing Light: initially set to -6° (Final adjust to preference) Landing Light Lens 4531 (1 pc) Gasket, 4532 (1 pc) May be painted in this area to create a “beauty ring” 1/8” minimum gap for moisture drainage 0.5” Landing/Taxi Light Mount 4228 (1 pc) Hole for original nut (no nut plate here) Flat Washer, AN960-6 (6 pcs) Check Nut, MS35649-262 (6 pcs) Taxi Light, 01-0770346-04 (1 pc) Screw, 101-0127 91772A157 (6 pcs) Screw supplied by light Nut supplied with lights Nut supplied with lights Landing Lights 01-0770346-02 (1 pc) 2.6” Coreless area of right wing. If your wing is not coreless: (1) Remove inner laminate and core. (2) Fill edges with epoxy/micro. (3) Apply 2 BID E-glass extending 1” past cored out area. Nut Plate, K1000-08 (8 pcs) or use Clickbond Nutplates CN614CR08P Nut Plate, MS21069-06 (6 pcs) Machine Screw, MS24694-S52 (8 pcs) Note: Optional Parts available through Kit Components Inc. A/C Up Outboard Fwd Spring, 3614 (6 pcs) 3-31 6/08-10-07 Chapter 3 REV. 0/02-15-02 WING SYSTEMS Lancair International Inc., Represented by Neico Aviation Inc., Copyright © 2000 , Redmond, OR 97756 Cross section of Light Assembled View Fig. 3:J:2 Outboard Fwd A/C Up J 4. After the wing is closed, trim the skin up to the edge of joggle as shown. J 5. Adjust joggle thickness to 0.2” . At 0.2” the lens will be flush with wing skin. J 6. Trim the plexiglass to fit the opening. We suggest temporarily installing small pieces of gasket material to simulate gasket thickness. J 7. Using a plexiglass drill bit install the lens. J 3. Install light mount. Alignment: (1) Tight up against the leading edge. (2) Align inbd/outbd as shown in Fig. 3:J:3. Plexiglass MAIN SPAR 0.2” is the combined thickness of the plexiglass and gasket. Adjust joggle height as required. Adjust joggle depth with epoxy/micro to obtain 0.02” (after completing chapter 11). Typical fill is .0 to .08”. 0.2” Keep a light even gap Gasket Light Mount Adjust Joggle Height to 0.2” with epoxy/micro. Wing Skin 3-32 Chapter 3 REV. 0/02-15-02 WING SYSTEMS Lancair International Inc., Represented by Neico Aviation Inc., Copyright © 2000 , Redmond, OR 97756 Landing/Taxi Light Installed Fig. 3:J:3 J 8. Install the lights. Install the gasket, lights and lens with the adjust ment mechanism and set . Note: One of the four screws of the light remains. The adjustment mechanism consists of three (3) screws. The fourth screw is the original screw holding the light together. A/C Up Outboard Fwd Note: Beauty ring not shown for clarity Optional Parts available through Kit Components Inc. 3-33 9 1/2” Chapter 3 REV. 0/02-15-02 WING SYSTEMS Lancair International Inc., Represented by Neico Aviation Inc., Copyright © 2000 , Redmond, OR 97756 K. Speed Brakes (Optional) Speed Brake Installation Fig. 3:K:1 Speed Brake Drain Tube Installation Fig. 3:K:2 K 1. After closing, install the drain tube. Lightly sand the aluminum tube and install such that both ends are flush. Upper Wing Skin Speed Brake PF 1 Speed Brake Hous- ing 4247-01 Speed Brake Housing Support A/C Up Fwd (Inside of support is filled with Micro) Precise flight Speed Brakes 4934-12 (12 Volt System) 4934-24 (24 Volt Sysem) Note the 1/4” aluminum drain tube installed in the housing support Upper Wing Skin 4200-01 (left) 4200-02 (right) Machine Screws, MS 24694-S5 (14 pcs) Speed Brake Housing 4247-01(left) 4247-02 (right) Passage for electrical connection Note: Optional Parts available through Kit Components Inc. Outboard A/C Up Fwd 1/4” aluminum drain tube Note: If you are not installing speed brakes, install cover plates (P/N: 4530) available through Kit Components Incorporated. 3-34 Chapter 3 REV. 0/02-15-02 WING SYSTEMS Lancair International Inc., Represented by Neico Aviation Inc., Copyright © 2000 , Redmond, OR 97756 L. Fuel and Hydraulic Lines Schematics Line Schematics for Wings Fig. 3:L:1 3/12-15-04 3-35 Chapter 3 REV. 0/02-15-02 WING SYSTEMS Lancair International Inc., Represented by Neico Aviation Inc., Copyright © 2000 , Redmond, OR 97756 Line Schematics aft of Main Spar Fig. 3:L:2 3-36 3/12-15-04 Chapter 3 REV. 0/02-15-02 WING SYSTEMS Lancair International Inc., Represented by Neico Aviation Inc., Copyright © 2000 , Redmond, OR 97756 Fuel Lines withGascolator and Pump Fig. 3:L:3 3/12-15-04 3-37