CHAPTER 28 REVISION LIST

stiffener. The handles are install ju.st above the lower stiffener channel, toward the rear section. A removable panel will later cover this mechanism. Latches: The latching system is rather unique E<!ld very secure, it was designed for the pressurized model. The difference between a standard Lancair IV latch system vs. a pressurized model is essentially the number oflatches installed. The standard Lancair IV utilizes two latches at the bottom of the door while the pressurized model has eight along with a second actuation handle. These latches offer the ability to reach out and draw down on the latch pin. The final air seal for the door is via a pump-up door seal, this is common to both models. The difference is in the method of pumping up the seal. The standard IV uses a simple hand pump while the P model uses an automatic, electric air pump. (The electric air pump is also available as an option on standard Lancair IV's.) Lancair IV door Figure 28 Hinges Gas strut Luncuir Internnlicnal Inc,, Represented by Neico Aviation Inc., Copyright 101994, Redmond, OR 97756 2. CONSTRUCTION A LOWERDOORFRAME Al. Cleco the top half of the fuselage in place. It is necessary to have the top half of the fuselage clecoed firmly in place for the door installation to ensure a good fit. It may be a good idea to install another cleco on each side of the door if you have not already done so. Trimming Fuselage Joggle Fig1.u:e 28:A:l Initially trim joggle to 1 1/4" Loncnir fotill'nnUonul Inc,, Rcprcsc.nled by Ncico Aviation Inc., Copyrighl 101994, Redmond, OR 97766 A2. Trim the fuselage joggle in the door area to 11/4". Eventually the joggle will be trimmed down to approximately l". Do not trim the upper part by the hinges. The joggle on the upper part will end up being approximately 2" wide. _J 6" Alignment Holes Figure 28:A:2 07'' 1.2" 6" L A3. Drill two 1/8" diameter reference holes in the joggle as shown in Figure 28:A:2. These holes will be used for aligning the door frame. Lunc:uirlnlt!rnnlionnl Inc,, Rcprcscnlcd by Ncic:o Avinlion Inc., Copyright li!I 1994, Redmond, OR 97756 I I I I I I I I I I I I Aligning the Door Frame Figure 28:A:3 Alignment hole - _j~FWD Align the door frame to the alignment holes Armrest I I t \:::_::_:::_-::-=::2~-=-=-=-=-::-:::-::_:-:_::_::--:_::_::--:_::_=_:--_-___:__:::_:::::_:::..._-._"'-""co----_-__)_) I ---------- I ------ -------- _______ .,,' Joggle shown in solid line JDoor frame shown in dashed line A4. Temporarily install the lower door frame. Align the lower edge of the door frame to the two holes you drilled in step A3. Center the door frame (fore and aft) in the door opening for now. In order for the door frame to fit flush against the inside of the joggle, you will have to trim the door frame where it bumps against the core in the fuselage. Note that the frame has a beveled section along the bottom, where it mates up to the lower fslg. The nearly level, inbd portion of this area will later serve as part of the arm rest as well. Lancnir Inlcrnntionul Inc., Ileprcscnlcd by Ncieo Aviation Jne,, Copyright 101994, Redmond, OR 97756 Alignment Blocks Figure 28:A:4 Alignment Blocks at Lower Edge of Door Armrest Alignment Blocks Along Sides of Door Trim this corner of the block as necessary. The idea is to get a 1/2" gap at the door seal location. The joggle will be trimmed flush with the door frame later Joggle I Door frame 1/Z' wood align- ment block A5. Supergl ue 1/2" wood blocks every 6-8 inches along the outside of the door frame. The purpose of the blocks is to provide a 1/2" gap for the door seal. Along the sides of the door, the door frame and door stiffener are very close to parallel. Note that along the lower of the edge of the door, the door stiffener and the door frame come together at different angles as shown above. Shape the wood blocks at the lower edge of the door so that there is a 1/2" gap a the widest portion. Remember that the gap must be at least 1/2" for the door seal to fit and that the door seal will inflate up to 3/4". An easy way to check your gap is to stick play-dough in the gaps. The door seal in the inflated condition will conform to the different angles of the door stiffener the door frame. You may find it helpful to skim through the section on the door seal. Note that your door stiffener may not fit into the joggles as shown above. A later step will describe how to trim the door stiffener. Lanmir Int.ern.ational Inc:., Rilpre111nLed by Neieo Aviation Inc:., CopyrigM C 1994, Redmond. OR 97766 Aligning the Door Stiffener Figure 28:A:5 Door stiffener Wood alignment block Door frame A6. Align the door stiffener. From step A5 you know how to align the lower section of the door stiffener. Center the door stiffener fore and aft in the door opening. A7. Push the fore and aft sides of door frame in until they touch the wood alignment blocks on the door stiffener. Cleco the door frame in place when you are satisfied with the alignment. AB. Glue 1/2" wood alignment blocks on the outside of the upper door frame just as you did on the lower door frame. A9. Trial fit the upper door frame. The alignment should be obvious: the hinge pockets should align with the hinge mounting pads in the fuselage and align to the wood alignment blocks. The upper door frame will fit on top of the lower door frame. Adjust the lower door frame if necessary. AlO. Trim the door stiffener to fit into the joggle. The easiest method to do initial trimming of the door stiffener is as follows: 1. Draw a line 1" outside of the joggle on the fuselage. 2. Position the stiffener into the fuselage in between the wood alignment blocks. 3. Measure back 1" from the line onto the stiffener and draw a line. 4. Trim the door stiffener to this line. Lnncnir InlcrnnUonul Inc., Represcmtcd by Neico Avialion Inc., Copyright !l!l 1994, Redmond, OR 97756 All. Starting at the bottom. re-check the gap between the door frame and the door stiffener. Drill holes for clecoes or equivalent to hold the door frame and the stiffener in place. (You can also use #6-32 screws with corresponding washers and nuts). In some places you may find the clecoes to be too short. Use bolts at these locations. As you near the top, keep checking the gap between the door frame and or stiffener. Realign the stiffener and door frame if necessary. Note: The door the stiffener will seem to "grow" as you near the top. Reposition the upper door frame section to match the door stiffener as necessary. Cleco Alignment Holes for Door Frame Fig. 28:A:6 Al2. When you are satisfied with the alignment. remove the door stiffener. The door stiffener does not need to be in place for gluing the door frame in place. Lancnir International Inc.,Rcprcsenlcd by Ncico Aviation Inc., Copyright il:11994, Redmond, OH 97756 A13. Remove the door frame (upper and lower) and the door stiffener. A14. Using 40 grit sandpaper. thoroughly sand all bonding areas on the top half of the fuselage and the door frame and clean with MC. A15. Apply release tape to the bottom half of the fuselage where the door frame and fuselage contact. (You will bond this portion permanently when the two fuselage halves are glued together). You should deco or screw the lower part of the door frame in place to assure that it makes contact with the fuselage bottom during the bonding process. A16. Apply a thin coat of Hysol™ to the door frame and top half of fuselage in the bonding areas. Al 7. Add 10% flox to your Hysol™. Using the Hysol™ /flox mixture, spread it evenly onto the fuselage bonding area or the door frame. You should have a good idea of how much Hysol/flox is required to fill any gaps. It is best to spread the Hysol/ Floxmixturein a "V" shape as you did on the capstrips to avoid bubbles. The upper door frame is bonded on top of the lower door frame so make sure you have adequate adhesive on the bonding surfaces. A18. Position the door frame in place using the alignment holes as shown in Figure 28:A:5. A19. Bond the lower door frame in place. Align using the alignment holes you pre- viously drilled. A20. Bond the upper door frame in place. A21. Fill the "step" between the lower and upper door frame pieces with micro to allow for a smooth transition. This is necessary to allow for a good seal. A22. Now that you have bonded the door frame you can trim the door joggle flush with the door frame. Lnncuir Intcrnntional Inc,, llilprcscntcd by Nc!co Aviation Inc., CopyrighL iI!l 1994, Redmond, OR 97756 B. DOORSKIN The door skin should be trimmed to size so as to fit into the fslgjoggle. You'll note that the joggle appears too deep for the door skin, this is due to the fact that the joggle must also accept the door stiffener. When these two are bonded together, the joggle will be filled. The hinges are set into the deep joggles on the fslg top. These two joggles must be parallel to each other, if not, a bind will occur when the door is opened. The hinges mount on the top, outside of the fslg and under the door skin and stiffener. Door Skin Fig.28:B:1 Trim door skin to fit in the joggled area Bl. Trim the door skin, sizing it to fit inside the door/fslg joggle using the same method as you did with the door stiffener, This will surely be a back and forth fit, typically requiring at least three sessions to get it just right. You may use the door stiffener you already trimmed as an initial guide, but make sure you do not take too much material offi Since the fslg joggle is deeper than just the door skin, you must place some shims on the joggle to elevate the skin. You must do this in order to achieve an accurate fit. An even 0.07" gap will allow for paint and slight movements. Lancair lnternotlomtl Ine., Rc,prellllnted by Noh:11 Avial.ion Inc., Copyright C 1994, Redmond, OR 97756 B2. Trim the door stiffener to fit the core in the door skin. You will most likely have to trim the lower side of the door stiffener to fit the door skin. B3. Place the door stiffener back into the joggle. The wood alignment blocks should still be superglued to the door frame so you can double check your alignment. B4. Place the door skin back in place (on top of the door stiffener). Stick tongue de- pressors in the gap along the perimeter to get an even gap. Door Skin, Door Stiffener, and Joggle Alignment Holes Fig. 28:B:2 -- - . Using the pre-existing holes in the door frame and joggle, drill through the door skin from the inside. B5. Drill #23 C0.154" dia.) holes every 3" through the door skin. door stiffener. and ioggl e in the fuselage. You should use the pre-existing holes you drilled through the door frame and the joggle. Start at the bottom and work your way up both sides at the same time. The #23 holes are for #6-32 screws (and corresponding washers and nuts) from the hardware store. but you can use whatever works. Use more screws where required. Secure each bolt before proceeding to the next hole. Lnncair lnlemalionnl Inc., RcpreliCnlcd by Ncico Avinlion Inc., Copyright e 1994, Redmond, OR 97766 C. DOOR WINDOW The window hole size is determined by the latch pockets in the door stiffener. It is aligned vertically using the windshield and the aft left window. Do not trim to the scribe lines on the door skin (they are only used to determine the shape). The initial part of this chapter is done with the door and stiffener still bolted to the fuselage. You will initially draw the outline of the window hole on the outside of the door skin. Then you will remove the door skin and fit the window. You will then glue it in and bolt the door skin (with the window) to the fuselage to cure. You should read through this whole section and plan the bonding process. Door Window Location Figure 28:C:1 .,,.-;=.-_-.::.::------- - ... , ) /,' ,','~ JI I .,. I / 1 / I I • • I , Door wmdow .' ,I ; I I I/ / / I I '--------- I , / I 1 / I \ 1 I I ~ I I • I I { I I ,~----- ~::.:~~===-=---~-) Door stiffener outline Cl. On the outside of the door skin, mark the location of the inside edges of the latch pockets by the window as shown, The window hole is cut flush up against the innermost latch pockets. You need to check for this on both the forward and aft edge of the door hole. C2. Starting at your marks from step Cl. draw a line parallel to the scribe line. The line will most likely be on the inside on the scribe lines (so the window hole will be a little smaller than shown by the scribe lines) . Lllncnir lnlcrnoUannl Inc., Represented by Nllico Aviullon Im:., CopyrighL 1!!11994, Redmond, OR 97756 Window Hole Location Figure 28:C:2 ----------------- ) The lower edge of the door window should follow the lines of the aft window and the windshield C3. Draw a line that follows the lines of the lower edge of the aft window and the windshield. The lower edge of the door window should follow the lines of the aft window and the windshield. The scribe line should be of good help to determine the shape even though it may not be at the correct location. Stand back and see if your line looks right. C4. Draw a line at the top scribe line. Stand back and see if this looks right: does the line you.just marked look like it would intersect that of the top edge of the rear window? Adjust accordingly. You will connected these four lines with a radii in the corners later in this section. C5. Remove door skin and stiffener. Transfer the lines from the outside of the door skin to the inside. One method of accomplishing this is to drill a few 1/16" dia. holes along the lines. Then simply redraw the lines on the inside of the door skin. You will be using these lines in step C7 to ensure that you will have at least 2" of bonding area between the door window and the door skin. C6. On a table, place the door skin with the inside facing up. Find something soft to lay the door skin and window on to prevent scratching the window. C7. Lay the window into the door skin. Using the line you drew in step C5, position the door skin so you have at least 2" of contact area between the door skin and the window. Warning: it is important that you have 2" of bonding area between the window and the door skin. Lnncnir Inlernnlional Inc., Reprencnled by Neico Avinlian Inc., Copyright «:l 1994, Redmond, OR 97766 CS. Connect the four lines you marked in steps C2-C4 with radii like on the scribe line. C9. Trim the door skin flush to this line. Double check that you have at least 2" of bonding area between the door skin and the door window. If you have more than 2" of bonding area between the door skin and the door window, you may trim the excess off the window. ClO. Bevel the window cutout as you did with the other window cutouts in Chapter 18. Cll. Drill 3/16" holes every 4" around the perimeter of the window (not through the window). Leave a 1/8" gap between the edge of the window and the bolt. This will allow the window to move to allow the door skin and window to conform to the top fuselage half during bonding. Install washers and nuts on each of the bolts. C12. Turn the door skin and frame over and draw a reference line on the window showing the edge of the cutout. Make another line 1/2" to the inside. This is the line you will remove the protective barrier up to. Cl3. Remove the window. C14. Remove the protective material on the bonding side up to the line you just drew. C15. Apply a layer of 3/4" wide electrical tape to the outer surface of the windows, covering the narrow clear areas between the protective barrier and the edges of the fuselage cutouts. The edge of the electrical tape should be held 1/8" short of the cutout edges. Cl6. Clean the bonding areas of the windows with isopropyl (rubbing) alcohol. When cleaning the bonding areas, use a soft cloth such as a T-shirt. Do not clean the edges. The edges may absorb the alcohol and cause crazing. Sand thoroughly so no "glossy" areas remain. Be careful while sanding up to the electrical tape edges not to damage the tape. C17. Using 40 grit sandpaper, sand the bonding areas on the door skin. Do not touch the sanded areas in order to keep them clean. Do not use alcohol or any other solvent on the windows after they have been sanded. Itis sufficient to simply blow them clean. Cl8. Glue tongue depressors in the door joggle to simulate the thickness of the door stiffener. Cl 9. Bond the window in with Hysol. As always, first apply a thin coat of pure Hysol™. Then mix a little flox in with the Hysol and apply the mix to the door skin in the bonding area. Snug up the clamping bolts just enough to hold the window in place. The bolts will be retightened after the door is back in place on the fuselage. Lnneair Intern1tlionnl Inc., Represented by Neico Avinlion Inc., Copyright© 1994, Redmond, OR 97766 020. Bolt the door skin (with the window in it) to the fuselage. This is where you'll need an extra hand to help you tighten the bolts. Make sure you can get out of the fuselage after you are done! You can either exit through the baggage door or the landing gear cutout. 021. Tighten the bolts enough to get a good sgueezeout from the Hysol. Do not tighten them too much or the bonding surfaces will separate. Door stiffener _... Door skin-/ Checking Door Stiffener Fit Fig. 28:C:3 4 BIDE glass Door window Protective barrier Electrical tape 022. Check door stiffener fit. You may need to shave a little of the window. Refer to Figure 28:C:3. 023. Secure the window with 4" wide 4 BID. Note that the 4 BID reinforcement extends all the way to the edge of the door. Ltmcnir Inlernntionnl Iru:,,Represenled by Neico Aviation Inc., Copyright© 1994, Redmond, OR 97756 6 BID Carbon Reinforcement on Door Fig. 28:C:4 ( ~-----.,L.:___:Th=e~aft=·.::side reinforcement extends up to the upper part of 6BID side reinforcement The aft side rein• forcement makes a butt joint with the lower 6 BID reinforcement. The reinforcments must not extend onto door skin and stiffener bonding area. the core area in door. Lower6BID reinforcement Extend the lower reinforcement up to the lower edge of the core area in the door. C24. Apply a 6 BID carbon stiffener as shown in Figure 28:C:4. A 6 BID reinforcement at a 45° weave bias is required along the bottom edge of the door and along the aft side. The BID is applied flush up against where the fuselage joggle and the door make contact. 1. The lower reinforcement is approximately 4" wide and 31" long (measure the exact dimensions on your door. The width is governed by the location of the core (see the above figure). 2. The aft side reinforcement is approximately 34" long. The width is governed by your window and joggle location. Lnncnir lnhirnaliornLl Inc., Represented by Ncico Aviation Inc., Copyright 4' 1994, Redmond, OR 97756 D. DOOR STIFFENER In this section you will cut out the 7 latch access panels. You will then make flanges and install the nutplates. The door stiffener will then be bonded to the door skin. Latch Access Panels Figure 28:D:1 4.75" Dl. Cut the latch access panels in the door stiffener using the dimensions in Figure 28:D:1. You will note that some of the latch pockets do not have a dimension to the center. The center is at the widest part of these latch pockets. The cut along the sides should be 0.7" from the top of the radius. Use a rotary type cutter. Lanrair lnlernnllonul Inc., Rcpnrncmled by Ncico Aviution Inc., Copyright© 1994, Redmond, OR 97756 Access Panel Nutplate Locations Figure 28:D:2 ---- -----The 3 BID flange is 1/2" at nut- ", plate locations and 1/4" elsewhere '-. The lower aft left access panel requires a third nut- plate in this corner so make sure to leave enough flange. This nutplate is installed later. D2. Make 3 BID flanges for the access panels in the door stiffener. a). Cover the panels with release tape. b.) Tape the panels back into position in the door stiffener. c.) Lay a 3 BID flange onto the inside of the stiffener extending about 1/2" onto the piece that was cut out. This forms the joggled flange to hold the access panels. Note that you'll need a larger flange area for the lower aft access panel as shown in Figure 28:D:2. d.) After cure, remove the panels, trim the 3 BID flange down to about 1/4" except where nut plates are to be installed. At the nutplate locations leave 1/2". Lnncnir lntl!rnnUonul Inc., Rcprci;cnled by Ncico Aviation Inc., CopyrighL ,fl 1994, Redmond, OR 97760 Nutplate Installation Figure 28:D:3 AN 426AD3-8 rivets~ MS 24693-S28 screw '-- 3 BID flange Kl000-06 nutplate D3. Install the MS24693-828/826 screws with Kl000-06 nutplates as shown in Figure 28:D:3. You may also use the K2000-06- nutplates in tight places. D4. Place release tape around door frame joggle area. When you bond the door skin to its stiffener, excess adhesive will squeeze out around the door perimeter. You must be sure that this adhesive does not bond the door permanently closed! Simply lay some plastic release tape over the full fuselage door joggle. If you so choose, you could fit the stiffener pieces first, remove them and then apply this release tape. D5. Using 40 grit sandpaper. sand the bonding areas between the door stiffener and the door opening and clean with MC. Bonding Door Skin to Stiffener Figure 28:D:4 Door skin Align the door skin to the door frame using the alignment holes. Door stiffener should already be aligned in the door opening using the wood alignment blocks. Luncnir Intcrnntionnl Inc,,Rcprcscnlcd by NcicoAvinlion Inc., Copyright ICl 1994, Redmond, on 97756 D6. Check for a final time that you have the proper spacing between the door frame and the door stiffener. Ifyou removed the 1/2" wood spacer blocks you previously used to align the door frame, glue them back on. The most critical location is by the latches so make sure you have proper spacing at the latch pockets. The inflatable door seal and its mating piece require 0.4" minimum but it will inflate up to 3/4" if necessary. Should your previous alignment be off (if the holes you previously drilled don't line up) you should re-drill the holes. This is also a good time to check the gap along the rest of the perimeter of the door stiffener. When bonding the door stiffener to the door skin, remember to apply more adhesive to the areas with gaps between the door stiffener and the door skin. D7. Place the door stiffener back in the door opening. Using the holes you already drilled through the joggle, door stiffener, and the door skin. Stick a few bolts through from the inside through the joggle and the door stiffener. DS. Pre-install the door skin. This is a last check prior to bonding the skin to the stiffener and the time to drill for more of the temporary clamping bolts. If necessary, sand the mating surface of the stiffener to achieve a flat fit against the door skin. D9. Bond the door skin to the door stiffener with Hysol™. As always, first apply a thin coat of pure Hysol. Mix in 10% flox with the Hysol and apply a generous amount to the bonding areas. Carefully lay the door skin onto the door stiffener. Secure the door in place with all the bolts. Install more bolts if required. We prefer to install the bolts from the inside so that after cure, you can remove the nuts (on the outside) and knock the bolts through. Wipe off excess Hysol™. DlO. Mark the height of the door stiffener on the door frame. This is the height you will trim the door frame to later (you can of course trim the door frame with the door on if you think it is easier). Do not trim the arm rest or the top. The top will be trimmed after the overhead console is installed. Dll. Lift (or pry) the door loose from the release tape and sand to clean up excess adhesive, etc. Your door should now be in pretty good shape and fitting the fuselage joggle opening in the best possible manner. Dl2. Trim the door frame as described in step DlO. L_::C~A'_~=*=~=JA1.=.,=~=A=~=1n=®~W~~---__Jil 2s-;o ]i-.:C=h=a::,Pc..:~:.:~.:.ro-=!=sAND...L_F_S_L_G_C_L.::.Po-=cs-=~.::.2o.:...'u=s~-=1-=4....:-9:.:5_+!-~ Lancuir Intllrnulional Inc., Reprrumnted by Nnico Aviation Inc., Copyright© 1995, Redmond, OR 97756 E. HINGING THE DOOR Door Hinges Figure 28:E:1 Door Hinges (Part# DH34B) The deep binge joggles will be pretty close to parallel but you should establish this for certain. (Note that from initial appearance, these two deep joggle bases will look quite out of parallel, this is due to the curvature of the top fslg skin - the joggles really are quite close to parallel.) The easy method of establishing parallel door hinges is to make a simple fixture that establishes two in-plane pads, then place that on the joggles using a micro release to take up any discrepancies. Door Hinge Joggle Fixture Figure 28:E:2 27' 2" x 4" or equivalent -~ Note that the fixture extends past the hinges. This will help you align the hinges heightwise. E 1. Cut a hinge fixture from a piece of 2 x 4 or equiv. Anything similar will work fine provided the two bases (where the hinges locate) are parallel to each other. Note that the fixture extends a little forward and aft of the forward and aft hinges as shown in Figure 28:E:2. The purpose of this is so you can easily align the hinges heightwise. Cover the hinge pieces and the fixture base with release tape. This fixture is then used to set the pads. Using quick set glue, temporarily attach the hinges to the bottom of the wood fixture in the proper position. The three simple issues of alignment are: Lanc:air Int.crnathmnl Inc., RepreMlnt.ed by Neieo Aviation Inc., Copyright 0 1994, Redmond, OR 97756 1. The hinges must be "in plane" with each other. 2. The hinges must be aligned (fwd/aft) such that their hinge pin axes are concentric with each other. 3. The hinges must be spaced apart the correct distance to fit into the joggles. The hinges should be 20.5" apart but check this dimension with your joggles. 4. The hinges must be as far forward as possible to avoid a collision with the door stifner and the nuts will fit on the bolts. Note: Check the hinge alignment by simply connecting· the hinge sections which attach to the door skin using a flat piece of wood. Use superglue or bolts to secure the flat piece of wood. If the hinges rotate freely up and down, then their alignment has been achieved and you can continue with setting the micro pads in the fslg door hinge joggles. ·-, -~ / y-- 1 ~.✓'· Door Hinge Leveling Pad Figure 28:E:3 Hinge pocket [" I ,- I INBD E2. Set the fslg door hinge joggle pads. Release tape the hinges. Prep the joggles on the fslg top and place an epoxy-flox pad on the joggle. Carefully lay the hinge fixture assembly onto the pad and press it down until the door hinge fixture makes contact with the fuselage. This will correspond to where the fwd edge of the fwd hinge and aft edge of the aft hinge become flush to the surface of the top fslg. (The other side of the hinge will be below the surface which is normal.) Lom:air Inh:rnntionnl Inc., Represented by Neko Aviation Inc., Copyright C 1994, Redmond, OR 97766 The thicker portion of the hinge, that with the pivot pin in it, should be just off the edge of the step on the fslg joggle. Note: For cosmetic reasons, we typically fill the large lightening hole with micro. And we do not recommend that you fill over this hinge piece with micro since the hinge will be installed and removed several times. When it's all completed, that contour disparity with the fuselage looks quite acceptable. Bolting door hinges to fslg Figure 28:E:4 MS24694-S54 screws Door hinge ~==-==.:::....-----/ 0 '. Door frame NOTE: THE HINGE PINS NEED TO BE INSPECTED AND POSSIBLY RE- PLACED EVERY YEAR. PLEASE ALLOW FOR TIITS MAINTENANCE IN INSTALLATION. E3. Bolt the hinge section (fuselage side) into position. After the micro pad cures, use MS24694-S54 countersunk screws with AN365- 1032A lock nuts and a washer (AN960-8) from the under side. Once again, be sure the hinge pins are aligned concentric with each other before you set the attachment screws. Elevating Door Hinges Figure 28:E:5 Prop the hinge up with tongue depressors or equivalent Lancnir InternutiDnal Inc., Represented by Neico Aviation Inc., Copyright ID 1994, Reclmontl, OR 97756 E4. Attach the door to the hinges. This is a multi step process and it's helpful to have someone to briefly lend a hand. a.) Prop up the door hinge section so that it is up to the surface of the fuselage joggle. Use tongue depressors or equivalent. Note that one side of the hinge section will be below the joggle. b.) Add a micro pad on top of the hinge section to fill the area between hinge and the upcoming door skin. Cover the hinge with plastic tape so that the micro will stick to the door, not the hinge. c.) Place the door into position on the fuselage and set the clamping bolts if necessary to hold it in place while the micro cures. Door skin MS24694-56 Bolting Door Hinge to Door Skin Figure 28:E:6 Door frame 000 0 0 A/CFWD ~cnldI Micro pad MS24694-57 MS24694-S57-- 000 0 0 Lnncair lntcrnnlionnl Inc:., Represented by NcicoAvinlion Inc., Copyright ID 1994, Redmond, OR 97756 I 11 MS 24694-56 E5. Drill the door hinge attach screw holes. With the micro cured on the door hinges, carefully lift the door while the hinges are temporarily stuck in place. You must be very careful to not break loose the micro from the hinge piece. (This is where some help is required.) Using a #12 bit, drill through one hole on each hinge piece and set the machine screw (or any bolt to hold it). With one screw or bolt temporarily securing each hinge piece, one can relax a little as you drill the remaining three holes in each hinge piece. After the holes are drilled, the door surface side will have to be 100° counter- sunk to accept the machine screws. Use: MS24694-856 screws (long) MS24694-855 screws (short) to attach the hinge with AN365-1032 lock nuts. (Note: screw lengths could vary depending on the thickness of your micro pad. If you need a different length screw(s), please contact one of our service represen- tatives.) Also, do not yet permanently install the door, you'll need it off for additional installations processes.) Lnncnir lnlcrnntionnl Inc., Represenled by NeicoAvialion Inc., Copyrighl li!I 199'1, Redmond, OR 97756 F. GAS STRUT INSTALLATION The gas strut installs at the upper rear portion of the door. Note that this strut must be positioned with the shaft side facing down. In this position, it will self dampen at the end of the opening stroke and prevent any "banging" as the door reaches its full up and open position. Door strut 28:F:1 ' I I Door strut attach i \' 1•◄ --Door bracket '.ii 1\ ,1, ,1! I -----~-- IJ . - -.-- ' If I !/ Lancair lnlernationul Inc,, Rcpreimnted by Neico Avintion inc., Copyright 101994, Redmond, OR 97756 Door Strut/ Door Attach Bracket Figure 28 :F:2 , - , . ... ' .•. I ./ / / ~ Door stiffener /, ✓ ,::.:.:::::--.::~, + i, ' 'Door stiffener__..,; ~' 'I \ ' 'I r , , I I '' 'I _____ )) ----·- \ '·".::-::--------1.---~_j_ ---------- 1/8" phenolic ~ 1.5" PH-125x3x3 ~ I 3BIDon each side 1" ~ Door stiffener Luncnir Inlcmntionnl Im:., Rcproetmled by Neico Aviation Im:,, CopYright © 1994, Redmond, OR 97756 .\ I Door Strut/ Fuselage Attach Bracket Figure 28:F:3 - 71/2" t Gas strut Max. extension (door open): 20" Min. extension (door closed): 11.&: Slight scollop /-"' in frame \ \ Fl. Make and install the door strut/fuselage attach bracket. You have been supplied with a 1/8" x 3" x 3" piece of phenolic which will be fitted and attached with 3 BID on each side. Cut the phenolic piece to fit against the inner door skin, butted against the stiffener. The bracket will be located 1 1/2" forward of the door stiffener as shown. Install the bracket using epoxy/flax with a couple of dabs of quick set glue in the corners to hold it firmly. Apply the 3 BID to each side, extending about 1" onto the door surfaces and all across the bracket surfaces. When cured, drill the 5/16" dia. hole to attach the gas strut. See Figure 28:F:2 for dimensions. Lancnir International Im:., Rcpreacntcd by Ncieo Aviation Im., Copyrighl © 1994, Redmond, OR 97756 Approx. 11/4'' Door strul/fslg bracket, position Figure 28:F:4 Door strut/ fuslg. bracket Door frame ----1- VERTICAL F2. Make and install the door strul/fslg attach bracket. This is also a simple, 1/8" phenolic piece which is installed using 3 BID on each side. Trim the phenolic bracket to size (adjust as necessary to fit well against your fuselage. Note that the bracket is mounted vertically. When installing, it is a good idea to use quick set glue to temporarily hold this bTacket in place. F3. DOOR GAS STRUT DIMENSIONS (lengths available): Maximum 20" Minimum 11.8" The door will be fully open when the dimension reaches 20". The minimum dimension available from the strut is 11.8", anything less will bottom out the strut and create a jam thus not allowing the door to close. Luncuir Intcrnationul Inc., Represented by Noko Avinlion Inc., Copyrighl © 1994, Redmond, OR 97766 F4. From the open position, move your door slowly closed and verify that the minimum dimension is not less than what is available from the gas strut. Adjust the bracket on the fuselage if necessary. NOTE: For best strut position (in the cabin) when the door is closed, the fslg bracket should be located such that the strut does compress to within 1/8" of its minimum dimension. This will raise the strut Note that the door frame will require a mild "scallop" shape cut out ofit for clearance of the gas strut shaft when it transitions through its upper, near fully extended positions. Door gas strut installation Figure 28:F:5 PC480-2 Ball stud Door \ bracket PH-125~3 ~,..P iW/2300-90 Locknut ~UP FWD W/2300-90 Locknut \ //11) r:P' Fuselage / bracket PC480-2 Ball stud Attaching the door gas strut. The gas strut should be attached as follows: a.) The upper strut pivot fitting installed facing aft on the door. b.) The lower strut pivot fitting installed facing fwd on the fslg bracket. c.) The strut aligned with the shaft down and body up. Note: that it is not necessary to permanently install the strut yet as the door will be removed for latch installations, etc. Note: You should always insert the "keepers" on the strut ends during any operation since the strut could pop off otherwise. L~C2';~~~~~~fl~=1,.~"'~~~,.~~=!B=-®--=W~~----J1·1;s_3;·····•·1f-c_h_a_,p'=i~~,..,~,.,~=--sAND7'c-cR=E-=•;=,~"'L-=a=-c=L=-Po=cs""7E=/o-=-6u=•l=;--9'--4--1-f-¾CH L11nmir Intemnlionnl Ini:,, Reprcncntcd by N11ko Avfolion Inc., Copyright© 1994, Redmond, OR 97756 G. DOOR LATCHES Before you install the door latches, the simple process of installing the fuselage top must be completed. You should already have the top positioned and have a good fit of the fuselage top. Prior to installing the top we suggest that you complete the following steps: 1. Install the overhead duct as described in section L of this chapter. 2. Install the flange for the aft pressure bulkhead as described in a later Chapter. (Both the overhead duct and the flange for the aft pressure bulkhead may be installed with the top on should you want to wait). Installing the Fuselage Top Figure 28:G:a Fuselage bottom Lancnir Inlcrm1tional Inc., Represented by NeiroAvintion Inc., Copyright. lfl 1991, Redmond, OR 97766 Fuselage top G 1. Prep all bonding areas. The bonding areas include: 1. The joggles between the fuselage bottom and top. 2. The joggles between the fuselage top and the vertical stabilizer. 3. The bonding areas between the lower part of the door frame and the fuselage bottom. 4. The section on top of the firewall and where it makes contact with the fuselage. G2. It is a good idea to practice closing the fuselage before the real thing. If you just drop the fuselage down in place, you may have a problem with the adhe- sive being scraped off. Practice lowering the fuselage top in place by pulling the sides out some so that the joggles will make direct contact. Make sure you have enough help to accomplish this successfully. Inspect all bonding areas for gaps. Install more screws or clecoes as required. NOTE: Ifyou already installed the firewall blanket, pull it back and scrape off the silicon for the 2 BID. (Refer to Figure 28:G:b) G3. Apply a thin coat of pure Hysol™ to all bonding areas. Mix in flox with the remainder of the Hysol and apply it to the bonding areas where you already applied the pure Hysol. You will need to fill the core on top of the firewall. Build up a 1/8" tall "V" shape with the Hysol. G4. Lower the fuselage top onto the fuselage bottom and cleco or screw it in place. Ideally you should pull the sides of the fuselage out to make direct contact onto the adhesive. You can not just drop the fuselage in place as you normally would as this tends to scrape off the adhesive. Make sure you have a good squeezeout along the joggles. Larn:air International Inc.,Rcprei;entcd by Ncico Aviation Inc,, Copyright 01994, Redmond, OR 97756 Flush2 BID here BID Reinforcements Securing Fuselage Top Figure 28:G:b u [ Extend 11/211 ------►/ D-./1 onto the firewall FWD ... 4 11 wide4BID Fuselage top 2"wide3BID Fuselage top +hJJJ;;~;:-::.:===~~F~•o;r~w:;:a~r~d~•:e:ction of vertical stab \ -~111/ 211 wide 3 BID frt ~FWD G5. Apply BID reinforcements as shown in Figure 28:G:b. In summary: 1. Apply a 2" wide 3 BID to the joints between the fuselage top and bottom and to the joint between the fuselage top and the vertical stabilizer. 2. Apply a 4" wide 4 BID to secure the fuselage top to the firewall. Extend this reinforcement 2" onto the fuselage bottom. Also add a 2 BID onto the forward side of the firewall as shown. Lnncuir Intcrnntlonnl Inc,, Rcprcimnted by Ncico Aviation Inc., Copyright I!!> 1994, Redmond, OR 97766 G6. On the outside of the fuselag:e. fill the g:ap top with micro. between the fuselag:e bottom and The reinforce- ment extends 1 1/2"onto the door frame and the stiffener 6BID carbon reinforcements 6 BID Carbon Reinforc Fig. 28:G:c FWD Armrest 10" J_ ement in Fuselage of the do Qr opening: and onto the door G7. Apply 6 BID reinforcements to the aft side frame and stiffener as shown in Figure 28 E-glass stiffener as shown. The 6 BID wi beneath the door frame. Also apply a 6 BID After you prepare all bonding surfaces supe :G:c. Superglue a 10" x 11/2" 2 BID 'll extend onto the E-glass stiffener to the forward side of the stiffener. rglue the 2 BID E-glass stiffener in place. " wide and 34" long. It extends 10" The aft 6 BID reinforcement itself is 4 1/2 beneath the door opening. The BID will ex the stiffener. The forward 6 BID reinforcem the door stiffener and 3" forward ofit. tend 11/2" onto the door frame and ent is 10" long and extends 11/2" onto GS. After cure. g:rind the flang:e for control pus hrod clearance, Chapter 28 I REV. PC6 / 5-1-94 DOOR AND FSLG CLOSEOUT Lnm:air Inlcrnntionnl Im:,, Represented by Ncieo Aviation In~., Copyright© 1991, Redmond, OR 97756 ~ )O' )0, Phenolic guide <I') (11) I O> ii~ I Mounting srews El, ® Typical Door Latch System Figure 28:G:1 11 '-. / ,/,,--:::.-·~ .... • 6 I ! L@) ✓ '-.... .... '-.... .... -4--Hook (315-01) .. i .. I I !A ◄ 1 Roller and roller pin ◄ Anchor (315-02) I II I I ~-◄- 1I n ' ◄◄11-- Anchor acljustor bolt (AN4-4A) n Anchor acljustor plate (315-05) Mounting screws :, The latches will surely be a lot of fun, they always are with any door! The latch system developed for the Lancair IV's was designed, by the motion of the latch its elf, to reach out and pull down thus helping to achieve a better fit. The standard Lancair IV simply uses two of the latch body assemblies at the bottom of the door frame actuated by one handle. The IV-Pmodel uses more latches and two handles due to the rigorous demands of a pressurized cabin. There are three latches on the lower edge operated by the same handle. There are three more latches on the aft side and two on the forward side operated by the same handle. Lancair International Inc., Represented by Neico Avlnlion Inc., Copyright O 1994, Redmond, OR 97756 G9. Assemble the latches. These assemblies swing the hook through a 90° plane, draw down and achieve an "over-center" selflocking condition. They should be smooth operating with very little drag when properly assembled. Look for any burrs etc. in the laser cut pieces. Hand file and smooth as necessary. Five of the eight latches are identical while the three others are similar. The differences are explained in the assembly instructions. Attaching the Clevis to the Links Figure 28G:2:a @Jl)+-c1evis (315-04) ~,..__Clevis pin (315-08) < !>Links (315-03) ~ a.) Press the small pins into the ends of the clevis, they must be centered on the clevis tab end. The vise is handy for this purpose. Insert a link on each side as shown. Insert the Assembly in the Hook Figure 28G:2:b r Insert the link/clevis into the hook 0 Insert the hook into the latch housing ~ 0 The holes through the latch housing, hook, and the clevis must align. ®,._ Cir-clip ~Latch housing * __ Clevis, links and hook ----Clevis pin _,.-Cir-clip washer (315-12) Cir-clip {RR-03) L__<-_> __i_~ __,._.._.,~_~_-_.i_~_'D_®_W_-"- _____,J![~~:~~ ]f-C.::.h:.....:..:a,:,pD.::.t~:..~-c-2=:C..AND,L,,RE,c-c•;cc~=~-cGc-ccCL=-4-=~1-=so=~,'c~4-=UT=---+-f--¾'--li Lancuir Intcrnallonal Inc., Represented by Ncico Aviation Inc., Copyright II:l 1994, Redmond, OR 97756 b.) Insert link/clevis assembly into the hook. Then insert this assembly into the latch housing. You will need to align the hole that goes through the hook and clevis with the slot in the latch housing. We find the easiest way to accomplish this is to lay the assembly on its side. Then take a wire and align all the holes. Next insert the clevis pin. You will need a cir-clip washer on each side of the latch housing. Notice that the bevelled edge of the washer faces the latch housing. Attach a cir-clip on each side. Drive Pin Installation (5) Figure 28:G:2c Drill for and install the spiral pin (RP-01) here Add washers (AN960-516L) between the latch housing and the hook as necessary 0 = Drive pin c.) This is where the latches differ. Five of the eight latches are identical and use drive pins while the other three use AN5-33A bolts. The purpose of the bolts is for emergency door openings which will be fully explained in the emergency procedures of the operating handbook. You will complete assembling the five identical latches first. Assemble 5 of the latches as follows: 1. If necessary, insert AN960-516L washers on each side in between the latch housing and the hook on each side. 2. Center the drive pin through the hole in the latch housing. 3. Using the hole in the clevis as a guide, drill a# 41 size hole through the center of the drive pin. Insert the RP-01 spiral pin. Lancnir Inlemntional Inc., Re1misenled by Neko Avintion Inc., Copyright(!} 1995, Redmond, OR 97756 1. Drive Pin Installation Figure 28:G:2d - AN5-33A boll ill, drill iral pins Using#41 dr holes for sp (RP-01) Drill 118" hole through sprocket for spiral pins (RP-02) Leave enough sprocket for t room between bolt head and the chain 2. he 1/411 thick phenolic/ orkot guide AN5-33A bolt -l~ll: cation of phenolic/orkot guide ·ocket #25B11A 0 3. 1/32" gap Note: Cut the threads of the bolts so you Extra long bolts have been provided. can install the flex shafts, d.) The remaining three latches all use AN pin but they are installed slightly different latches, install the AN960-516L washer 5-33A bolts in place of the drive in each one. As with the other 5 s as required. ert a chain sprocket on an AN5-33A 1. Assemble 1 of the latches as follows: ins bolt. Insert the bolt/sprocket through the 1 your latch assembly oriented correctly will need roughly 1/32" (the thickness of an the sprocket and the latch housing. Make atch housing. Make sure you have as shown in Figure 28:G:2d. You AN960-516L washer) gap between sure there is room for the phenolic Chapter28 I PCll I 3-22-95 DOOR AND FSLG CLOSEOUT Lancair Jnternntional Inc., Re11resented by Neico Avintion Inc., Copyright© 1994, Redmond, OR 977!i6 ~ >o< ~