Chapter 13: Firewalls Forward (Part 1)

Nose Gear Brace Mounting Holes ......................................................................... 13-11 D. Nose Gear Installation ............................................................................................. 13-12 Left Side View ................................................................................................................ 13-13 E. Nose Wheel and Tire ............................................................................................... 13-15 F. Nose Gear Doors .................................................................................................... 13-17 G. Nose Gear Micro Switch ......................................................................................... 13-26 Nose Gear Down Switch ...................................................................................... 13-26 Chapter 13: Firewall Forward Chapter 13 REV. 0/02-15-02 FIREWALL FORWARD (Part 1) 13-2 Lancair International Inc., Represented by Neico Aviation Inc., Copyright © 2008 , Redmond, OR 97756 Note: Optional Parts available through : (*) Lancair Avionics (**) Kit Components, Inc. # PART NO. (P/N) QTY DESCRIPTION OPTIONAL ITEM (not included with kit) 550/540 - NOSE GEAR INSTALLATION 1) 4701 1 Nose Gear w/ Fork and Bushing (or alternative part 432-0005) 2) 4717-01 1 Nose Gear Bearing Block, Left 3) 4717-02 1 Nose Gear Bearing Block, Right 4) 433-0001 4721 2 Over-center Link Arms 5) 4722 2 Bushing 6) 4736 1 Nose Gear Ball Stud 7) F45-19 1 Bearing, Rod End 8) AN3-10A 3 Bolt,Undrilled 9) AN3-12A 4 Bolt, Undrilled 10) AN4-11A 4 Bolt, Undrilled (**Yes 2 with tow bar plate) 11) AN4-12A 9 Bolt, Undrilled (**Yes 2 with tow bar plate) 12) AN4-13A 2 Bolts, Undrilled (With Tow Bar Plate Option) **Yes 13) AN5-7 1 Bolt, Undrilled 14) AN5-41A 1 Bolt, Undrilled 15) 112-0026 6381K103 2 Bushing 16) RR-01 2 Circlip 17) 198-0004 9416K77 2 Clip, Safety 18) MS24665-140 3 Cotter Pin 19) HC-08 1 Hydraulic Cylinder, Nose Gear 20) AN363-1032 7 Lock Nut, All Metal 21) AN363-428A 2 Lock Nut, All Metal 22) AN363-524 2 Lock Nut, All Metal 23) AN365-428A 5 Nut, Nylock 24) AN310-5 3 Nut, Castle 25) AN316-5 1 Nut, Check 26) 198-0003 9416K71 2 Socket, Steel Ball 27) 160-0002 9416K15 1 Strut, Gas 28) 198-0006 9512K73 1 Stud, Ball 29) TB-1-03 1 Tow Bar Plate **Yes 30) TB-1 1 Tow Bar **Yes 31) AN960-10 20 Washer, Flat 32) AN960-10L 10 Washer, Flat 33) AN960-416 4 Washer, Flat 34) AN960-516 14 Washer, Flat 35) AN960-516L 10 Washer, Flat 36) 110-0002 4 Washer, Thrust 37 212-0073 2 Keeper Plate NOSE GEAR MICRO SWITCH 1) 1XE1-T 1 Micro Switch, Nose Gear 2) JM-1 1 Switch Arm # PART NO. (P/N) QTY DESCRIPTION OPTIONAL ITEM (not included with kit) NOSE WHEEL & TIRE 1) 4785 1 Anti-tube-pincher-dealTM 2) AN4-47A51A 1 Bolt, Undrilled 3) AN3-3A 4 Bolt, Undrilled 4) AN365-428A 5 Nut, Nylock 5) 430-0000 TR-5 x 8 PLY 1 Tire 6) TU-5.00-11 x 4 1 Tube 7) AN960-416 10 Washer, Flat 8) AN960-10 4 Washer, Flat 9) 59-3M-LA GM035-2 1 Wheel, Nose 10) Z02E276 1 Axle 11) GM038 1 Axle bushing NOSE GEAR DOORS (Obsolete parts were removed from this list due to space contraints.) 1) 6061-T6 6 ft 1 1/4” x 1 1/4” x 1/8” Gear Door Rails (approx. 36”) 2) GM318-01 2 Gear Door, Nose (approx. 35”) 3) GM320-36 2 Aluminum Gear Door Stiffener (34”) 4) MS20001 2 Hinge, Piano (34”) 5) 1 Phenolic crush plate, 3” x 1.125” 6) 240-0001 1 Nose gear door assembly 7) AN3-6A 1 Bolt, 10-32 x 25/32 8) AN960-10L 4 Washer, lite 3/16 9) HFC-3AU 12 Female rod ends 10) BJ-04 2 Rod ends 11) AN3-7A 7 Bolt 12) AN315-3 2 Checknuts 13) 209-0018 2 Bracket 14) AN3-10A 4 Bolt, Undrilled 15) AN5-20 2 Bolt, Drilled 16) AN363-1032 4 Nut, Lock (All metal) 17) AN365-1032A 142 Nut, Nylock 18) K1000-3 22 Nutplate 19) AN426A3-5 44 Rivet 20) AN426AD3-5 68 Rivet 21) MS24694-S48 22 Screw 22) MS24694-S50 4 Screw 23) AN526-1032R14 42 Screw, Washer Head 24) AN960-10 2314 Washer, Flat 25) CN614CR3P Nutplate 26) MS24694-S51 Screw, Machine 27) AN960-10L 3 Washer, Flat 8/09-01-14 Chapter 13 REV. 0/02-15-02 FIREWALL FORWARD (Part 1) 13-3 Lancair International Inc., Represented by Neico Aviation Inc., Copyright © 2000 , Redmond, OR 97756 3. CONSTRUCTION PROCEDURES A. Firewall Closeout Firewall Closeout Hardpoint Fig. 13:A:1 Bevel this corner to match the core. 5” 3” 5” 3” 1/4” phenolic Remove a 3” x 5” section of the aft laminate and core of the nose gear tunnel closeout. Install the piece of phenolic with epoxy/flox using proper bonding procedures. Apply 3 BID on ±45O extending 1” past the edge of the phenolic in all directions. 1” 1” The Phenolic must be thoroughly sanded prior to bonding! No shiny spots! Phenolic Block (PH-250-3x5). Chapter 13 REV. 0/02-15-02 FIREWALL FORWARD (Part 1) 13-4 Lancair International Inc., Represented by Neico Aviation Inc., Copyright © 2000 , Redmond, OR 97756 Firewall Closeout Fig. 13:A:2 A 1. Trim the nose gear tunnel closeout to fit the joggle on the firewall. A 2. Bond the nose gear tunnel closeout using epoxy/flox. Nose Gear Tunnel Closeout, 4023 Nose gear tunnel closeout joggle Chapter 13 REV. 0/02-15-02 FIREWALL FORWARD (Part 1) 13-5 Lancair International Inc., Represented by Neico Aviation Inc., Copyright © 2000 , Redmond, OR 97756 Firewall Flame Blanket General Overview Fig. 13:B:1 B. Firewall Flame Blanket The firewall flame blanket is composed of a silicon matrix with a ceramic weave and an aluminized surface. The blanket is premolded to the shape of the firewall. Note the preformed shape of the exhaust tunnels. There are four (4) hardpoints for the engine mount. Note that the Lycoming 540 installation has one additional hardpoint. In this chapter, you will reinforce this area of the firewall. There are four factory drilled engine mount holes on the Legacy firewall. 540 / 550 540 only 540 / 550 540 / 550 Hardpoint installed in firewall flame blanket Firewall flame blanket, FFB-002 540 / 550 540 / 550 Chapter 13 REV. 0/02-15-02 FIREWALL FORWARD (Part 1) 13-6 Lancair International Inc., Represented by Neico Aviation Inc., Copyright © 2000 , Redmond, OR 97756 Drilling Remaining Holes For Engine Mount Fig. 13:B:2 Holes #1-#4 are pre-drilled on the firewall. These holes are common to both the 540 and 550 installa- tions. Note that hole #5 is unique to the 540 installation. In this section you will drill for the nose gear brace holes and if you are installing the 540, you need to drill hole #5. B 1. Install the nose gear over center link weldment (4719) on the engine mount. Refer to Figure 13:D:1. The weldment must be installed prior to drilling the holes. B 2. Temporarily mount the engine mount to holes #1 - #4. Engine mount: Lycoming 540, P/N: 4861 Continental 550, P/N: 4860 (shown) B 3. Using a 1/4” diameter drill, drill the holes for nose gear brace and if installing the 540, drill hole #5. #1 #2 #3 #4 (540 only) #5 Nose Gear Brace Holes W A R N I N G The over center link weldment P/N 4719 must be installed prior to drilling the nose gear brace holes. Engine mount to firewall torque is 32 ft. lbs. 4/09-30-06 Chapter 13 REV. 0/02-15-02 FIREWALL FORWARD (Part 1) 13-7 Lancair International Inc., Represented by Neico Aviation Inc., Copyright © 2000 , Redmond, OR 97756 Firewall Reinforcements for 540 Installations only Fig. 13:B:3 Fwd A/C Up A/C CL B 4. Remove a 2” x 2” section of the aft laminate and core centered on the hole. This page is for Lycoming 540 installation only. B 5. Install a 2” x 2” x .250 piece of phenolic with epoxy/flox. B 7. Reinstall the engine mount and drill the center hole again. B 6. Additional engine mount for 540 installation, P/N 4070. Install with epoxy/flox. 4070 (l pc) Chapter 13 REV. 0/02-15-02 FIREWALL FORWARD (Part 1) 13-8 Lancair International Inc., Represented by Neico Aviation Inc., Copyright © 2000 , Redmond, OR 97756 Engine Mount Spacer Bonding Fig. 13:B:4 If you look on the aft side of the firewall flame blanket, you will notice seven areas with the insulation removed. To compensate for these recessed areas, we bond spacers to the firewall. B 8. Bond the phenolic spacers in place with epoxy/flox. This spacer is installed with 540 installations only. 2” dia. x 1/8” Thick phenolic B 9. Install the engine mount and observe the fit of the engine mount at the nose gear brace holes. If the fit is less than perfect, we suggest that you perform a release with epoxy/flox as shown on the left. Bond the spacer in place at the same time as you make the flox pad. Insert bolts through the holes of the engine mount to properly align the spacer. NOSE GEAR BRACE RELEASE Chapter 13 REV. 0/02-15-02 FIREWALL FORWARD (Part 1) 13-9 Lancair International Inc., Represented by Neico Aviation Inc., Copyright © 2000 , Redmond, OR 97756 Installing Firewall Flame Blanket Fig. 13:B:5 B 10. Prior to installing the firewall blanket, we suggest using a punch to create holes in the correct locations. B 11. Apply high temperature silicon (P/N: RTV-106) to the firewall. Apply additional silicon around the spaces. The four (4) bolts for nose gear brace are AN4’s. Apply a bead around the perimeter. A A AN7 bolt: 4 places for 550 installations 5 places for 540 installations Firewall flame blanket FFB-002 F i r e w a l l Apply a radius with high temperature silicon around the perimeter. TYPICAL CROSS SECTION AA ( Flame blanket installed ) Firewall flame blanket FFB-002 Outbd Fwd Insert bolts through all the holes and snug down while silicon cures. Chapter 13 REV. 0/02-15-02 FIREWALL FORWARD (Part 1) 13-10 Lancair International Inc., Represented by Neico Aviation Inc., Copyright © 2000 , Redmond, OR 97756 Note: # 5 hole only applies to 540 installations. Bolt AN7-25A (3 pcs.) Washer AN960-716 (5 pcs.) 540 Engine Mount, 4861 Nose Gear Brace Mounting Holes #1 #2 #5 #4 #3 540 Engine Mount Installation Fig. 13:C:1 C. Engine Mount Installation C 1. The four nose gear brace mounting holes are drilled by the builder. Engine Mount Holes #1 - 5 Lycoming 540 uses mount # 4861. Torque AN7 bolts to 37.5-41.2 ft-lb. (450-494.4 in-lb.) Torque AN4 bolts to 4.17-5.83 ft-lb. (50.04-69.96 in-lb.) Nose Gear Brace Mounting Holes Washer AN970-4 (4 pcs.) Locknut AN365-428A (4 pcs.) Bolt, AN4-10A (4 pcs.) (or AN4-11A, as necessary) Engine Mount Bolt AN7-13A (2 pcs.) Washer AN960-716 (5 pcs.) Washer, AN960-416 (4 pcs.) Bolt, AN7-25A (3 pcs) 540 Engine Mount, P/N: 4861 Firewall Flame Blanket FFB-002 Washer AN970-7 (5 pcs.) 1/09-18-02 4/09-30-06 Drill four nose gear brace mounting holes. Washer AN960-716 (5 pcs. as needed) Locknut AN365-720A (5 pcs.) Firewall Blanket Firewall Add one or two AN970-7 washers between the motor mount and the firewall. This will help prevent sag for fitting the cowling. Chapter 13 REV. 0/02-15-02 FIREWALL FORWARD (Part 1) 13-11 Lancair International Inc., Represented by Neico Aviation Inc., Copyright © 2000 , Redmond, OR 97756 Engine Mount Holes #1 - 4 Note: # 5 hole only applies to 540 installations. Bolt AN7-25A (2 pcs.) Washer AN960-716 (4 pcs.) 550 Engine Mount 4860 Nose Gear Brace Mounting Holes #1 #2 #4 #3 550 Engine Mount Installation Fig. 13:C:2 Nose Gear Brace Mounting Holes Washer AN970-4 (4 pcs.) Locknut AN365-428A (4 pcs.) Bolt AN4-10A (4 pcs.) (or AN4-11A, as neces- sary) Engine Mount Bolt AN7-15A 13A (2 pcs.) Washer AN960-716 (5 pcs.) Washer AN960-416 (4 pcs.) Bolt, AN7-25A (2 pcs) 550 Engine Mount, P/N: 4860 Firewall Flame Blanket FFB-002 Lycoming 550 uses mount # 4860. Torque AN7 bolts to 37.5-41.2 ft-lb. (450-494.4 in-lb.) Torque AN4 bolts to 4.17-5.83 ft-lb. (50.04-69.96 in-lb.) 1/09-18-02 C 1. The four nose gear brace mounting holes in the firewall are drilled by the builder. The actual nose gear brace is pre-drilled. 608-10-07 Drill four nose gear brace mounting holes in the firewall. The actual nose gear brace is already pre-drilled. Firewall Blanket Washer AN960-716 (5 pcs. as needed) Locknut AN365-720A (4 pcs.) Washer AN970-7 (4 pcs.) Firewall For the top bolts only (bolt hole positions #1 and #2 in this drawing): Add one or two AN970-7 washer between the motor mount and the firewall. This will help prevent sag for fitting the cowling. Chapter 13 REV. 0/02-15-02 FIREWALL FORWARD (Part 1) 13-12 Lancair International Inc., Represented by Neico Aviation Inc., Copyright © 2000 , Redmond, OR 97756 Nose Gear Assembly Exploded View Fig. 13:D:1 D. Nose Gear Installation D 1. Assemble!- Install the assembled linkage on the engine mount. Over-center link arms, 433-0001 4721 (2 pcs) Nose Gear, 4701 ( includes the fork ) Nose Gear Bearing Block, Left 4717-01 Circlip, RR-01 (2 pcs.) Bolt, AN4-12A Washer, AN960-416 (2 pcs.) Nose Gear Hydraulic Cylinder, HC-08 Check Nut, AN316-5 Bolt, AN5-7 Over Center Link Weldment, 4719 Bolt, AN5-41A Bolt,AN4-11A (2 pcs) Washer AN960-416 (2 pcs) Bolt, AN5-17 (2 pcs) Washer AN960-516 (2 pcs) Bushing 112-0026 Washer AN960-516 (2 pcs) Castle nut AN310-5 (2 pcs) Cotter Pin, MS24665-140 Cotter Pin MS24665-140 (2 pcs.) Castle Nut AN310-5 Washer, AN960-516L (2 pcs) Locknut AN363-524 Ball Stud 198-0006 9512K73 Install with Loctite. Steel Ball Socket 198-0003 9416K71 (2 pcs) Gas Strut, 160-0002 9416K15 Safety Clip 198-0004 9416K77 Washer, AN960-10 (4 pcs) Locknut AN365-428A (4 pcs) Fork Tow Bar Plate TB-1-03 Bushing, 4722 (2 pcs) Locknut AN363-428A (2 pcs) Ball Stud, Nose Gear 4736 Bolt, AN4-12A (4 pcs) (With the optional Tow Bar Plate, the front two bolts are AN4-13A). Rod End Bearing, F45-19 Nose Gear Bearing Block, Right, 4717-02 Nut, AN365-428A Insert Yoke here. Circlip, RR-01 Bolt, AN3-10A (3 pcs.) Bolt, AN3-12A (4 pcs.) AN960-10L (or AN960-10 as required) Lock Nut, AN363-1032 (7 pcs) Washer, AN960-516 Nut, AN363-524 Safety Clip 198-0004 9416K7 NOTE: 1. Ream the holes of the weldment as necessary using 1/4” and 5/16” reamers. 2. See Figure 13:D:2 for Retract Yoke Assembly Bushing supplied with nose gear strut 6/08-10-07 Bushing 112-0026 Thrust washers 110-0002 (2 pcs) Install one thrust washer on each side of bushing 112-0026. Chapter 13 REV. 0/02-15-02 FIREWALL FORWARD (Part 1) 13-13 Lancair International Inc., Represented by Neico Aviation Inc., Copyright © 2000 , Redmond, OR 97756 0° to 3° F I R E W A L L Aligning Nose Gear to Mounting Pads Fig. 13:D:2 Engine Mount Adjust as necessary to align over center link arms. It will align by itself if assembled. The airplane must be leveled properly to set the nose gear strut. If you did not build the aircraft alignment jig, level the airplane in a roll using the wing tips and in pitch using the canopy joggle. Use C-clamps to hold the nose gear in place. Adjust as necessary to set strut vertical. SMARTOOL 90O FRONT VIEW 4717-02, Bearing Block 4717-01, Bearing Block 1/09-18-02 D 3. Align the strut as shown in side view, top view and front view. Clamp as shown. Retract the gear to check for any binding. D 4. Once aligned, drill holes through the bearing blocks. Left Side View D 2. Adjust the rake of the nose gear between 0 to 3 degrees forward. There are a number of things to consider before final drilling of the gear bearing blocks. 1. The bearing block must align to the mating plates of the engine mount such that you get sufficient edge distance around the bolts. 2. Prior to drilling the bearing blocks, swing the gear and check for clearances! Pay particular attention to the clearance between the over center link weldment and the nose strut. Also check clear ance between the hydraulic cylinder and the over center link weldment. When you are satisfied that the mechanism clears and swings freely, you can drill for the bearing block. Note: Make all adjustments without the gas strut attached. 2/06-30-04 TOP VIEW Chapter 13 REV. 0/02-15-02 FIREWALL FORWARD (Part 1) 13-14 Lancair International Inc., Represented by Neico Aviation Inc., Copyright © 2000 , Redmond, OR 97756 Nose Gear Strut Installation Fig. 13:D:3 D 5. Install the nose gear strut as shown. Note the difference between left and right side (left side shown). Use washers between the nose gear bearing block and the mounting plate of the engine mounts required to fill the gap. These washers will basically fill the gaps and prevent you from bending the bearing blocks when tightening the bolts. The ball stud (P/N 4736) installs on the left side only. The stud is 5/16” in diameter so, drill only this hole out to 5/16”. All other holes are 3/16”. On the right side, replace this stud with an AN3-10A bolt. Bolts, AN3-12A (4 pcs.) Locknut, AN363-524 Washer, AN960-516 AN960-10L (or AN960-10 as required) AN960-516 (or 516L as required) Locknut, AN363-1032 Circlip Groove Nose Gear Strut Engine Mount Circlip, RR-01 Mounting Plate Gear Door Rail Nose Gear Bearing Block: Left Side 4717-01 Right Side 4717-02 Engine Mount Install washers between bearing block and gear door rail as required. Install washers between engine mount and bearing block as required. Bolts, AN3-10A (3 pcs.) 4 bolts are used on the left side and 3 bolts are used on the right side. AN960-10L (or AN960-10 as required) 6/08-10-07 Chapter 13 REV. 0/02-15-02 FIREWALL FORWARD (Part 1) 13-1 Lancair International Inc., Represented by Neico Aviation Inc., Copyright © 2008 , Redmond, OR 97756 14b 7/09-10-08 Alternative Nose Gear Installation Parts used for this alternative installation are the same as the parts used on the previous page. For greater detail, please refer to the previous page. Alternative Nose Gear Installation Fig. 13:D:1b Over-center link arms 433-0001 4721(2 pcs) Nose Gear, 432-0005 for the retractable gear* ( includes the fork ) Bolt, AN5-41A Washer, AN960-516 (2 pcs) Locknut, AN363-524 Washer, AN960-10 (4 pcs) Locknut, AN365-428A (4 pcs) Fork Tow Bar Plate TB-1-03 Bolt, AN4-12A (4 pcs) (With the optional Tow Bar Plate, the front two bolts are AN4-13A). Bushing supplied with nose gear strut Nose Gear, 432-0005 for the retractable gear* ( includes the fork ) * Note: The part number for the fixed gear’s nose gear is 432-0002. Chapter 13 REV. 0/02-15-02 FIREWALL FORWARD (Part 1) 13-15 Lancair International Inc., Represented by Neico Aviation Inc., Copyright © 2008 , Redmond, OR 97756 E. Nose Wheel and Tire Wheel Locknuts (3 pcs) Wheel Washers (3 pcs) Nose Wheel Assembly Fig. 13:E:1 Wheel Bolts Nose Wheel, GM035-2 (Matco)/ 59-3M-LA (Grove) Tube, TU-5.00-11 x 4 Tire, TR-5 x 8 PLY 430-0000 Nose Wheel, GM035-2 (Matco)/59-3M-LA (Grove) Wheel Washers (3 pcs) Wheel Bearing self sealing Washer, AN960-10 (4 pcs) Bolt, AN3-3A (4 pcs) Bolt, AN4-47A51A (1 pc) Washer, AN960-516416 (4 pcs) Nut, AN365-428A (1 pc) Nut, AN365-524A428A (4 pcs) Tow Bar Plate TB-1-05 (1 pc) Nose Gear Leg Bolt, AN5-11A AN4-12A (4 pcs) and Washer, AN960-516416 (4 pcs) With the optional Tow Bar Plate, the front two bolts need to be AN5-12A. AN4-13A. Fork Keeper plate (2 pcs) 212-0073 Washer, AN960-416 (1 pc) Axle Bushing (2 pcs) GM038 Washer, AN960-416 (1 pc) Fwd A/C Up Axle, Z02E276 Sleeve, 4798 Wheel/bearing assembly MATCO/Grove wheels 1/09-18-02 Wheel Bearing, self-sealing Wheel Race 8/09-01-14 Chapter 13 REV. 0/02-15-02 FIREWALL FORWARD (Part 1) 13-16 Lancair International Inc., Represented by Neico Aviation Inc., Copyright © 2008 , Redmond, OR 97756 Assembling Tire and Wheel Fig. 13:E:2 E 1. Insert the tube into the tire. Then inflate the tube with a small amount of air. E 2. Insert the tire and tube assembly into the rim half that has the passage for the valve stem. Pull the valve stem through. Apply Talcum Powder to the tube and inside the line. Apply a bead of silicon around the perimeter of the tire where it makes contact with the rims. Nose Wheel, GM035-2 (Matco)/59-3M-LA (Grove) Tube, TU-5.00-11 x 4 Tire, 430-0000 TR-5 x 8 PLY E 3. Position the assembly on the work bench with the wheel half facing down. Note the world famous Lancair designed anti tire tuber pincher deal. You will see a notch designed to fit around the valve stem. The anti pincher slides between the tube and wheel and helps prevent tube pinching when the two halves are put together. Locknuts, AN363-1032 (3 pcs) Washers, AN960-10 (3 pcs) E 4. Insert the wheel and the Lancair patented anti-tube- pincher-deal™, 4785 Tire, tube and outer rim half with valve stem. Bolts Washers, AN960-10 (3 pcs) 8/09-01-14 Chapter 13 REV. 0/02-15-02 FIREWALL FORWARD (Part 1) 13-17 Lancair International Inc., Represented by Neico Aviation Inc., Copyright © 2000 , Redmond, OR 97756 F. Nose Gear Doors Nose Gear Door Fig. 13:F:1 Nose Gear Door GM318-01, approx. 35” long (2 pcs.) Aluminum Gear Door Stiffener GM320-36, 34” long (2 pcs.) Screws, AN526C-1032R14 (2 pcs.) 1/09-18-02 TBA 6/08-10-07 34” piano hinge Phenolic crush plate, 3”x 1.125” Bracket, 209- 0018 (1 pc per side) Washer, AN960- 10 (1 pc per side) Locknut, AN365- 1032A (1 pc per side) Washer, AN960-10 (2 pcs per side) Gear Door Rails 6061-T6-1.25” x 1.25” x 1/8” (6 ft. supplied), 36” long Locknut, AN365-1032 (2 pcs per side) INTENTIONALLY LEFT BLANK DUE TO UPDATE REV. 5/06-20-07 Chapter 13 REV. 0/02-15-02 FIREWALL FORWARD (Part 1) 13-18 Lancair International Inc., Represented by Neico Aviation Inc., Copyright © 2000 , Redmond, OR 97756 INTENTIONALLY LEFT BLANK DUE TO UPDATE REV. 3/12-15-04 INTENTIONALLY LEFT BLANK DUE TO UPDATE REV. 3/12-15-04 3/12-15-04 Chapter 13 REV. 0/02-15-02 FIREWALL FORWARD (Part 1) 13-19 Lancair International Inc., Represented by Neico Aviation Inc., Copyright © 2000 , Redmond, OR 97756 Gear Door Rail Installation Fig. 13:F:7 F 1. Cut 2 pieces of the 6061-T6, 1.25” x 1.25” x 1/8” angle aluminum to 36”. Notch the railing to clear the nose gear bearing block. 36” Notch the nose gear tunnel closeout to accept the rails. Gear Door Rail Machine Screw MS24694-S51 Nutplate CN614CR3P VIEW AA 1/2” 1” 7-1/4” 13” Drill a 3/16” diameter hole and countersink. A A 6/08-10-07 You may want to do a micro release between the gear door rail and the nose gear tunnel to get a good fit so the rail cannot move. Chapter 13 REV. 0/02-15-02 FIREWALL FORWARD (Part 1) 13-20 Lancair International Inc., Represented by Neico Aviation Inc., Copyright © 2000 , Redmond, OR 97756 Gear Door Rail Support Fig. 13:F:8 Gear Door Rail Screw MS24694-S50 (2 pcs.) Nose Gear Bearing Block Gear Door Rail Support, 4751 (1 pc.) Locknut AN363-1032 (2 pcs.) Washer, Flat AN960-10 (2 pcs.) 1/09-18-02 Chapter 13 REV. 0/02-15-02 FIREWALL FORWARD (Part 1) 13-21 Lancair International Inc., Represented by Neico Aviation Inc., Copyright © 2000 , Redmond, OR 97756 Securing Hinge to Rail Fig. 13:F:9 36” rail 34” hinge Left Rail Shown 6061-T6 Extruded Hinge MS20001 Rivets AN426A3-5 (12 pcs.) Install the Rivets every 3”. The lower surface of the hinge is set level to the lower surface of the rail. Rivet AN426AD3-5 Rail SIDE VIEW OF LEFT RAIL FWD The gear door hinges (MS20001) are riveted to the gear door rails (6061-T6) and attached with screws to the gear doors (GM318-01). Rail A/C Up 1/09-18-02 NOTE: Hinge is reversed. Remove pin and flip hinge sides around. Non-door side of rail 2/06-30-04 Chapter 13 REV. 0/02-15-02 FIREWALL FORWARD (Part 1) 13-22 Lancair International Inc., Represented by Neico Aviation Inc., Copyright © 2000 , Redmond, OR 97756 Securing Hinge and Stiffener to Nose Gear Door Fig. 13:F:10 Bevel edge to accept the hinge. + or -35” trim to fit 1/2” AN426AD3-5 Rivets (68 pcs.) Secure the gear door stiffener to the gear door with hard rivets approxi- mately every 2” MS24694-S48 (22 pcs.) Gear Door GM318-01 Extruded Hinge MS20001 Nutplate K1000-3 (22 pcs.) Gear Door Stiffener GM320-36 Rivet AN426A3-5 (44 pcs.) 1” 1/2” 1/09-18-02 3/12-15-04 Gear Door Rail Support, 4751 Hinge Nose gear door, GM318-01 Gear Door Stiffener GM320-36 Chapter 13 REV. 0/02-15-02 FIREWALL FORWARD (Part 1) 13-23 Lancair International Inc., Represented by Neico Aviation Inc., Copyright © 2000 , Redmond, OR 97756 Nose Door Plunger Assembly Nose Gear Door Spring Fig. 13:F:3 HOW THE GEOMETRY WORKS: 1. By moving the up stop “down”, the gear doors will open wider and you will have more clearance between the pushrod and the over-center link. However, you don’t want the doors too wide.” 2. By moving the up stop “up” the gear door will open less and you will have less clearance between the pushrod and the over-center link. To determine the location of the up stop you need to observe the clearance between the over-center link and the gear door pushrod arm. You will notice when retracting and extending the nose gear that the clearance between the over-center link and the gear door pushrods depends on the length of the pushrods. 6/08-10-07 F 1. Remove the spring from the back of the nose gear door plunger assembly by removing the Allen “stop” screw. F 2. Reassemble the plunger without the spring. Note: Refer to the next page for a drawing and photo of the completed assembly. Chapter 13 REV. 0/02-15-02 FIREWALL FORWARD (Part 1) 13-24 Lancair International Inc., Represented by Neico Aviation Inc., Copyright © 2000 , Redmond, OR 97756 F 7. When you are satisfied with the clearance between the nose gear and nose gear doors, use the plunger housing as a guide to drill the two bottom holes through the firewall in approximately the center of the slots. F 8. Install the plunger bolts (AN3-7A), washers (AN960-10) and nuts (AN365-1032A). Plunger Installed on Firewall (new photo) Fig. 13:F:5 F 2. Drill the two holes for the two top bolts to secure the plunger to the firewall. Install the bolts (AN3-7A), washers (AN960-10) and nuts (AN365-1032A). Bolts, AN3-7A (4 pcs.) The latest engine mounts come with the holes located on the plate. You may need to slot the holes in order to allow the bolts to slide into place. 6/08-10-07 F 4. Attach the gear door pushrods to the plunger. F 5. Position the plunger directly over the nose-gear strut on the firewall. F 6. Fully compress the plunger. Completed Nose Door Plunger Assembly Nose Gear Up Stop Fig. 13:F:4 Firewall Chapter 13 REV. 0/02-15-02 FIREWALL FORWARD (Part 1) 13-25 Lancair International Inc., Represented by Neico Aviation Inc., Copyright © 2000 , Redmond, OR 97756 Nose Gear Door Actuator Assembly Mounted to the Firewall Fig. 13:F:6 Gear Door Rail Gear door push rod, female rod ends HFC-3AU Bracket 209-0018 F 3. Center the control horn on the gear door stiffener and mark the location. F 4. Fabricate a 3” x 1.125” x .250” phenolic or aluminum plug. See Figure 13:F:1 for a view of its location. F 5. Sand the plug to fit inside the stiffener rail. This is used to prevent the door from being crushed. Place it in the door, beneath the control horn. F 6. Position the control horn on the door so that the push rods are vertical. F 7. Drill the holes and install the hardware. F 8. Attach the gear door push rod on one side. F 9. Retract the nose gear and verify tht the nose gear doors completely close. Adjust the rod ends as necessary. F 10. Repeat these steps for the the other door. F 18. After the final adjustment, remove the plunger and re-install the spring. Now re-install the plunger assembly. 6/08-10-07 Nose gear door plunger, mount 203-0006 Gas spring 160-0000 Link, short, for Nose Door Plunger 229-0002 Firewall Link, long, for Nose Door Plunger 229-0000 Chapter 13 REV. 0/02-15-02 FIREWALL FORWARD (Part 1) 13-26 Lancair International Inc., Represented by Neico Aviation Inc., Copyright © 2000 , Redmond, OR 97756 Nose Gear Micro Switch Fig. 13:G:1 G. Nose Gear Micro Switch Nose Gear Down Switch A micro switch is mounted to the 4719 over-center linkage to indicate if the nose gear is down and locked. The switch is activated by the 4721 lower over-center linkage. Use the hardware supplied in the JM-1 packet to secure the 1XE1-T micro switch to the 4719 upper over- center linkage. Two switch mounting holes are predrilled in the linkage for this purpose. The nuts and lockwashers should be on the bottom of the 4721 linkage. Use a drop of Loctite on these nuts just to be sure of a good hold. The right, 4721 over-center linkage should press the switch arm when the nose gear is locked in the down position. You should be able to hear the “click” of the switch as it contacts and releases. The micro switch and switch arm are secured to the 4719 over-center linkage with the screws provided in the JM-1 packet. Upper Over-center Linkage 4719 Switch Arm JM-1 Nose Gear Micro Switch 1XE1-T Lower Linkage 4721 A/C Up Fwd 2/06-30-04