RALLY ASSEMBLY MANUAL
Storm Rally 105 · Maintenance Manual
Overview
The Rally Assembly Manual provides detailed instructions for assembling various components of the Storm Rally 105 aircraft. It covers the installation of cables, the instrument panel, seats, floors, and the control stick, ensuring proper assembly and adherence to safety standards.
- Cables must be passed through designated holes and boxes during assembly.
- The instrument panel requires specific cutting and positioning for installation.
- Seats must be centered and secured with rivets and structural adhesive.
- Floors need to be adjusted to fit the fuselage and other components.
- Reinforcements should be glued in place before final assembly.
- Control stick installation involves connecting to aileron and rudder systems.
Document
Source
Originally published by stormaircraft.com. Sprinkle hosts a reference copy with an added summary, specifications and searchable full text.
Document details
- Type ·
- Maintenance Manual
- File size ·
- 3.7 MB
- Publisher ·
- stormaircraft.com
- Language ·
- en
What is the RALLY ASSEMBLY MANUAL?
The RALLY ASSEMBLY MANUAL is a maintenance manual for the Storm Rally 105.
Where does the RALLY ASSEMBLY MANUAL come from?
This copy of the RALLY ASSEMBLY MANUAL was originally published by stormaircraft.com and is hosted on Sprinkle as a free, searchable reference copy.
Most owners only have the POH. Here's the essential set for the Storm Rally 105.
- Pilot's Operating Handbook / AFM
- Checklist
- Maintenance Manual
- Parts Catalog (IPC)
- Systems & Wiring
- Service Bulletins on file
- Type Certificate (TCDS)
In this document
Cables Installation
Instructions for passing cables through main landing gear box and control stick holes.
Instrument Panel Assembly
Details on preparing and installing the instrument panel with anchor nuts and structural adhesive.
Seat Installation
Guidelines for centering and securing the seat support with rivets and adhesive.
Floor Assembly
Steps for positioning and securing the forward and rear floors, including drilling for cable passage.
Reinforcements
Instructions for gluing composite reinforcements to the rear floor and ensuring proper fit.
Control Stick Connection
Details on fitting the control stick and connecting it to the aileron torsion rod.
Full document text
RALLY ASSEMBLY MANUAL rev.2 STORMAIRCRAFT 104 5. Pass cables through main landing gear box dedicated bushes as shown below. 6. Pass cables through control stick dedicated holes as shown in detail A below. RALLY ASSEMBLY MANUAL rev.2 STORMAIRCRAFT 105 7. Pass cables through forward floor central hole. Fit cables to pedal system as shown in detail B below with M5 bolts. RALLY ASSEMBLY MANUAL rev.2 STORMAIRCRAFT 106 INSTRUMENT PANEL Prepare instrument panel 01-240-00 cutting instrument plates dedicated housings. Install anchor nuts to fit the panels. Position instrument panel perpendicularly at 100mm from dash panel edge fixing fuselage side profile and dash panel profile. Glue with structural adhesive instrument panel to fuselage and dash panel. Clean and sand before gluing. RALLY ASSEMBLY MANUAL rev.2 STORMAIRCRAFT 107 SEATS Centre seat support on seat as shown below. Drill seat lower section through seat support fitting holes. Centre seat support (or the adjustable seat support as shown in photo) on rear floor as shown below (remind the consider the rear console position) and mark position. Remove seat from seat support and drill seat support fitting holes. Rivet anchor nuts to reinforcements 0260 using solid rivets 2.5. Glue with structural adhesive reinforcements 0260 to rear floor lower section in correspondence of seat support fitting holes. RALLY ASSEMBLY MANUAL rev.2 STORMAIRCRAFT 108 FLOOR Position forward floor 01-330-00/1 and rear floor 01-320-00/2. Adjust them to fit fuselage, main landing gear box and struts profile where required. Centre forward console 01-250-00/1 on forward floor and rear console 01-250-00/2 on rear floor and mark position. Drill 2,5mm holes to fix consoles to floor successively. Remove consoles from floor. Drill forward floor 01-330-00/1 to pass cables from forward console as shown below. RALLY ASSEMBLY MANUAL rev.2 STORMAIRCRAFT 109 Drill rear floor 01-330-00/2 to pass cables from rear console as shown below. Glue composite reinforcements in correspondence of rear console fitting holes. Glue with structural adhesive reinforcements 0259 and 0260 to rear floor lower section as shown below. RALLY ASSEMBLY MANUAL rev.2 STORMAIRCRAFT 110 Now you can glue rear floor to main landing gear box, baggage plan structure and struts. Clean and sand before gluing. Glue the forward floor only after all rods, cables and tubes lines have been passed. Tip: connect the elevator control rods and the aileron torsion rod to the control stick and pass the rudder cables before gluing the forward floor. RALLY ASSEMBLY MANUAL rev.2 STORMAIRCRAFT 111 CONTROL STICK Pass rudder cables through control stick dedicated holes. Fit Control Stick to forward support. Now you can connect control stick to ailerons torsion rod through the two end rods as described in “Connecting the ailerons controls cables to the Control Stick” section and make final regulations.