CHAPTER 16 REVISION LIST

The following list ofrevisions will allow you to update the Lancair IV construction manual chapter listed above.

Under the "Action" column, "R&R" directs you to remove and replace the pages affected by the revision. "Add" directs you to insert the pages shown and "R" to remove the pages.

Current Page(s) affected Rev.# Action Description

16-1 0 None No changes 16-2 B13 R&R Added part numbers. 16-3 thru 16-5 0 None 16-6 B17 R&R Edited text before and in step Al. 16-7 B17 R&R Added <cradles> to step A2. 16-8 thru 16-10 5 R&R Changed Figure 16:B:1, 2, & 4

Changed Steps Bl - BG Renumbered Steps B5 & BG

16-11 0 None 16-12 B17 R&R Added text to step C3. 16-13 thru 16-14 0 None No changes 16-15 B17 R&R Rewrote C5, edited fig. 16-16 B7 R&R Revised 16-17 & 16-18 5 R&R Clarified Step C12 & Figure 16:C:7:b 16-19 thru 16-21 0 None No changes 16-22 5 R&R Changed Step D5 & Figure 16:D:3 16-23 thru 16-24 0 None No changes 16-25 B17 R&R Added text, Added text to Figure. 16-26 B17 R&R Removed El, modified Figure. 16-27 B17 R&R Removed page due to improved part. 16-28 B17 R&R Added text to NOTE, modified figure. 16-29 B13 R&R Edited Fig. 16:F: 1. 16-30 0 None No changes. 16-31 5 R&R Changed Step F3. 16-32 B7 R&R Revised Fig. 16:F:4 16-33 & 16-34 0 None 16-35 B13 R&R Cleaned up Fig. 16:F:7. 16-36 5 R&R Clarified Figure 16:F:8.

Lancair International Iuc., lleprescntecl by Neirn Aviation Inc. Copyright ,I) J!l!J!J, Heilmond, OR !J7i5G

REVISIONS

CHAPTER16 MATING WING TO FUSELAGE

From time to time, revisions to this assembly manual may be deemed necessary. When such revisions are made, you should immediately replace all outdated pages Mth the revised pages. Discard the out dated pages. Note that on the lower right corner of each page is a "revision date". Initial printings will have the number "O" printed and the printing date. All subsequent revisions will have the revision number followed by the date of that revision. \Vhen such revisions are made, a "table of revisions" page will also be issued. This page (or pages) should be inserted in front of the opening page (this page) of each affected chapter. A new "table of revisions" page wi11 accompany any revision made to a chapter.

ARROWS Most drawings will have arrows to show which direction the parts are facing, unless the drawing itself makes that very obvious. 11A/C UP'refers to the direction that would be up if the part were installed in a plane sitting in the upright position. In most cases the part shown will be oriented in the same position as the part i tselfwill be placed during that assembly step. However1 time goes on and changes are made, so careful attention should be paid to the orientation arrows.

CONTENTS 1. INTRODUCTION 2. SPECIAL PARTS, TOOLS, AND SUPPLIES LIST

A. PARTS B. TOOLS C. SUPPLIES

3. CONSTRUCTION PROCEDURE A. INCIDENCE TEMPLATES B. FUEL LINE TUNNEL C. MATING WING TO FUSELAGE D.SHEARPANELSUPPORTS E. SHEAR BOX COVER F. WING ROOT FAIRINGS

4. PHOTOPAGES

~C2"';;~~~*~~~!!!:!~Alw~1.,~~~,,,,,....,,~A~~~;n~®~IV~!_ __ _J1r·•·16:~ •.•••. J1--c-~ __ ap"-'~-'-~-1-~_w_rN-"~'--R-;-~-F-,u-s-E-•~-/-~-1~_1_7-_92_-+~f-X-Luncuir In~cmution11\ Inc., Hcprcscnllld by Ncico Aviation Inc., Copyrighl Cl 1992, Redmond, OR 97756

1. INTRODUCTION

When you complete this chapter, your Lancair N will look like a true airplane and you'll see light at the end of the tunnel. Mating the wings to the fuselage is surprisingly easy but you do need quite a bit of room. A 35' x 25' shop or hangar gives you adequate room to insert both wings into the fuselage.

Joining Wings and Fuselage Figure 16:i: 1

Lea Bott.om~ WingFillet ~

(1032L) c::::::,/

Also in this chapter you will be installing the premolded wing root fairings between the wings and the fuselage.

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Lnncnir International Inc., Represented by Neico Avinlion Inc., Copyright O l!l!JG, lwdmond, OR !17756

2. SPECIAL PARTS, TOOLS, AND SUPP

A. PARTS Left wing assembly Right wing assembly Fore and aft spar shear panels Bottom fuselage assembly Left top wing fairing Left bottom wing fairing Left fairing T.E. cap Right top wing fairing Right bottom wing fairing Right fairing T.E. cap 1/2" thick Clark foam 1" thick Clark foam

LIES LIST

Chapter 16 I REV. 0/ 11-17-92

MATING WING TO FUSELAGE Lanc11ir Intcrnnt!onn\ Im.,Rcprl!scnted by Ncko Avintion Inc., Copyright CJ 1992, Redmond, OH 97756

~

)a

1)0<

B. TOOLS Saber saw Dremel tool Spring clamps Cleco pliers Clecoes Transit Water level Carpenter's (bubble) level

Chapter 16 I REV. 0/ 11-17-92

MATING WING TO FUSELAGE Luncnir Internalionnl Im:., Rcprcs.enh.'O. by Ncico Avinl!on Inc., Copyrighl IC 1992, Hcdmond, OH 97756

M

%

C. SUPPLIES Bondo 5/8" thick plywood Epoxy Flox Micro Mixing cups Paint brushes Paper towels Fiberglass

Chapter 16 I REV. 0/ 11-17-92

MATING WING TO FUSELAGE Luncalr Intcrn11.liom1l Inc:.,Rcprcscntcd by NcicoAv!ulion Inc:., Copyright Cl 1992, Redmond, OR 97756

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,,';D

3. CONSTRUCTION PROCEDURE

A INCIDENCE TEMPLATES

To find the correct wing incidence a plywood template is temporarily bonded to each wing as a level reference.

Wing incidence template Figure 16:A:l

Wing/

With some modification, your BL 25.5 wing cradle(s) can be used as a wing incidence template. Use the template on blueprint#A-109 to mark a line on the cradles indicating the proper incidence angle.

Al. Trim the top edge of the cradle to the incidence line, or glue some blocks on the line to set a level on.

L!;~=~~~~~z!:0_r~.Jl~~l,~~~~A§l,§:o£:l!§:_®__:JV:__:!_ ___ l~l-'=C~'h~aLpt=e~r~l~6 __ _c_R_E\_' __ J_3_ln_,i_l_-2_5_-9_9 __ -+~~~ c...>-?'.~...IIV'CLF..rJfl'""- -~ MA TING WING TO FUSELAGE

Lancnir [nt1m1,1tional Jue., Hepresentet! by Neictl Aviation Inc., Coprri!:ht ,D !!J!J!J. He<ln11md, OH !Jii5G

A2. Use Bonda to secure the cradles (incidence templates) to the top wing skins at BL 25.5. The templates should fit the contour of top wing skin fairly close but due to builder differences, a small discrepancy (1/8" gap in an area) is acceptable.

Securing incidence templates in position Figure 1 G :A: 2

Wing

Incidence template is vertical (to the world) when wing is at ~ proper dihedral angle.

Wing/

incidence template in position on wing

L!;;<!.""'f~zi~°-!§,A,,;§,l.,~~~=A§.l.§'.O:=§::.""_:IV:.._'l!'._ ___ l ~ I-C'--h_a_,_p_te_r_l_G __ ~R_ll_V_. __ B_l_7_11_-~_JF_,-_fJ'_.J __ -i+"i\--n O:? ~'IFg,,...nrK~ -~ MATING WING TO FUSELAGE

Lnncair Jnternationnl Inc .. lfopresenu•d by Ni:,kn Aviation Inc., Copyright 1) J!J!JD, Hetlm1m1L OR !lii5G

B. FUEL LINE TUNNEL

The fuel lines from both wings must pass under the main wing spars at the center of the fuselage. A fiberglass tunnel is formed in this area to provide better protection for the lines.

Fuel line tunnel Figure 16:B:1

Fuselage~ ___ -:::-:::-:--:::::::::::::::::::::==1 --~ :::---

Firewall

I ,

I I

/

Fuel line tunnel

~cz~~=~==f;,==A=V'=l,=,:==,,,,,,,,,,=.4==.l,=,,l!l_==c..®.......::'IV~..!....--_J'I~~:~ ]e-C:::~:::a:::,Pc,~:::;_:....:::l~:'....W_I_N.1.G_n; __ •V_~_F_U_S_E __ 5:'....~:._::~...:-::....-9:....3:.__-J+')?.).j

Lnncnjr lnlcrnntionul Inc.,Rcpro~cnlcd by Noico A\'iotion Inc,, Copyright ll!l 1992,Ilcdmond, OR 9775G

BL Cutapieceofl"thickClarkfoamas shown in Figure 16:B:2.Round the long edges for easy glassing.

Mold for fuel line tunnel Figure 16:B:2

Fuel line tunnel mold is shaped from Clark foam. Foam is covered with a

7e tap:.tick nails or wood sticks

into ends of foam .mold so you can grasp the mold while

applying the 4 BID

B2. Apply release tape to the tunnel mold. One layer of duct tape works well.

B3. Apply 4 BID to the fuel line tunnel mold.

B4. When the 4 BID has cured, remove the tunnel from the mold. The easiest way to do this is to dig out the foam with a screwdriver or narrow chisel, then scrape and roll the duct tape off the inside of the tunnel. Trim the tunnel to 7" in length.

~~"":;~~~~:=~!":'.==Al=_.=li.,,,=!.flll=,,....._,__=4==1..=Jl==c..®~IV~!._ ___ JII ~~:~ 1•1--"C MAc...h_;_.,apc.c~"-~'--1--'~'-WIN--GLRE_;-~-· _FU_S_E_~_/ _~_-:_-9_3 __ -H-J>ei

Lnnc11ir Inlcrnationnl Inc., Rcprcsenlcd by NcicoAvinlion Inc., Copyright 4!l Ul92,Ilcdmond, OR 97756

BS. Position the fuel line tunnel in the fuselage, centered on BL 0, with its forward edge at FS 89.75. Mark the location of the tunnel on the bottom fuselage shell.

Positioning fuel line tunnel Figure 16:B:3

FS 89.75

I / Fuel line tunnel

...--------------,

Bottom fuselage shell/

B6. With 40 grit, sand the fuel line tunnel and the areas of the bottom fuselage shell where the tunnel will be bonded. Clean these areas with MC.

Bonding in fuel line tunnel Figure 16:B:4

Fuel line tune!~

Epoxy/flox

1111111~

Tunnel is bonded to fuse with Hysol. Form a radius along the longtunnel edges

/111111 Ill I

I A/Cup

Left..._LRight

Bottom fuselage shell

B7. Bond the fuel line tunnel to the bottom fuselage shell with Hysol. Form a radius in the Hysol along the edges of the tunnel where it meets the fuselage shell. There is no need to reinforce the bond with fiberglass yet. This will be done when you install the main spar shearbox.

Luncuirlntcmutionnl Inc., Rcpr1rncnted by Ncico Avinlion Inc., Copyright ID l!l92,Rcdmond, OR 97756

C. MATING WING TO FUSELAGE

The Lancair IV wings are set to a positive 1.6° incidence. This means that the L.E. of the wing is higher than the T.E. Don't confuse this condition with the horizontal stabilizer which was mounted with negative incidence. Recheck your fuselage to be sure is has not strayed from level.

Mating wing to fuselage Figure 16:C:1

Right wing

I

Fuselage/

Left wing

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Lnntnir Inlernatlonnl Inc., Represented by Neko Avinllon Inc., Copyright O 1992, Redmond, OR 97756

Cl. Holes need to be cut through both sides of the fuselage so the main and rear wing spars can slide into position. Mark the location of the spar holes on the fuselage as shown in Figure 16:C:2.

Spar holes in fuselage Figure 16:C:2

WL 22

13 1/2" 6" 14 1/2"

L □ LI:c□ =•~--"1----f T f

+I I()

<"! ..... I()

en u..

C2.

C3.

I()

+1' I() I() +I ui ..... 11'! en ..... en ..... M u.. en .... ..... u.. en

u..

Cut out the four spar holes in the sides of the fuselage.

Slide the two wings into the fuselage so the main spar bolt holes align with each other. This step requires more than one person, so enlist a helper or two to handle those big wings. The forward face of the right main spar should be located at FS 90 and the wings should be centered so that the inboard ends of the top wing skins are approximately equa-distant from the fuselage sides at the rear spar. The BL 0 location of the wing assembly will usually be to the left of the centerline mark on the floor. This is because the fuselage is not symetrical. Use two tables and some blocks of foam to hold the wings in position. Slide the main spar bolts through the bushings to hold the wings at the proper cliheclral.

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Lancair lnternationnl lnc., Hepresentcd by Ncko Aviation Inc., Co1wri!;:ht ID 1999, Hcdmoncl. OR !l775G

Locating wing spars Figure 16:C:3

Table supports the wing dm·ing the mating process. Another table under the inboard wing area will

also help with support.

L11ne11ir Inlernnlional Im:., Reprei;entcd by Ncico Aviation Inc., Copyright Cl 1992, Redmond, OR 97756

C4. The wing tips should be level with each other. Use a water level or a transit to adjust the height of the wings. See Figure 16:C:4.

Leveling wings Figure 16:C:4

Water level is used to level the tips of the wings. Be sure

that the fuselage is level.

Level-,~==:::::::::::::====i::::;:;:;:;;•d[============:::::==1-Level

Lc:;..;iit~'.'.::=*==t,==_.=•=,r,=y;-=<F711.=..tfl==l..='.l'-.='.:a=-®~IV~:!_ __ _Jl•I•····~·~:~~······jt-cMA_h~ap~~-~-1_~_,-V-IN_G,._RE_;-~--_F_U_S_E_~-1~_~_17_-_92_-t-~ Lnnc11ir Jnlcrm1liom1l Inc., Ifoprci;cntcd liy Nnko Avintion Inc., Copyright O 1992, RL-dmond, OR 97756

C5. Now for the fine tuning of wing placement. Check the alignment of the fuselage centerline with the centerline on the floor. Draw a reference line on the floor perpendicular to the fuselage centerline near the wing's leading edge. Confirm that your line is perpendicular by using triangulation. Mark two points on the wing L.E. equa-distant from the fusealge centerline. Use a plumb bob at both points to align the wing leading edge with the line drawn on the floor.

✓ Mark a point

Setting wing sweep Figure 16:C:5

Mark a point ----

I

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Liuu:air Jntematinaal Inc., Represented hr Neicll Aviation !nc .. Copyri~ht <\) HJ!l!I, Redmond. Oil !177fi(l

C6. - To set the wing incidence, place a Smart Level (a bubble level will also work) on YJI.. the top edge of the incidence template. When the Smart Level reads 110°11

, then the wing is set to the proper incidence. DON'T ADJUST THE WING SO THE SMART LEVEL READS 1.6°. THE POSITIVE INCIDENCE HAS BEEN BUILT INTO THE INCIDENCE TEMPLATE. Check both wings to make sure there is no discrepancy between the incidences, both should be equal. Adjust the foam blocks under your wing to hold the proper incidence.

Setting wing incidence Figure 16:C:6

Smart level (or bubble level)

----....,--,..,...--------. Wing in~nce template

~--------'-----'-------

1"11-_Foam block

Wing

Table

Adjust foam blocks (or whatever you are using for support) for proper wing incidence

C7. The two spar shear panels were provided m your "A" kit and are matchdrilled with the main wing spars. To ease the job of trimming these panels to fit in the fuselage, it is highly recoII1II1ended that you cut a cardboard template to find the final shape of these panels. Make this template accurate, taking into account the spar bolt locations and the 8 3/8" panel height. Don't get in a hurry and trim the shear panels way off the target. Take it slow and steady.

NOTE: Be sure the forward shear panel is forward of the main spar. Otherwise, the spar bolt bushings will not line up. You can double check the Forward (F) and Aft (A) part numbers on the shear panels by looking for the seatbelt reinforcement on the aft panel. This reinforcement is a 1211 wide, increased BID area running the full height of the aft panel (in the center).

CB. Cut the shear panels to match the cardboard templates. The main spar bolt bushings should all line up when the shear panels are properly tri=ed. Slide the AN12-7 5A through the bushings to assure yourself or proper alignment. A perfect fit of the shear panels is hard to achieve and is not required. If you end up with a few 1/8" gaps between the panels and the fuselage, this is acceptable.

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Lnncnir Inlernnlioillll Inc., Reprosenlcd by Neico Aviation Inc., Copyright© 1992,Redmond, OR 97756

Fitting spar shear panels Figure 16:C:7:a

Spar shear panel

Fuselage

Bubble level

~

0

~~ ©

0

Top of shear panels should be level. Seats will mount to the shear panel

flanges later in construction.

Fitting spar shear panels Figure 16:C:7:b

Aft shear panel

Wing

/ Measured

7 at Centerline of fuselage.

83/8"/

AN12•75A bolt AN960-1216 washer MS21044N12 locknut l

Note: The wing spars need only to be high enough to clear the fuel line tunnel. The 8 3/8" shear panel

height can vary up to 1/4".

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Loncnir lnlcrnntionnl Inc., Represented by Ncku Aviulion Inc., Copyright !fl 1992, Redmond, OR !l775G

C9. When satisfied with the fit of the spar shear panels, use 40 grit to sand them where BID tapes will be applied. Also sand the bottom fuselage shell where the panels are located. Clean these bonding areas with MC.

ClO. Bond the shear panels to the bottom fuselage shell with a thick epoxy/flax mixture. Form a 1/4" radius with the excess flax around the shear panel/fuselage junction. Use the AN12-75A main spar bolts and their MS21044N12 locknuts to hold the panels in proper alignment during bonding. The locknut should just be snug for this step. Any more pressure would make wing removal and installation difficult. Be sure not to get any flax on the main spars. This would also make removal difficult.

Fwd shear panel

Fuselage

3BID 3" wide

Bonding shear panels in position Figure 16:C:8

Spars

I~ Aft shear panel

3BID 3" wide

Cll. When the shear panels have cured in position, sand the flax radius smooth and clean with MC.

C12. Secure the shear panels to the bottom fuselage shell with 3 BID, 3" wide laminates. Notice that the spar sides (the sides of the panels that the spars rest against) of the shear panels are not secured to the fuselage with BID. This would interfere with the spar fit and is engineered into the design.

Lnneuir lnlCl'nnllonnl Inc., Rcprc~cntcd by Ncico Avinlicm Inc., Copyrlghl e 19!12, llcdmond, OR 97756

C13. The rear spars will be bolted to the forward face of the gear box later in construction. For now, wood temporary supports will hold the rear spars in position at the proper wing incidence. This way, you can continue with the construction of the wing fairings without waiting for the gear box. See Figure 16:C:9.

A/Cup

Supporting rear spars Figure 16:C:9

' ' '

.' ... ·I·/.--···~-~ ..-, ~ ;"- ...

~ Rear spar ~(right)

Wood rear spar support block

(use dabs of Bondo to hold in place)

Ltmeuir Intcrnntional Inc., Hcpresenh.>d by Neico Avfolion Inc,, Copyright IC 1992,Rcdmond, OR 97756

D. SHEAR PANEL SUPPORTS

The shear panels must be reinforced with two brackets on each side of the fuselage.

Shear panel supports Figure 16:D: 1

.,,~ (-:;,~ ,,

.,,,.,,,,..,,,,. .... M I '

I ! Shear panel

....---support

..,, .,,,. ,;, ; I t

- I I

I , -

Shear panel support

' I

I I ' I

I I • I

• I I I

1 ~ ,,... ., I _.t' ;,

_, I , ,

Shear panel

Shear panel

/

Note: four shear panel supports are required.

Dl. Using the templates on Blueprint A109, cut the shear panel supports from 1/4" thick, 2 ply per side prepreg. Notice that there are templates for the forward supports and aft supports. Although the drawings in this section may show the supports as being identical, there are slight differences in size.

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Lnnrnir Jnternulionnl Jnc.,Rcprnscntcd by Neico Avinlion Inc., Copyright 0 1992, Redmond, OR 97756

D2. Fit the shear panel supports at the locations shown in Figure 16:D:2.

Support locations Figure 16:D:2

Shear panel support

~ Inner surface of

shear panel supports should be flush with

the shear panels.

Shear panel

Shear panel ~ support

~ Shear panel

supp~ Flush A ~Shear panel support

Shear panel

~ ◄ ... --- Shear panel

/ Bottom fuselage

IJ11I1]IIIIID?::~===1,!\~rrffiiim

D3. With 40 grit, sand both sides of the shear panel supports. Clean the supports with MC.

D4. Sand the areas of the fuselage sides and shear panels where the shear panel supports will be mounted. Clean these areas with MC.

Lunrnir lnlernalionul Inc., Hcprc~ntcd by NeicoAvinlion Inc., Copyrighl O 1992,Rndmond, OR 97756

D5. Bond the supports to the shear panels and fuselage with an epoxy/micro mixture. Form micro radii with the excess micro. Don't apply the BID to the shear panel supports until you have installed the small fiberglass section described in the next few steps. Trim the shear panel flanges even with the inboard edges of the supports as shown in Figure 16:D:3.

D6. Apply release tape to a flat surface in a 8" by 12" section.

D7. Lay up 5 BID on the flat release surface you just made. When the BID has cured, remove it from the flat surface.

DS. Cut two pieces from your 5 BID piece to fit between the shear panel supports on the left and right ends of the shear panels. See Figure 16:D:3.

Bottom shear panel support Figure 16:D:3

Shear panel

supp~

~ 1t'..,......____

' .s,, ~

5 BID Bottom shear panel

support

Shear panel support

Shear panel

Notice that shear panel flanges have been trimmed even with the inbd edges of the shear panel supports.

Lnncair Intcmnlionnl Inc., Rcprcmmlcd by Ncico Aviulion Inc., Copyright e 1992, Redmond, OR 9775G

Shear panel

D9. Sand the top surfaces of both the 5 BID pieces and clean with MC.

Dl0. Bond the 5 BID pieces into position with an epoxy/flox mixture. Be sure the bottom supports are mounted about .060" below the level of the shear panel flanges. The pieces will be reinforced with the same 6 BID that secures the shear panel supports to the fuselage sides.

Height of bottom shear panel support Figure 16:D:4

Shear panel support-----.._

.060" Shear panel support

Shear panel

...,.-flange c:_~=====:;;:::==~~";;::::::::J-~

Shear panel

Fuselage

5 BID bottom shear panel support 1'---

Shearpanel

Mount bottom shear panel support .06011 below the level of the shear panel flanges.

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Lnncuir lnlcrnationnl Inc., Ikprcscnlcd by Ncico Avi11lion Inc., CopyrighL Cl 1992, R£.'O.mond, OH 97756

Dll. Secure the shear panel supports to the shear panels and fuselage with 6 BID as shown in Figure 16:D:5. Notice that this BID also secures the bottom shear panel supports.

Securing shear panel supports Figure 16:D:5

6BID

~ 6BID

✓ ,

7rpanel

6BID

Lnnc11ir lnternnUonul Inc., Repre~enlcd by Nt'ko Avi11Uon Inc., Copyrlghl O 1992, Hcdmond, OR 97756

E. SHEAR BOX COVER

A prepreg shear box cover is used to isolate the cockpit from the elements. The cover is bonded to the shear panel flanges to avoid air leaks that would result from making the cover removable. This is a premolded part #1037.

Shear panel su[)ports

I

I

I

I I

I

' I

Shear panel __,,.,,v

Shear box cover Figure 16:E:1

Pre-built Shear box cover P/N 1037

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Lanc11ir lutnnational inc., Hep resented hr N1iirn Avi1ltin11 Inc., Cupyrird1t ·D i!l!l!l, Rcclm1m1!, OH !J775Ci

E 1. Use the dimensions in Figure 16:E:2 to cut the shear box cover from 2 BID per side, fiberglass prepregpanel. The cover should rest on the shear panel flanges and the bottom shear panel supports. This will completely isolate the cockpit from the spar area and provide a flat surface for later mounting of the seats.

Cutting shear box cover Figure 16:E:2

...... --Shea~r~u.c,e~l~s~u~p!p:o~rt:s:___,,~f

0

V Shear panels

X"

0

' Shear panel

Shear box cover (2 BID prepreg) P/N 1037

Note: No specific dimensions are given because they can vary from builder to builder. Measure X and Y

on your airplane.

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Lancair Jnt1•t·11ational Jnc_, Heprescntetl !Jr Ncieo Aviation in~., Copyriehl ,j) l!}!J!J, Hcilmnnd, OH !lii!iG

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Due to revisions, tl1is page l1as been removed.

Chapter lG I REV. Bl7 /l-25-99 '>d MA TING WING TO FUSELAGE ),0(

Lancair lnwrnntional l11c .. lfopn•sented lir Neicll Aviation Inc., C11p;Ti1,:ht ,[) l!l!l!l. Hei!mond, OH 9775G

NOTE: The shear box cover is bonded in position with Hysol. Although the process is described in the next few steps, DON'T bond the cover in position at this tilne. Wait until you have installed the jack points and seat belt bolts and are ready to install the seats. The longer you have access to the shear box area the better.

Bonding shear box cover in position Figure 16:E:4

Shear box cover ""' P/N 1037 ~

/ // // ½ /

/2 /

Shear p~el ///

/2 /

/2 /

/2 /

/2 /

/2 /

Hysolbond

E5. Bond the shear box cover in position with Hysol. As usual, mix a little flox in with the Hysol to give it more body. To avoid air leaks, be sure there is Hysolsqueezeout all around the bonding area.

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L:mcair lr11ernatinnnl Im:., Represented by Neico Aviation Im . Cnpyl'ight ·D Hl!J!J, lfodmom!. OH 9775G

F. WING ROOT FAIRINGS

Wing root fairings help smooth the airflow between the wings and fuselage. Premolded fairings are provided in your Lancair N kit. There are three pre­molded pieces in each fairing, a bottom half, top half, and T.E. cap.

Right Top-----i11o. Wing Fillet

Right Bottom--___ .,.. Wing Fillet

Wing Root Fairing Figure 16:F:1

~...____ Left AFt Extension Fairing

(1055L)

~Left Top Wing Fillet

(1031L)

/◄!-----Foam Wing Profile (Left)

Left Bottom Wing Fillet

(1032L)

NOTE: The aft fairing parts are installed in Chapter 19.

Luncnir Internntionul Inc., ReprirnBnled by Neie0Avi11lion Ine., Copyright O l!l9G, Redmond, OR 07756

Fl. Before fitting your wing fairings, you should check that the inboard edges of your wing are flat and straight. It doesn't matter if your inboard edges are vertical to the world or at any other angle, but for appearance sake, the inboard edges should be straight. This is also a good time to trim the inboard ends of your flaps flush with the wing skin.

Trimming inboard edge of the wings Figure 16:F:2

O.K. - Inboard edge of wing trimmed vertical (to the world)

~..-----------(

Wing O.K. - Inboard edge of wing trimmed

perpendicular to top wing skin.

~..---------=------.-

Trim edge of wing and flap flush to each

other. Wing

Flap

F2. Slide the wings into the shear box and insert the main spar bolts. When the rear spar is resting on it's wooden support, the wings should be at the proper incidence. Recheck the incidence anyway with the incidence template just to be sure. You wouldn't want to align the wing fairings with an improperly aligned wing.

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Loncair Jnte.rn11l!onal Ine., Hcprcscnh!d by Ncko Aviation Inc., Copyrighl 01992,HOOmond, OR 97756

Note: You may want to hold off on installing your wings until you have made the foam wing profiles described in the next few steps. This way, you can slip the profiles into position without cutting them in pieces to fit around the main and rear spars.

F3. Cut two pieces of 1/2" thick Clark foam shaped 1/4" larger than the wing profiles at BL 25 .5. These foam profiles will be used to hold the wing fairings in the proper shape when the wing is removed. Use your old plywood BL 25.5 wing cradle or profile as a template to cut the foam (but remember to cut them 1/4" larger all around). Apply 2 BID to the inboard surface of the left wing profile. This 2 BID will reinforce the foam in the area where people may step on the fairing when entering the aircraft.

F4. Cut smaller pieces of 1/2" thick Clark foam that will hold the wing shaped pieces 5/8" inboard of BL 25.5. If you have already installed the wings, you will have to carefully cut the foam profiles in three pieces (each) to fit around the spars. Use Bonda to bond the small braces to the fuselage and the foam wing profiles. Also use a little Bonda to secure the profile pieces together again if you had to cut them. The small foam braces will be removed after the fairings are built. See Figure 16:F:3.

Securing foam wing profiles Figure 16 :F:3

Fuselage ---~ --

Clarkfoam/ wing profile

Foam profile braces (2 or more needed)

F5. Trim the bottom half of the wing fairings to the scribe marks. As usual, it is a good idea to trim the skins a bit larger than the scribe marks indicate so you have some extra skin to "trim to fit" later.

Luncuir lnh1r11utionul Inc,, Represented by Nclco Aviation Inc., Copyright li:l 1992,RC!dmond, OR 07766

F6. To position the bottom fairings, align the contours with the wing airfoil at BL 25.5. The leading edge of the bottom fairing must be flush with the wing L.E .. If the trailing edge of the fairing does not line up with the wing T.E., this can be easily be corrected later. To help hold the fairing in the proper position, you can temporarily bond pieces of tongue depressors to the bottom wing skin, forming a cradle to support the fairing. Some sanding of the foam wing profiles will be required for a good fairing fit. The T.E. of the fairings should be 19 1/2" below the top of the WL 22joggle.

Positioning bottom wing fairing Figure 16:F:4

Fuse!~:

Main\

Clark foam wing profile

Wing

Bottom fairing

Wood bilks help keep fairing aligned with wing skin

Note: Be sure BOTH wing fairing T.E.'s are equal distances from the top of the WL 22 joggle. The 19 1/2" dimension can vary + - 1/2", but keep the left and right

fairings equal.

191/2"

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Lnncnir Internntionnl Im., Rcprooontcd by Nllico A via lion In~., Copyright© 1992,ROOmond, OR 97756

F7. Use a few clecoes to hold the bottom fairing against the fuselage. Drill the cleco holes only through the fairing and the outer laminate of the fuselage skin. Don't drill totally through the fuselage skin.

FS. Trim the top wing fairings to the scribe lines and fit them to the bottoms. Again, the L.E. fit is most important. The T.E. can easily be modified later. The foam wing profiles will have to be sanded for proper fit of the top fairings. When satisfied with the fit of the fairings, use a few clecoes to hold the top fairings in place, again only drilling through the outer laminate.

Positioning top wing fairing Figure 16:F:5

Fuselage-....~

Cleco/ Bottom fairing

Cleco (notice how the Cleco is only penetrating the outer /fuselage laminate).

L Top fairing

/

Wood block for alignment help

~~~---. ~

Foam.wing profile

Wing

'Wood block for alignment help

F9. Remove the top and bottom fairings and use 40 grit to sand the areas where they will be bonded to the fuselage. Clean these areas with MC.

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FlO. Bond the bottom and top wing fairings to the fuselage with a thick epoxy/flox = ~

mixture. The fairing L.E. joggle is also bonded together with epoxy/flox. The T.E. of the fairings are also bonded together with epoxy/flax. Use an epoxy/micro mixture to bond the fairings to the foam wing profiles. A few more clecoes may be necessary to hold the fairings against the fuselage. Apply 2 BID to the L.E. joggle, overlapping onto the fuselage by 1 ".

Bonding fairings in position Figure 16:F:6

Flox

Micro

----1t-__:;:i; "~I

-=t

Flox Micro

Wing

2BID

j

~ L.E. of fairings bonded together with epoxy/flox (double joggle does not cover full L.E.)

~ ~ -=, T.E. of fairings bonded together with epoxy/flox

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Lnncair Intcnuitionnl Inc., Represented by Neico Aviation Inc., Copyright.01992, Redmond, OR 97756

Fll. Ifneeded,cutthefairingT.E.'ssotheyareevenwiththewingT.E.'sasshown. (The later model wing fairings come trimmed with the joggle.)

F12. Later in the construction, the extension fairings are installed at the aft edge of the wing fairings.

Installing the Fairing T.E. Cap Figure 16:F:7

Top Wing Fairing

_ tA/C Up

F~

Bottom Wing Fairing

NOTE: If you have an earlier

F13. The wing fairings should now be stiff enough so you can safely remove the wings without losing proper alignment. Apply two BID to the outer surface of the foam wing profiles, wrapping onto the inner surface of the top and bottom fairings. The fairings are now structurally complete.

Lrmcn.ir Internnlional Inc., Represented by Nefoo Avinlion Inc., Copyright O 1096, Redmond, OR 97756

F15. The wing fairings should now be stiff enough so you can safely remove the wings without losing proper alignment. Apply two BID to the outer surface of the foam wing profiles, wrapping onto the inner surface of the top and bottom fairings. The fairings m·e now structurally complete.

Glassing the foam wing profile Figure 16:F:8

Fuselage

2BID

~ Bottom fairing

Notice that this shows the left fairing with the 2 BID reinforceinent on the inboard side of the foam.

F16. To clean up the fairings cosmetically, grind down the fairing edges where they join the fuselage. Add some micro to these areas and sand a smooth transition between fairings and fuselage. The L.E. and T.E. of the fairings can also be sanded, cleaned and smoothed out with micro.

Fl 7. From inside the fuselage, reach into the wing fairings and remove the foam braces that you installed in Step F4.

Lancnir lnlcrnntionnl Inc,, Rcpruimnlcd by Ncica Aviation Inc., Copyright il:l 19!}2, Redmond, OR 97766