dacron highlandermanualchapter4

8/10/2019 DACRON HighlanderManualChapter4

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Final Assembly

Now that you have your covered surfaces painted itstime for final assembly. Everything you had totake off to paint can now be put back on i.e. floorboardscontrols and such. At the factory the first

thing we do is get the plane back on its gear, and then the tail feathers go back on. Be sure to grease the

bolts when you put them in for the last time. Think as you go so you only have to put it together once,i.e. floors have to be in before the fabric, and all wiring and fuel systems that go under floors, beforethe floors.

1. INTERIOR

The interior can be as plain or as fancy as you want. Here we will discuss how we put in our deluxe

interior kit.

Step 1

Open the interior kit box as early as you can so you can unroll the fabric and get it laying flat.The baggage area is done first. There is no wrong way to put the glue on whether you start at the top or

bottom is your choice. Spray both the fuselage and the back side of the fabric. The piece for this area

has a seam in it that goes along the top edge. Trimming is required around tubing and rudder cable

guides and along the bottom. Plan the front edge carefully so the front piece lays in nicely. See figure1.1

F igure 1.1

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Step 2

Once both rear pieces are in, complete the front pieces. The front pieces have the door opening

already trimmed in so complete that area first and work to smooth it out from there, cutting around the

tubing and rudder guides as in the rear piece. See figure 1.2

figure1.2

2. RUDDER CABLE INSTALLATION

STEP 1

Clamp the rudder pedals in a neutral position so that the foot tube is about 6 from the firewall.Fitting the rudder cable guide tubing is as follows. Cut 18 pieces of the tubing about 2 long with a

long taper at one end. Pull through the bushings with pliers and trim flush with both sides of bushing.

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STEP 2

Pull rudder cable through all the bushings (leave plenty at each end for final fitting) and cutaccordingly.

Starting with Serial#194 the fuselage has cable fair leads in the front and rear locations. These fair

leads are the same as the ones behind the seats for flap & Ailerons. Use Part# F3030.0 for guides.

STEP 3

At the rudder end, fit a 2 length of heat shrink tubing over the cable then fit an F-0840.0 Nicopress

sleeve. Feed the end of the cable back through the Nicopress sleeve and tighten the loop around athimble. Ensuring that the thimble is held securely in position, swage the Nicopress sleeve with an

approved tool. Trim the surplus cable approx 1/2 from the sleeve. Put the heat shrink over the cut

end, up to the Nicopress sleeve, and then shrink sleeve it into place.

STEP 4

The rudder cable is attached to the rudder horn using a shackle which is attached to the rudder horn

with an AN3-5 bolt flat washer and castle nut. Refer to figure 2.1 Rudder Cable Attachmentbelow.

F igure 2.1

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STEP 5

Bushings (F-0845.0) are provided for the attachment of the toe brakes to the rudder pedals. All 4bushings have a tab on them. The 2 outer pedals positions have the tab on the outside of the rudder

pedals and the inner pedals have them toward the middle. The outer tabs attach to the turnbuckle. The

inner ones are to stop the feet from slipping sideways off the pedal. The bushings are inserted into the

top tube of the rudder pedals and held in place with the small bushing stops (F-0845.1) provided.Secure each bushing with CCP44 1/8 x Stainless Rivets. The inner bushings (with tab) have a

further CCP44 rivet (that fixes the bushing to the rudder foot tube) to hold them in the correct position

i.e. so that the tab actually stops the feet from slipping sideways. See Figure 2.2

F igure 2.2

STEP 6

Attach MS21252-3RS turnbuckle (fork-end) to rudder pedal with AN3-5 bolt. See Figure2.3

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Figure2.3

STEP 7

With the pedals still clamped, place the cable under light tension and secure the cable to theturnbuckle and then Nicopress (F-0840) in the same way as in Step 3. The turnbuckle should be

tightened initially to the neutral position, i.e. about half way into the turnbuckle. Turnbuckles to be in

safely should not show any thread. They are also secured after final assemble and adjustment with thesupplied safety wire.

3. RUDDER CABLE RIGGING

STEP 1

Visually check that the cable systems have been correctly fitted and are symmetrical. Operate the

control, ensuring that full and free movement is achieved. Adjust as necessary to ensure that therudder is in the neutral position with pedals even, then safety wire the turn buckles.

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4. BRAKES

Step 1

Mount the brake cylinders next. The larger of the two pairs have the reservoir on them. We put them

on the left side and the other two on the right side. See figure 4.1.A

Figure 4.1.A

Step 2

Bolt the hydraulic main wheel assembly cylinder mount brackets to the toe brakes using AN3-4A

bolts with AN365-1032A nuts. Do not tighten the nuts all the way. The assembly should move freely.Line up the shaft out of the brake cylinders and drill 5/16 holes in the mount bracket. Remove the

clevis that comes on the cylinder and discard. Bolt the cylinders onto the brackets with the AN316-5R

nuts provided. See figure 4.1.B

Figure 4.1.B

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Step 3

Make up the brake lines so that the line coming from the far left cylinder on the bottom goes to the

top of the third cylinder in line. The bottom line from this cylinder goes to the left brake assembly atthe wheel. We route this line under all the tubing back to where we want it to come out of the fuselage

and burn a hole there with a soldering iron. Match the alignment of this hole with a corresponding hole

in the inside of the landing leg.See figure 4.2

F igure 4.2

Step 4

Put another hole in the bottom of the leg for the brake line to come out of. Note some of the landing

gear has a plate in the bottom so make sure you put the hole above them. See figure 4.3

F igure 4.3

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5. Firewall

Put the firewall back on now in preparation for mounting your engine.

6 Mount your engine

It is now time to mount your engine. Depending on your engine choice you can either purchase your

mount from the factory or make your own. We will not address particular engine installations in thismanual. Refer to your engine installation manual that comes with your engine.

7 Put Wings Back On

Now that the engine is on, the weight is enough to put the wings back on without worry of the plane

tipping over while just one wing is on.

Step 1

Turn wings upside down on sawhorses and prep for installation by reaming all the flap and aileron

hinge brackets. Also ream the lift strut attach brackets, the mounting holes in the spars, and clean outthe pulley positions.

Step 2

Assemble the bottom pulleys at this time and pull the cables out, (just let them hang for now).

Step 3

Turn the wing over and cut out the gas cap hole and the top aileron cable, again just let it hang out fornow.

Step 4

You have had the wings on and off several times during the build stage so get your hardware out and

this time grease the bolts when you put them on because they never have to come out again. The only

difference now is the pitot line, when putting the wing up to the fuselage the line goes in front of thewing mounting position. ***NOTE*** BE CAREFULL WITH THE LEFT WING AND DO NOT

DAMAGE THE PITOT TUBE WITH THE LIFT STRUT.

Step 5

Once you have both wings back on and the hardware properly secured with the cotter pins ensure that

the front tube doesn't hit the Butt rib when swinging back and forth, if it does use a sanding drum andremove material from the Butt rib until it clears with about an 1/8 clearance all around.

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8. Jury Struts

Put the Jury Struts back on now. Secure the hardware and yourefinished. It does not matter if thefront of the Jury Struts look straight behind the rear of the strut. The purpose of the strut is to hold the

lift strut straight. Look down the Lift Strut from the top and adjust the Jury Strut wing clamp up or

down until the Lift strut is straight. Tighten it there.

9. TURTLE DECKThe turtle deck F- 2260 fits between the rear windshield bracket (on the head rack) and the next cross

tubes over the baggage area. See Figure 9.1

Figure 9.1

STEP1

The leading edge sides of the turtle deck need to be trimmed so that the control cables etc can pass

through without snaggingFigure 9.1gives a good idea of how the sides should be trimmed. Remove

small pieces as a time until you get good clearance.

Trim out a half-moon radius at the front to clear the head rack tube leaving 1/8 clearance. Cut out arelief area for clearance of the flap and cross over cables. It is better to do this when the aileron cable

etc are fitted as the line of the slot is not parallel to the turtle deck line.

STEP2The turtle deck is secured to the fuselage by screws, which are located two on either side and three

along the rear edge of the turtle deck.

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The 7 tabs should have the F-2270 nut plates attached with AN426A-3-4.1 soft rivets. The turtle deck

is then drilled to allow the screws (AN526-832 R-6) to fit into the nut plates.

Camlock style fasteners can be substituted to facilitate easier turtle deck removal.

10. Install Panel and Wire

The Instrument Panel is supplied to you as uncut. It is bent to fit the fuselage but final fitting is up to

the owner and instrumentation. These are but just a few.

We will not get into wiring of panels in this manual. It is up to the owner how this is done and up to the

individual components schematics.

11. Cowlings

The cowlings

Boot F- 2600

Boot cowl is fixed to the fuselage with 4 AD44ABSLF 1/8 x large head aluminum rivets.

Boot to windscreen with 11 AD44ABSLF 1/8 x large head aluminum rivets.

Top fixed to both boot and bottom cowlings (You need to make an opening for oil checking)

Top F- 2610

Bottom F-2620

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The Cowlings should be fitted after the engine has been installed (even temporarily) as itspositioning

and cut-outs are relative to the engine.

STEP1

Trim top cowling to molded-in line. If necessary, enhance the clarity of the line with a fine tip

permanent marker or masking tape,see Figure11.1.

Figur e 11.1STEP2

Assemble top and bottom cowlings together and securely clamp. Drill 1/8 holes at the rear andforward edges and Cleco them together,see Figure 11.2.

F igure 11.2

STEP3

Slide the cowling over the nose of the fuselage.

STEP4

Clamp a straight edge horizontally across the engine propeller flange. Align the cowlingsymmetrically with the propeller flange, ensuring adequate fore and aft clearance for the propeller, see

Figure 11.3.

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F igure 11.3STEP5

Recheck that the cowlings are straight and symmetrical then drill 1/8 holes through the fuselage

mounting tabs. Secure with Clecos.

STEP6

Locate and mark the cowling for the cooling duct assembly required for your engine.

STEP7

Remove the cowling. Cut out the holes marked at Steps 5-6.

STEP8

The eight fuselage-cowling tabs need to have nut plates F-2630.0 fitted. Center them to the Cleco holesdrilled earlier. The nut plates are held in place by AN426A-3-4 soft rivets.

STEP9

The two halves of the cowling are joined together using F-2630.0 nut plates on the bottom cowlingwith AN526-832R6 screws through the top cowling into the nut plates. The nut plates should have a

nominal 5 spacing.

All the nut plates and screws may be replaced with cam-lock type fasteners.

12. WINDSHIELD FITTINGSTEP 1

Cut windshield from the Lexan sheet supplied in your kit F-2220. A rough template is provided in

order to cut the sheet down to a more manageable size; please note this is not an exact size as the finalcut will be determined by the positioning of the butt ribs (W-0280.0/W-0280.1) and the boot cowling

section.

Do not undercut, cut to the outside of the pattern. For protection from scratching, leave the

covering paper on the Lexan until all fabrication operations have been completed.

Fit the Lexan to the rear windshield angle bracket and the butt ribs first.108


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STEP 2

With both wings extended and butts ribs in position carefully lay the cut Lexan windshield and

canopy cover in position. Align the Lexan sheet so the rear edge of the sheet lies parallel to the rearedge of the rear windshield bracket (attached to the head rack), allow at least1/8 overlap and secure

with clamps.

Note-You will have to make relief cuts to allow access to the rear wing attachment bolt otherwise

you will have to remove the windscreen to remove the wings. See figures 12.1a and b.

Figur e 12.1a F igur e 12.1b

STEP 3

Position both butt ribs so they fit snugly against the end wing rib. From the top of the Lexan sheet

mark the line of the outer edge of the butt rib with masking tape - You willneed to remove some of the

protective plastic cover to allow for visual sighting).

Remove Lexan sheet and cut to size sand and smooth all edges.

STEP 4

In the rear windshield angle bracket drill 6 x 1/8 holes on the center line, positioned 1 in from each

end and then equally spaced between the 2 outer 1 holes, then in each butt rib, drill 9 x 1/8 holes the

first 1 from the front of the butt rib and then every 3.

STEP 5

Return the sheet to the top of the cockpit area and clamp into place. Using the holes drilled in step 4to carefully mark and then drill the Lexan, hold in position with Clecos.

STEP 6

Fold the Lexan forward and down to form the windshield and tuck it under the cowling (just fit theboot section) when finally trimmed the Lexan extends about 2 to 3 below the level of the boot cowl.Push the Lexan up tight to the cowling for a snug fit. Drill 1/8 holes and Cleco the Lexan to the 4 tabs

running vertically on each windshield post. Mark a half circle around the front spar leaving enough

space to easily remove or install the wing spar to head rack locking pin. See figure 12.2

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Figur e 12.2

STEP 7

The Lexan is then trimmed to follow the line of the rear of the down tubes.

*NOTE*The Lexan once trimmed should have all edges sanded and smoothed.

Only use water based markers on the Lexan otherwise they become permanent.

STEP 8

Return Lexan sheet to its original position and clamp securely; ensure that the left and right brackets

fit snugly with the Lexan sitting between the tabs and the brackets

STEP 9-FINAL ASSEMBLY

Please note, before final assembly the two angle brackets and the rear head rack bracket must have

their final paint cover. Also when riveting to the butt ribs or fibreglass cowlings use rivet washers tospread the load.

Return Lexan to its original position; clamp securely. Ensure there are no sharp edges and the topcowling is in position.

Working from the rear head rack bracket fix Lexan with large head rivets.

STEP 10

Fold the Lexan onto the securing tabs and position the angle bracket around the upright tubing and on

the outside of the Lexan. Fix with large head rivets.

STEP 11

Ensure a tight fit around the windshield and cowling as well as a secure and tight fit to the butt ribs.

13. INSTALLATION OF DOORS AND WINDOWS

STEP 1Cut the larger piano hinge F-2810.1 to fit under the square tubing on the fuselage.

Drill and deburr 14 to 15 holes on each side of the hinge at 2 intervals opposite the hinge joints.110


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Clamp the hinge to the fuselage and drill and cleco all the holes to the fuselage from one end to the

other. Remove the hinge and deburr the holes.

Repeat the above with the hinge on the door.

Repeat the above process for the window to door assembly using the smaller hinge F-2810.2

Now rivet the door hinge to the fuselage with 012634-9 1/8 x aluminium sealed rivets, then

completely rivet the rest of the door & window frames.

14. INSTALLATION OF LEXAN

STEP 1Remove doors and windows, by removing hinge pin. Place on the lexan sheet F-2890. Carefully

trace the outline of the bottom section of the doorframe onto the lexan sheet. Using the trace line as a

guide draw a second line extending the line a further 2 inches, the top will be cut level with the outside

edges of the tubes. Next trace the window in the same manner.

STEP 2Using a jigsaw on low speed or a sheer carefully cut the lexan to shape. Work slowly removing small

amounts of material at a time.

STEP 3

Find the center line of the door tubing where the Lexan will fit, mark, punch and drill holes using

1/8 drill, clean and de-burr. Holes should be uniformly spaced approximately 4 inches apart.

STEP 4

Once all the holes are drilled and deburred, cleco the lexan onto the frames, put the window back onto

the door using the hinge pin, then put the door back on the fuselage.

STEP 5

When you are satisfied with the fit and finish of the panels rivet the panels onto the tubing using the

large head 1/8 x aluminum rivets. You can use a fine grain sand paper on a sanding block to achieverounded and smooth edges. Retain as much of the protective plastic covering as you can until final

assembly.

STEP 6

Repeat the whole process for the other door and window.

. STEP 7Window and door Latch F-2870 is fitted to the bushings on the bottom center of the window and door

frame(s). The Lexan will need to be drilled to allow access to the bushing. The inside handle is inserted

into the bushing and the outside handle attached to the other end. The inside handle is designed to lockagainst the middle tube. The 2 handles are secured together using F-2870.2 roll pin you will need to

drill the hole for this pin through both the handles when adjusted to give best locking action.

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15. GLARE SHIELD

After final installation of the instrument panel has taken place, and the windshield is in place andfastened down you are ready to make your Glare shield (F2300.3). There is included in your kit a 1X

3 piece of very thin aluminum sheet (020). This is for the Glare shield.

Step 1

First take a piece of cardboard and cut it to the fit between the windshield and the panel leaving a

nice overhang (3/4 to 1) over the top of the panel. When you get the fit you want and are satisfied withthe cardboard fit trace this outline onto the aluminum sheet and cut it out. There is no ledge for the

glare shield side to lay on, it just hangs out there.See figure 15.1

Figure 15.1 Figure 15.2

Step 2

When you are satisfied with the overall fit, you can paint or cover the shield with your choice of

coverings. It looks nice to leave an inch or two of loose covering on the windshield side. See figure

15.2112


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16. DOOR GAS STRUT INSTALLATION

Figure 16.1

Step 1

Install F-2810.1 Door cylinder brackets to fuselage with 4 each MS21919 WDG 4 Adel clamps and

4 each AN 3-4A bolts each with an AN960-10 washer and an AN365-1032 nut. These brackets are oversized and need to be trimmed to fit each side. See figure 16.2

Figure 16.2

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Step 2

Clamp with a small hose clamp the F-3441.0 gas strut bracket to the rear tube of the door. Use the

gas strut as a guide to help figure out where the best location is to mount this. The door is to be almosttouching the wing when open. Care must be taken not to get this too low on the door or the gas strut

wont close all the way. Once satisfied with the door location mark the fuselage location andmount the

gas strut to the door cylinder bracket on the fuselage.

Figure 16.3

Step 3

Re-check to make sure the door will close with the gas strut installed. Drill and rivet the gas strutbracket o the door with 4 each CCP 42 Rivets.

*Note* the nut on the door should just clear the fuselage when it goes by. See figure 16.3

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