Quicksilver MAX Sprint, Assembly Manual

Page 1: ...ASSEMBLY MANUAL AIRFRAME KIT 99110 S ___DATE__ __j_ DOC 872 01 AT...

Page 2: ...the claim is valid Air Tech Inc reserves the right to accept or reject any claim 4 NOTE Only ONE claim per kit will be reviewed DO NOT begin assembly until you have completed your inventory The packi...

Page 3: ...gulation FAR Part 103 Contact the Experimental Aircraft Association EAA DIRECTLY in Oshkosh Wisconsin on how to obtain a copy of the EAA Custom Built Sport Aircraft Handbook for information on aircraf...

Page 4: ......

Page 5: ...7 ROOT TUBE SPARS 8 WING COVER LOCATION FABRIC TENSION 9 FABRIC INSTALL 10 RIB END CUT OUT 11 COMPRESSION STRUT INSTALL 14 DIAGONAL STRUT INSTALL 15 RIB INSERT 18 UPPER WIRES 19 LEADING EDGE OUTBOARD...

Page 6: ...p ribs are installed so that the orientation of the fabric is established on the Spars The Root end of the fabric is secured Only then can tension be pulled towards the tip We use a cheap Wal Mart typ...

Page 7: ...This will keep wires organized All LOWER flying WIRES must be the wire closest to the Wing Spar The LEADING EDGE OUTBOARD WIRE Vertical hole is located 2 Outboard of the Compression Strut hole This wi...

Page 8: ...LOW and Aileron Compression Stut ABOVE VERY IMPORTANT Each Tube should be marked FWD and AFT in respect to the Tube Connector Fitting AFT END of the Bellcrank Strut has the shorter length AFT of the S...

Page 9: ...AN4 26a 10240 LEFT SIDE ASSEMBLY SHOWN REPEAT FOR RIGHT SIDE 1 1 2...

Page 10: ...BLANK PAGE 6 3b Section 4 6 Air Tech Inc...

Page 11: ...TRUT 71020 1 PER WING TRAILING EDGE OF WING DIAGONAL STRUT 40420 1 PER WING WING IS SHOWN UPSIDE DOWN DO NOT CONFUSE THE COMPRESSION STRUT HOLE WITH THE COMPRESSION STRUT BOLT HOLE HEAT CUTTING THE BO...

Page 12: ...TS ARE LOCATED UNDER THE T E SPAR CHANNELS IF SO A SPACER THE THICKNESS OF THE MOUNT MAY BE NEEDED AT THIS TIME TO ALLOW FOR THE MOUN THE MOUNT AT FINAL ASSEMBLY 1 4 LOCKNUT 10510 1 4 LOCKNUT 10510 IN...

Page 13: ...menstion is from the End of the Wing Spar L E T E to the edge of the fabric Mark the Spars at the 2 location Secure the LOOPs so that the Fabric is securely fixed Another OPTION is to tie the Loops to...

Page 14: ...RIBS 40169 WITH VELCRO IN SECTION 12 WING TIP NOTICE...

Page 15: ...Trace the lines onto the Trailing Edge pocket for each Rib See NOTE for Tip Rib Carefull not to cut into the main TOP surface fabric For all 9 Rib locations 12 Section 4 11 Air Tech Inc...

Page 16: ...cator Hole in Template COMPRESSION STRUT CUT OUT TEMPLATE Hidden hole under fabric Do Not cut out at this time Compression Strut holes are located at 62 157 48cm 130 330 2cm 159 403 86cm from Root End...

Page 17: ...for Wood Carving A modified Soldering Iron is the most common tool Simply shape the soldering tip into a Blade Shape SEE COMPRESSION STRUT CUT OUT TEMPLATE SECTION 12 WING COVER ATTACHMENT CONT D One...

Page 18: ...F LEADING EDGE OUTBOARD WIRES CUT WITH TEMPLATE POP ALL 3 STRUTS INTO PLACE DO NOT CUT FABRIC FOR BOLT HOLES LEADING EDGE COMPRESSION STRUT BOLT HOLE IN FABRIC CUT DURING CABLE INSTALL COMPRESSION STR...

Page 19: ...Section 4 15 Air Tech Inc...

Page 20: ...Aircraft using the EXTRUDED Channels DO NOT need this washer Aircraft using the EXTRUDED Channels DO NOT need this washer D DETAIL B 8 8 DIAGONAL STRUT ATTACH Cont d DETAIL A...

Page 21: ...BLANK PAGE 6 3b Section 4 17 Air Tech Inc...

Page 22: ...PAR Best to have help when installing the ribs While carefully pushing the rib into the pocket help should be pushing down on the front tip of the rib as it moves thru the rib Pocket While pushing hol...

Page 23: ...LEADING EDGE SLOT Cut Out TEMPLATE is in SECTION 12 L E OUTBOARD W ING TIP WING IS SHOWN TOP IS UP T E OUTBOARD LEFT WIRE SET 20586 L E INBOARD T E INBOARD Section 4 19 Air Tech Inc...

Page 24: ...D TEMPLATE ARE FOR THE LEFT WING FLIP THE TEMPLATE OVER FOR THE RIGHT WING COMPRESSION STRUT COMP STRUT BOLT HOLE FULL SIZE TEMPLATE WITH INSTRUCTIONS IN SECTION 12 LEADING EDGE LEFT WING SHOWN Sectio...

Page 25: ...LLCRANK COMPRESSION STRUT BELLCRANK STRUT Heat cut holes for Grade 5 Bolts make sure compression struts are in line with holes Assemble Hardware in sequence shown below and in following pages Steps1 7...

Page 26: ...T AN4 30A 10270 Not a cut out for clarity only CAREFULLY HEAT CUT THIS HOLE USING TEMPLATE AS GUIDE 1 3 4 SADDLE 20290 WING WIRES COMPRSSION STRUTS CON T ANTI DRAG WIRE 71032 OTHER END IN STEP 7 THIS...

Page 27: ...AR TRAILING EDGE SPAR WING WIRES COMPRESSION STRUTS CONT ASSEMBLE AS SHOWN FOR STEPS 4 5 AND 6 WING WIRE T E LOWER OUTBOARD 20546 1 4 X 2 BOLT 10410 1 4 X 2 BOLT 10410 1 4 X 2 1 2 BOLT 10428 WASHERS A...

Page 28: ...t 48 11 16 123 65cm 116 11 16 1296 cm 165 3 4 421cm From ROOT END of T E Spar Heat cut to expose 1 4 hole and assemble as shown in 3 Places WING TIP 1 4 20 LOCKNUT 10511 COURSE THREAD W ING TRAILING E...

Page 29: ...3 16 hole 12 3 4 from front of Comp Strut VIEW A A Loosly attach Strut as to get a measurement on where to cut the end Fish Mouth Ideally help is available While pulling on Tip Rib Pushing on Comp Str...

Page 30: ...PERATION 1 CABLES BOLTS NUTS 2 AN BOLTS 3 AN BOLT GAUGE 4 CASTLE NUTS PINS THREAD LOC 5 BOLT TIGHTENING 6 TIGHTENING PROCEEDURE 7 LOCATING HOLES HEAT SEALING 8 STAND OFF ASSEMBLY 9 NICO GAUGE 10 TOOLS...

Page 31: ...ate in the performance of Final Assembly Sections of the manual may be performed in a different order than presented based on the particular requirements of the builder for example time space experien...

Page 32: ...to replace a washer than a scored or damaged part If needed add a washer under the head to take up length IMPORTANT Particular care is necessary during bolt tightening Bolts which pass through Tubes...

Page 33: ...the length in 1 8 fractions Example An AN4 24 Bolt is APPROXIMATELY 2 4 8 or 2 1 2 in length NOTE To identify the second of TWO digits as an 8 would be incorrect since 8 8 1 A call out of AN5 28 would...

Page 34: ...r number on its head DO NOT USE a Grade bolt unless it is specified NOTE AN bolts are used throughout the construction of the aircraft for structural integrity NEVER USE SUBSTITUTES See your Quicksilv...

Page 35: ...correctly secured with a Cotter Pin THREAD ADHESIVE Thread adhesive Loctite 290 may be supplied with the kit and is required on ALL threaded fixtures bolts push pull control cable rod end bearings et...

Page 36: ...ious page for the proper method of bending Cotter Pins NOTE When Castle Nuts are tightened the Cotter Pin holes may not line up with the slots in the nut when the torque setting is reached Back off to...

Page 37: ...hrough a Tube 2 is to tighten the Nut 3 or Bolt 1 only to the point that all the Items 4 between the Nut 3 or Fitting 5 and the Bolt Head 1 come into contact with one another and then continue tighten...

Page 38: ...n pencil with a blade at the tip which will cut and heat seal in ONE step However sometimes the correct tool is not easily available and therefore some builders may have to improvise If you are unable...

Page 39: ...efer to Figure 1 10 A single stand off in a typical application is shown Cut a 1 2 13 mm piece of Fuel Line 1 Thread a Nylon Tie Wrap 2 around a typical part 3 through the Line and around the airframe...

Page 40: ...ength of the cables for nicks or cuts in the jackets WARNING DO NOT USE cables which show signs of damage or that have broken or untwisted individual strands which make up the cable WARNING DO NOT USE...

Page 41: ...dge Assy Assembly LEOB Leading Edge Outboard A R As Required Lwr Lower atch Attach Mnt Mount Brckt Bracket O D outside diameter brk Brake Outbd outboard Brng Bearing pdl Pedal carb Carburetor pit Plat...

Page 42: ...icone Spray Lithium Grease WD 40 Pencil Pliers Regular Needle Nose Wrenches Open End Box End S A E 3 8 7 16 1 2 9 16 Sockets S A E 3 8 7 16 1 2 9 16 Allen Wrench S A E 1 8 Protective Material carpet o...

Page 43: ...RUDDER ASSEMBLY 2 2 ELEVATOR ASSEMBLY 2 12 STABILIZER ASSEMBLY 2 13 TAIL TUBE ASSEMBLY 2 15 TAIL SKID ASSEMBLY 2 17 TAIL BOOM BRACE ASSEMBLY 2 18 Section 2 1 Air Tech Inc...

Page 44: ...40333 Section 2 2 Air Tech Inc...

Page 45: ...RUDDER COVER AND RUDDER LEADING EDGE Section 2 3 Air Tech Inc...

Page 46: ...RUDDER LEADING EDGE AND CONTROL ARM Section 2 4 Air Tech Inc...

Page 47: ...RUDDER LEADING EDGE AND CONTROL ARM Section 2 5 Air Tech Inc...

Page 48: ...3 Section 2 6 Air Tech Inc...

Page 49: ...Section 2 7 Air Tech Inc...

Page 50: ...Section 2 8 Air Tech Inc...

Page 51: ...RUDDER BALANCE STRUT Section 2 9 Air Tech Inc...

Page 52: ...Section 2 10 Air Tech Inc...

Page 53: ...RUDDER HINGE BOLT Section 2 11 Air Tech Inc...

Page 54: ...BLANK PAGE Section 2 12 Air Tech Inc...

Page 55: ...TOP VIEW 10500 bolt Heat cut slits TEMPLATE Page 12 3 AN3 14A 10035 sections Locknuts 10510 Washers 10560 70130 Section 2 13 Air Tech Inc...

Page 56: ...40275 Section 2 14 Air Tech Inc...

Page 57: ...STABILIZER LEADING EDGE ASSEMBLY Section 2 15 Air Tech Inc...

Page 58: ...e up the space by stacking washers under the Locknut This will facilitate any adjustments during Test Flights that may require an adjustment in Tail Incidence Section 10 Tighten all Nuts DO NOT Over T...

Page 59: ...AIL B DETAIL C DETAIL A SIDE VIEW HOLES DRILLED AT AN ANGLE TO MATCH TAIL SKID SEE PAGE 2 18 FLEX SLEEVE 20397 Installation 14 Bolt may seem to long Add washers under the nut 8 to take up space This a...

Page 60: ...RKS CLEVIS PIN 10440 41150 SAFETY RING 20310 1 1 4 LOCKNUT 10510 2 1 4 WASHER 10560 3 HINGE FORK 10390 4 AN4 27a 10250 5 1 X 1 8 SADDLE 20270 6 AN4 25a 10220 7 FLEX SLEEVE 20397 7 FLEX SLEEVE 20397 8...

Page 61: ...BLANK PAGE Section 2 19 Air Tech Inc...

Page 62: ...the Hardware Bolt and Saddles onto the Tail Skid 41150 During Final Assembly be very careful not to Crush These Tubes by Over Tightening Detail B When installing Tail Brace Tube 40425 into Channel 20...

Page 63: ...TAIL BOOMS TAIL BRACES 9 8 8 6 11 11 4 4 4 8 7 7 7 13 3 15 14 14 16 16 DETAIL C DETAIL C DETAIL B A DETAIL A B C Section 2 21 Air Tech Inc...

Page 64: ...he Root Tube Some builders will attached the Root Tube to the top of a wood saw horse to facilitae the assembly of the Wings Installation of the Hirth F 23 engine installs the engine mount angles betw...

Page 65: ...o NOT attach at this time 5 16 Locknut 10540 Finger Tight Only ROOT TUBE AN4 30a 10270 AN5 25a 10312 o The Hirth F 23 will mount to the AFT part of the Root Tube See the Engine Install Instructions fo...

Page 66: ...Section 3 3 Air Tech Inc...

Page 67: ...1 SECTION 5 AILERONS TRAILING EDGE ASSY 2 NUTPLATE COMPRESSION STRUTS 3 LEADING EDGE ASSEMBLY 4 COMP STRUT INSTALL 5 FABRIC INSTALL 6 EYEBOLT HORH ATTACH 7...

Page 68: ...Section 5 2 Air Tech Inc...

Page 69: ...Section 5 3 Air Tech Inc...

Page 70: ...Section 5 4 Air Tech Inc...

Page 71: ...Section 5 5 Air Tech Inc...

Page 72: ...YOU TUBE SEARCH QUICKSILVER AILERON INSTALL Section 5 6 Air Tech Inc...

Page 73: ...Section 5 7 Air Tech Inc...

Page 74: ...SSEMBLIES NOTES 2 GENERAL ARRANGEMENT 3 TIRE WHEEL ASSEMBLY 5 NOSE GEAR 6 RUDDER PEDALS CABLES 7 RUDDER PEDAL STOP 8 TRI BAR ASSEMBLY 10 LANDING GEAR DOWN TUBE MAIN AXLE 11 AFT RUDDER CABLE PULLY 12 S...

Page 75: ...heel Tire Assembly The Standard wheels on the QS single place aircraft is the 5 Black Plastic Wheels w 5 Tires Some builders will opt for the larger Wheel Tire kit for the rear wheels Typically the no...

Page 76: ...F O R W A R D TRIKE GENERAL ARRANGEMENT Section 6 3 Air Tech Inc...

Page 77: ...BLANK PAGE 6 3b Section 6 4 Air Tech Inc...

Page 78: ...the outlet for the Inner Tube valve stem This is the typical tire wheel assembly This assembly uses the Azusa nylon 5 rims with 5 tire and tube If your kit is supplied with larger wheels tires only o...

Page 79: ...NOSE GEAR ASSEMBLY NOTE If Steerable Nose Wheel kit is used assemble this page with that kit 41300 41300 Section 6 6 Air Tech Inc...

Page 80: ...UDDER CABLE ASSEMBLY Safety Ring 20310 Clevis Pin 10440 thru this 3 16 hole to attach to top of Spring 91115 See Note on page 6 5 Non Skid Tape 20190 Trim as shown 1 4 Locknut 10510 Drill 1 4 6 3mm us...

Page 81: ...6 7 Section 6 8 Air Tech Inc...

Page 82: ...for the Rudder Pedals During Final Assembly the adjustment of this bolt will limit the travel of the Rudder Proper adjustment will not allow the Rudder to contact the Elevator Adjustment is obtained b...

Page 83: ...n Down Tube aligns with hole in Crosstube Nose Wire attaches to front of Root Tube 20331 Shackle is shown for reference only TRI BAR ASSEMBLY RUDDER CABLE 91113 See Page 3 2 for upper attachment of th...

Page 84: ...RIGHT SIDE SHOWN Section 6 11 Air Tech Inc...

Page 85: ...R CROSSTUBE Left Side Shown 1 4 LOCKNUT 10510 1 4 WASHER 10650 AXLE STRUT 40381 Left Side Shown 1 X 1 8 SADDLE 20270 5 16 WASHER 10570 5 16 LOCKNUT 10540 AN4 16a Bolt 10140 20 1 2 Section 6 12 Air Tec...

Page 86: ...Section 6 13 Air Tech Inc...

Page 87: ...AXLE FILE AND DEBURR ANY INTERERENCE ON NOSE STRUT AXLE STRUT TENSION STRUT 41300 TENSION STRUT 41300 NOSE STRUT 40365 NOSE STRUT 40365 INBOARD Section 6 14 Air Tech Inc...

Page 88: ...TION 8 SEAT MOUNT CONTROLS SEAT MOUNT SUPPORT TUBE 2 THROTTLE ASSEMBLY 3 SEAT ATTACH 4 CONTROL STICK 5 AILERON CABLE GUARD 6 ELEVATOR CONTROL 8 ROOT TUBE BELLCRANK 10 FUEL TANK 12 Section 8 1 Air Tech...

Page 89: ...Drill to 5 16 Section 8 2 Air Tech Inc...

Page 90: ...the Throttle Lever IDEALLY ATTACH THIS ASSEMBLY TO SEAT AFTER STEPS ON PAGE 8 9 In some instance there is interference with the Push Pull interference with the Push Pull Tube 40177 Sould be mounted as...

Page 91: ...SEAT MOUNT ASSEMBLY AN4 17a 10150 2 places rear AN4 15a 10120 Section 8 4 Air Tech Inc...

Page 92: ...0 0 Section 8 5 Air Tech Inc...

Page 93: ...VERTICAL 91111 Control Cable 70389 AILERON CONTROL CABLE GUARD ATTACH 40337...

Page 94: ......

Page 95: ...10045 AN3 16a 4...

Page 96: ...NOTE 11 is a Nylon Washer This bolt gets Castle Nut FINAL ASSEMBLY MAY REQUIRE A NEW HOLE BE DRILLED AN4 15a 10120...

Page 97: ...22 1 4 to aft end of tube Section 8 10 Air Tech Inc...

Page 98: ...offs CABLE Actions must be SMOOTH and EASY Lock Jam Nut 7 onto 4 AFTER Final Assembly USE LOCTITE Be certain that LOCKRIB 14 is in GROOVE of Control Cable Final adjsutment to the Aileron Bellcrank wil...

Page 99: ...es are De Burred Some Fuel Caps do not Require this hole be Drilled Check that the installed Cap provides venting 30205 RUBBER FUEL TANK BUSHING 30290 Install Bushing then Fittings Grip Fittings with...

Page 100: ...1 SECTION 9 WING TAIL ATTACH WINGS TO TRIKE 2 KINGPOST ASSEMBLY 3 ASSEMBLY NOTES 4 UPPER LOWER WIRE ATTACH 5 TAIL GROUP ATTACH 6 Section 9 1 Air Tech Inc...

Page 101: ...USE OUTBOARD COMPRESSION STRUTS TO RAISE WINGS REFFER TO SECTION 4 PAGE 8 THE INSTALLED ENGINE MAY PREVENT THE WING TIPS FROM RESTING ON THE GROUND Section 9 2 Air Tech Inc...

Page 102: ...KING POST ASSEMBLY FWD King Post 40205 Section 9 3 Air Tech Inc...

Page 103: ...st AFT hole in the AFT KP Channel 45681 Again be sure the wires are not snagged or twisted at the Tang end bolted to the wing You may need to adjust the height of the wings to allow this step Only att...

Page 104: ...UTS TO SUPPORT WINGS 20534 20544 20546 20547 CLEVIS PIN LOWER WIRES REF PAGE 6 11 FOR BOLT SIZE AFT KING POST RIGHT UPPER WIRES 20587 LEFT UPPER WIRES 20586 T HANDLE PIN 2 PLACES SAFETY RING 3 PLACES...

Page 105: ...ep CAUTION Be very sure the Upper Boom Tube aligns easily to Channel Once connected DO NOT raise or Lower the tail assembly This will damage Tubing Channels and or Bolts and or Bolts Attach the AFT en...

Page 106: ...URFACES INSTALL ADJUST NOTES 2 CONTROL STICK SET 3 AILERON CABLE ATTACH 4 AILERON TO WING 5 AILERON PUSH ROD 6 AILERON ADJUST 7 SYSTEM CHECK 8 ELEVATOR PUSH PULL TUBE 9 TAIL INCIDENCE 10 ELEVATOR ADJU...

Page 107: ...Bolt Adjustment AN43B 15a is later on this page ELEVATOR PAGE 2 12 depicts the Hinge assembly for the elevator to attach to the Stabilizer Connect the Center hinge first then the two outboard hinges A...

Page 108: ...02 MUST BE PARALLEL TO ROOT TUBE LOCTITE JAM NUT 10495 Adjust to LOCK Cable onto Rod End Bearing Ideally Equal threads Top Bottom LANDING GEAR DOWN TUBE 40291 Tie Control Stick in NEUTRAL Position Sec...

Page 109: ...TOP VIEW Section 10 4 Air Tech Inc...

Page 110: ...Section 10 5 Air Tech Inc...

Page 111: ...PUSH ROD Inboard hole Less Effort Less Travel Outboard hole More Effort and More Travel AILERON INSTALTION CONT D Section 10 6 Air Tech Inc...

Page 112: ...OCTITE TO JAM NUTS With Control Stick in NEUTRAL Position Adjust Control Rods till Ailerons align with Straight Edge along Bottom of Wing Same for BOTH Wings Location of Straight Edge should be near A...

Page 113: ...Section 10 8 Air Tech Inc...

Page 114: ...USH PULL TUBE 40178 70190 ELEV HORN 70070 3 16 LOCKNUT 10550 10550 AN3 14a 10035 1 4 CASTLE NUT 10521 AN4 15a 10120 AN4 15a 10120 40178 STOP WIRE 21564 Drill hole to 1 4 40177 1 4 LockNut 10510 ELEVAT...

Page 115: ...proximatly 1 2 12 7mm HORIZONTAL STABILIZER INCIDENCE X Flight Testing will determine the final numbers of Spacers Assuming all other adjustments W B are followed this Step will have an effect on the...

Page 116: ...Elevator and Horiz Stab need to held against bottom of straight edge 3 3 Position and hold the Control Stick so it points Straight UP 4 Align Holes in FWD Push Pull Tube 40177 and Elev Adjust Tube 800...

Page 117: ...fference is establish during the engineering of the aircraft is set by the pre made Wire Lengths Theres no practicle way for you the builder to change or adjust this setting BUT it MUST be checked to...

Page 118: ...CUMENT LABEL PLACEMENT CLEAN DEGREASE AREA APPLY LABEL REMOVE AIR BUBBLES WING TRAILING EDGE POSITION LABEL TO BE EASILY SEEN BY ANYONE APPROCHING THE AREA NEAR OR AROUND THE PROPELLER ONE LABLE FOR E...

Page 119: ...SEAM LINE 1 1 2 3 81cm 7 17 8cm SIDE VIEW CLEAN DEGREASE AREA APPLY LABEL REMOVE AIR BUBBLES DOC 846 18 Section 11 2 Air Tech Inc...

Page 120: ...LEADING EDGE OUTBOARD WIRE 2 RUDDER ELEVATOR 1 THRU 4 3 RIB END CUT OUT 4 WING COMPRESSION STRUTS 5 Section 12 1 Air Tech Inc...

Page 121: ...ROM MANUAL 2 CAREFULLY CUT OUT SLOT AND HOLE 1 3 ALIGHT HOLE 1 ON COMPRESSION STRUT BOLT HEAD 4 ALIGN PERPEDICULAR AND PARALELL EDGES WITH LEADING EDGE SPAR 5 TAPE TEMPLATE ONTO PLACE 6 MARK SLOT ONTO...

Page 122: ...G ZAG ON TUBE CENTER LINE TEMPLATE FOR RUDDER AND ELEVATOR 2 3 4 ALIGN TO ZIG ZAG STITCHING ALIGN TO ZIG ZAG STITCHING CUT OUT ON SOLID LINE ALIGN THIS LINE TO CENTER OF COMPRESSION STRUT TUBE TEMPLAT...

Page 123: ...CUT OUT SLITS EDGE OF RIB POCKET CUT OUT TEMPLATE RIB END CUT OUT TEMPLATE Section 12 4 Air Tech Inc...

Page 124: ...GTH OF ILLUSTRATION IS NOT CORRECT SEE DIMENSIONS ON SIDE OF TEMPLATE FINISH LENGTH IS 16 16 41 91cm 13 1 2 34 29 TEMPLATE WING COMPRESSION STRUT CUT OUT SLOT LINE UP FOR TRAILING EDGE CUT OUT LINE UP...