Wills Wing Fusion 141, Owner'S Service Manual

Page 1: ...Fusion 141 and 150 Owner Service Manual October 15 1998 Third Edition ...

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Page 3: ... mail comments willswing com October 15 1998 Third Edition Copyright 1994 1995 1996 1997 1998 by Sport Kites Inc dba Wills Wing Inc All rights reserved No part of this manual may be reproduced in any form without the express written permission of Sport Kites Inc dba Wills Wing Inc Fusion 141 and 150 Owner Service Manual ...

Page 4: ...ong the trailing edge left wing 15 From the rear keel 16 Along the trailing edge right wing 16 At the right tip 16 Along the right leading edge 16 Under the glider at the control bar 16 Laying the Glider Down Flat 18 Setting the Glider Up Flat on the Ground 18 Launching and Flying the Fusion 19 Minimum controllable airspeed and minimum sink airspeed 19 Using wing tufts to find the minimum sink spe...

Page 5: ...Batten tension 40 Leading edge sail tension 41 Car Top Mounting and Transport 41 In Closing 41 HGMA Fusion 150 COMPLIANCE VERIFICATION SPECIFICATION SHEET 42 HGMA Fusion 141 COMPLIANCE VERIFICATION SPECIFICATION SHEET 43 Assembly Diagrams 83E01 1 Fusion Crossbar Center 2 83E02 2 Fusion Front Leading Edge and Cam VG 3 83E03 2 Fusion Sprog Wire and Bracket Carbon Sprog 4 83E07 0 Fusion Sprog Carbon ...

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Page 7: ...tions PG Delivered customer response form Delivered glider parts kit Delivered owner s manual READ BEFORE FLIGHT CAUTION Use of this equipment may result in INJURY OR DEATH Please be sure you are qualified to fly this product are thoroughly familiar with and follow all proper procedures as explained in the owner s manual You are reminded that YOU FLY AT YOUR OWN RISK I have read and understood all...

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Page 9: ...net please visit us regularly at http www willswing com The site features extensive information about Wills Wing gliders and products a Wills Wing Dealer directory a comprehensive list of service and technical bulletins the latest editions of owners manuals our com plete retail price list a search engine e mail and more The most important contents of our internet site are the service and technical...

Page 10: ...sted or certified to any state or federal government airworthiness standards or requirements Federal Aviation Regulation Part 103 states in part ultralight vehicles are not required meet the airworthiness certification standards specified for aircraft or to have certificates of airworthiness and operators of ultralight vehicles are not required to meet any aeronautical knowledge age or experience ...

Page 11: ... be stable over a range of angles of attack from trim angle to 20 degrees below zero lift angle at 20 m p h and from trim angle to 10 degrees below zero lift angle at 37 m p h and from 10 degrees above zero lift angle to zero lift angle at 53 m p h 5 Flight maneuvers which show the glider to be adequately stable and controllable throughout the normal range of operation Note The Fusion has been des...

Page 12: ...nge full forward on the control bar with the VG set full tight is approximately 58 m p h for the Fusion The placarded speed never to exceed for the Fusion is 53 m p h An airspeed indicator is provided with the Fusion and should be used by the pilot as an aid to comply with the placarded limitations The placarded maximum maneuvering speed and the placarded maximum rough air speed of the Fusion are ...

Page 13: ...ng is well aware that pilots have and continue to perform maneu vers and fly in conditions which are outside the recommended operating limitations stated herein Please be aware that the fact that some pilots have exceeded these limitations in the past without dangerous incident does not imply or insure that the limitations may be exceeded without risk We do know that gliders which meet all current...

Page 14: ...n second shortest curved batten and the 5 batten fourth shortest curved batten The transverse batten does not need to be removed unless the rear leading edges are removed to short pack the glider for transport Please refer to page 6 in this manual for more information on this The new style Fusion sail does not have a batten pocket to hold the transverse batten The sprog internal washout strut supp...

Page 15: ... rear leading edges left and right remember that left and right are reversed if the glider is lying on its back upside down 4 Pull the rear leading edge straight aft to disengage it from the front Slide it forward inside the sail until you can fold the sprog past the internal sail ribs then remove the whole assembly from the from the sail Be very careful not to damage the sail with the hardware at...

Page 16: ... crescent adapter that is attached to the rear leading edge will be com pletely inside the front leading edge Note On early serial production gliders the black crescent may protrude 1 8 from the front leading edge when the rear leading edge is fully engaged 4 Remount the sail to the rear leading edge making sure to align the sail mount webbing squarely in the slot and attach the securing velcros T...

Page 17: ...r the rear wire junction and the end of the keel instead of a pad 3 Unfold the control bar legs a If the glider is equipped with a folding basetube i Straighten the fold in the folding basetube ii Preflight the folding basetube center hardware at this time checking that the nuts and coil spring pins are secure and that the tangs are straight and in good condi tion iii Slide the basetube center sle...

Page 18: ...r the inside of the basetube If the fitting is forced into the basetube it may be impossible to remove See your dealer if the fitting becomes difficult to install or remove 4 Flip the glider upright on the control bar and remove the bag and all the velcro ties Do not remove the leading edge tip protector bags at this time but do loosen the velcros on the tip bags If there is more than eight m p h ...

Page 19: ...rt or remove top surface battens with the crossbar tensioned except for up to the last four on each side and never insert or remove battens with heavy wind pressure on the top of the sail or in any condition which causes the battens to slide with great resistance in the pockets 9 Spread the wings all the way and check all cables for any twisted thimbles or tangled cables 10 At the rear of the keel...

Page 20: ...oop of the 505 batten string The proper 1 tension for the Fusion is very tight and it is easiest to install the batten string if you first set the VG to the full tight position Be sure to re set the VG to the desired setting prior to launch 15 At this time preflight the following from the open end of the wingtip a The sail mount webbing make sure that the sail is mounted by the inner loop of webbi...

Page 21: ... in this area check the internal rib zipper for the rib adjacent to the sprog Also from this point you can visually inspect the cam lever plate support strap cable attachment and bolts nuts and safeties at the crossbar leading edge junction When finished zip up the sprog access zipper Before attempting to install the bottom nose wires be sure that the control bar apex is pushed into place fully af...

Page 22: ...l tube itself See the diagram in the section on towing Alternately for performing a hang check the glider can be supported by pushing up from underneath the rear keel instead of pulling down and forward at the nose Make sure the anchor lock is installed properly There is not as much tension in the bottom wires to keep the keyhole tang engaged as with gliders with top rigging 20 By lifting up and b...

Page 23: ...ural security of the side wire loop the control bar and the crossbar and may reveal a major structural defect that could cause an in flight failure in normal operation Open the crossbar junction access zipper and look inside making sure that the bottom side wires are properly secured to the crossbar and that the nut and safety ring are in place Check the attachment of the cam lever plate to the cr...

Page 24: ...ar is properly oriented ends lower than center pivot is fully engaged on the pillar and is free to pivot Check that the back up hang loop is secured to the keel behind the base for the elevated hang system Check the control bar base bracket pulley for free rotation Overtightening of the mounting bolts will cause this pulley to bind Check the routing of the VG rope around the keel mounted pulley Ch...

Page 25: ... following The eight nuts and bolts which attach the crossbar plates to the wedge The four circlips which retain the crossbar pins which hold the crossbars to the center plates The shackle which holds the crossbar hold down strap to the front of the wedge The attachment of the VG triple block pulley to the bottom front of the wedge The attachment of the sweep wire plastic glide and retaining strap...

Page 26: ...r and rock it forward over the control bar and then lay it down Reverse the procedure to set the glider upright again Setting the Glider Up Flat on the Ground In areas where the ground is not rocky and when there are strong winds you may wish to set up the glider flat on the ground This is easy to do and relatively few parts of the set up procedure are different from what has been described 1 Afte...

Page 27: ...imately familiar minimum sink airspeed hereinafter referred to as MSA and minimum controllable airspeed MCA The most important of these two is MCA Minimum sink airspeed is that speed at which your descent rate is the slowest possible It is the speed to fly when you want to maximize your climb rate in lift or slow your rate of descent to a minimum in non lifting air You would normally not fly at MS...

Page 28: ...ht the flow will be chordwise along the wing and the tufts will point towards the trailing edge When the wing stalls the tufts will reverse direction indicating the local flow towards the leading edge At the first onset of stall the tufts will indicate the impending separation by first wiggling and then deflecting spanwise before they fully reverse and point forward The first onset of stall occurs...

Page 29: ... other gliders and watch your tufts on the inside wing which will be at the highest angle of attack you will get a feel for the way your minimum sink speed varies at varying bank angles Also be aware that in some thermalling situations such as when trying to maximize climb rate in a thermal with a very strong and very small core there may be an advantage in overall effective climb performance to f...

Page 30: ...e in a direction more than 45 degrees below the line of the keel tube itself As the following table indicates the load on the keel is also very sensitive to pilot weight and CG position With a nose release tether angle of 45 degrees the load on the keel is marginally acceptable at a pilot position corresponding to a free flight airspeed of approximately 30mph With an arms extended pilot position t...

Page 31: ...mounted with the vertical end at the front and the sloping end to the rear We recommend that you not stow your glider bag or any other cargo on the glider The practice of putting your glider bag inside the sail for example can drastically alter the pitch trim and static balance of your glider and adversely affect its flying and landing characteristics The best place to carry your glider bag or oth...

Page 32: ...eep the airspeed in the green for best control and stability and best structural margin at all times Yellow This region represents the upper speed range between maximum rough air maximum maneuvering speed and the speed never to exceed You should fly in this range only in smooth air as described above Red Line This is your never to exceed speed At no time should you fly faster than this speed The d...

Page 33: ... excellent performance It is the recommended VG setting for working lift when any significant degree of turbulence is present or when you are in proximity to terrain or other gliders Between VG full loose and VG one half the glider retains good ease of control and control response Tighter than VG one half the glider s roll pressures increase significantly and the roll rate becomes significantly sl...

Page 34: ...the shape of your pattern In particular we recommend against the technique of make a diving turn onto final This maneuver sometimes called a slipping turn is often taught to student hang glider pilots as a way to lose altitude during the approach While it will work reasonably well with low or medium performance low aspect ratio gliders which have high levels of yaw stability and damping and which ...

Page 35: ... are using a pod type harness you should unzip and confirm that your legs are free to exit the harness at least 500 feet above the ground and before you start your approach If there is any problem finding the zipper pull or dealing with a stuck zipper you don t want to have to try to fix that problem while also flying the approach Once established on a wings level short final into the wind body up...

Page 36: ...ong as you re running and flaring at the same time the glider will stay over your head or behind you Note Landing in a significant wind does not require a substantial landing flare the pilot merely slows to near zero ground speed and touches down The proper flare in light or no wind conditions is a dynamic action which causes a sudden and severe pitch up rotation of the glider Pilots who have trou...

Page 37: ...he ring on the sprog end paddle Leave the sprog end protruding from the zipper opening in the bottom surface as you fold in the wings and roll the sail the sprog will fold forward along the leading edge with the rear end of the sprog remaining outside the sail Do not remove the transverse batten from the sail Pull the neoprene cover over the end of the sprog paddle to protect the sail 7 Roll the s...

Page 38: ... not fold the basetube together with the center sleeve not fully retracted from the center hinge You will damage the sleeve b Do not fold the basetube together with your hands or fingers around either the basetube or the lower portion of the downtube It will hurt Fusion Stability Systems Several design features of the Fusion determine the glider s degree of stability in pitch a The combination of ...

Page 39: ...any slack in the bottom side wires 3 Tie a lightweight thread tightly across wing from one 4 batten end to the other The number four is the middle batten supported by the transverse batten and the one immediately adjacent to the sprog 4 Press firmly on end of 4 batten release then measure the height of the thread above the keel This should be 5 5 5 Note that this method will not disclose sprogs th...

Page 40: ...h stability in the extended angle of attack range that is investigated on a test vehicle In particular do not assume that adequate stability is only contingent on positive pitch pressure during flight testing However in the case of the Fusion excessive top steady state speed with pilot full forward is a significant indicator that the sprogs may be set too low If you can maintain a steady state spe...

Page 41: ... sail for wear tears UV damage loose stitching etc 4 Disassemble basetube pulley assembly clean lubricate with white grease and re assemble 5 Lightly spray all zippers on the glider with silicone spray lubricant Also spray your battens before you install them in the glider to lubricate the insides of the batten pockets Do not use any other type of lubricant Wipe off any excess silicone so that it ...

Page 42: ...r extremely hard landing you should have an annual inspection done on your glider to insure that you find all damaged parts Following any hard landing be sure to inspect the apex slider the control bar legs and basetube and all control bar fittings for damage Any time you replace a control bar leg or basetube you must carefully inspect all related fittings and replace any that are bent or damaged ...

Page 43: ... tensioning of the cable will induce fatigue and the cable will fail In tests we have conducted a cable bent one time to 90 degrees and then loaded to the equivalent of a normal flight load 100 times corresponding to 100 or fewer flights failed at only 56 of its original strength Some degree of fatigue due to repeated bending of cables is almost unavoidable in an aircraft that is assembled and dis...

Page 44: ...bottom side wires from the crossbar and feed them through the hole and out of the sail Unbolt the bottom rear flying wires from the rear keel Reassemble the hardware removed onto the bolts in the original order so that it doesn t get lost All disassembled assemblies on the glider must be reassembled in the proper order and orientation Use the exploded parts diagrams in this manual to help you 7 Un...

Page 45: ...ce of the sail Secure the velcro closure 3 Position the sail on the floor with the keel pocket up and the wings folded over so that the leading edges lie along the length of the root line with the mylar pockets lying on top 4 Prepare the frame Tape the sprogs and washout tubes to the leading edges The sprogs should be folded back towards the tip and the washout tubes should be folded forward along...

Page 46: ...crossbar and that no thimbles are cocked or twisted The VG activation cable passes between the leading edge and the side wire 12 Bolt the bottom rear wires and sail retainer webbing strap to the rear of the keel 13 Flip the glider up onto the control bar 14 Spread the wings slowly and carefully making sure that the sail rides forward as necessary at the nose without catching Be careful you can eas...

Page 47: ...ll tight it may be an indication that the sprogs are set assymetically Airframe Check the leading edges for possible bent tubes Check that the keel is not bent to one side Check for symmetrical twist in the leading edges by checking for symmetry in the alignment of the sail mount plugs Battens Check the battens for symmetrical shape and batten string tension The tension should be progressive with ...

Page 48: ...rst dismount the sail mount webbing by pulling it free and then to the outside of the leading edge You can use a flat bladed screwdriver to pry the webbing off but take care not to damage the webbing To remove the plug first check and record the rotational alignment by noting the position of the scribe mark on the plug relative to the scale on the leading edge tube Use the allen wrench provided in...

Page 49: ... with the control bar facing down glider bag zipper down to provide an extra measure of protection for the crossbar It should be securely tied down with webbing straps which are at least 1 2 wide but not tied so tightly or with such a small diameter rope that the mylar insert is permanently deformed If you drive on rough roads where the glider receives impact loads you should take extra care to pa...

Page 50: ...al parts and without coverbags and non essential parts 76 2 Leading Edge Dimensions a Nose plate anchor hole to 1 Crossbar attachment hole 127 0 2 Rear sail attachment point 221 63 222 48 b Outside diameter at 1 Nose 2 44 2 Crossbar 2 44 3 Rear sail attachment point 1 97 3 Crossbar Dimensions a Overall pin to pin length from cam lever bracket attachment point on leading edge to load bearing pin at...

Page 51: ...and without coverbags and non essential parts 74 2 Leading Edge Dimensions a Nose plate anchor hole to 1 Crossbar attachment hole 122 0 2 Rear sail attachment point 214 63 215 38 b Outside diameter at 1 Nose 2 44 2 Crossbar 2 44 3 Rear sail attachment point 1 97 3 Crossbar Dimensions a Overall pin to pin length from cam lever bracket attachment point on leading edge to load bearing pin at xbar pla...

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Page 53: ... and Cam VG 3 83E03 2 Fusion Sprog Wire and Bracket Carbon Sprog 4 83E07 0 Fusion Sprog Carbon 5 83E04 1 Fusion Noseplate 6 83E05 1 Fusion Rear Leading Edge 7 83E06 1 Fusion Keel 8 83E10 0 Fusion Aluminum Sprog and hardware Assembly 9 83E09 VG Folding Base Tube 10 80E08 VG Control Bar 11 Fusion 150 Frame Plans 12 Fusion 141 Frame Plans 13 Button Lock Apex Slider Assembly 14 Fusion Control Bar 15 ...

Page 54: ...23 4 12 1 5 20E 2305 TANG 3 HOLE FOLDNG BASE CENTER 2 6 10U 1140 WASHER STEEL AN960 416 4 7 10C 5111 BOLT NAS 623 4 11 1 8 40P 4208 WIRE FUSION XBAR SWEEP SET 1 9 15J 2010 GLIDE FUSION XBAR WEDGE BOTTOM 1 10 45K 1313 XBAR STRAP REAR WEDGE HOLD DOWN 1 11 20G 4010 XBAR CENTER WEDGE 7075 MACHINED 1 12 10S 1110 C CLIP FUSION XBAR PIN 4 13 20C 1762 XBAR PLATE CENTER COMPOSITE XBAR 2 13 1 20C 1766 XBAR ...

Page 55: ...6L 2 6 10N 1340 CASTLENUT 1 4 AN310 4 6 7 10B 2520 BOLT AN24 52 2 8 10A 2260 BOLT AN4 26 2 9 10A 2240 BOLT AN4 24 2 10 40P 3104 WIRE BOTTOM SIDE 1 8 AT STYLE 2 11 15D 2001 SADDLE 2 2 12 20C 1752 XBAR PLATE SUPPORT STRAP CAM VG 2 13 10C 5071 BOLT NAS 623 4 7 2 14 10N 1740 CLINCH NUT 1 4 MS21042 4 2 15 10U 5125 WASHER NYLON 75 316 020 2 16 40P 5100 WIRE VG CAM LEVER ASSY 2 17 45G 3066 COVER NEOPRENE...

Page 56: ... Carbon Sprog ID PART NO DESCRIPTION QNT 1 10A 2120 BOLT AN4 12 2 2 40P 6001 WIRE SPROG ASSY FORK EYE 19 5 2 3 10B 1101 BOLT AN23 10A 2 4 10N 1740 CLINCH NUT 1 4 MS21042 4 6 5 20E 2304 TANG 3 HOLE VG 2 LONG 4 6 20G 2451 BRACKET LE SPROG HINGE 52 LEFT 1 6 20G 2452 BRACKET LE SPROG HINGE 52 RIGHT 1 7 10B 2400 BOLT AN24 40 2 8 10N 1730 CLINCH NUT 3 16 MS20142 3 4 9 10B 2201 BOLT AN24 20A 2 10 20G 244...

Page 57: ...359 998 0647 Document ID TITLE DWG ID 015 1 2 0005 003 DATE REVISED XXX BY ANGLES XXXX XX T U S 05 X 83E07 0 Sprog DRW 04 07 97 06 10 97 Pearson Sprog ID PART NO DESCRIPTION QNT 1 20G 2440 SPROG FORK 2 2 40M 1161 SPROG ASSY FUSION 2 3 20G 2435 SPROG REAR END PADDLE 4 40M 1160 SPROG TUBE CARBON WRAPPED 5 40M 1160 SPROG TUBE CARBON WRAPPED 6 20G 2430 SPROG CENTER BRACKET 7 20G 2445 SPROG FORK THREAD...

Page 58: ...DESCRIPTION QNT 1 10A 2321 BOLT AN4 32A 2 2 10A 2341 BOLT AN4 34A 1 3 10A 2301 BOLT AN4 30A 1 4 10U 5125 WASHER NYLON 75 316 020 2 5 20C 1621 NOSEPLATE RAMAIR TOP EXTENDED 1 6 10U 1141 WASHER STEEL AN960 416L 6 7 20C 1631 NOSEPLATE FUSION BOTTOM SLOTTED 1 8 20E 2321 TANG 1 HOLE 2 SLOT 5 8 WEBBING 2 9 10N 1740 CLINCH NUT 1 4 MS21042 4 4 10 20G 2901 COLLAR KEYHOLE TANG BOLT 1 11 10U 5093 WASHER NYLO...

Page 59: ...IP SAIL ADJUSTER CAP SCREW 2 5 70G 4019 PLACARD SAIL ADJUSTER ALIGN 2 6 15J 1912 LOCKING SLIDE ADJUST ENDCAP 2 7 15B 0614 ENDCAP 3 4 049 2 8 40M 1151 WASHOUT TUBE FUSION TYPE 2 9 20G 2420 RECEPTACLE FLOATING W O TUBE 2 10 10N 1730 CLINCH NUT 3 16 MS20142 3 2 11 10D 1141 BOLT NAS 603 14P 2 12 10G 4210 CLEVIS PIN STEEL 3C77 REPLACE 2 13 10T 1111 SPACER AL 375 035 375 2 14 10U 1400 WASHER MS 15795 21...

Page 60: ...HOLE TANG BOLT 1 3 20G 2831 BASE PILLAR KP HANG 1 4 20G 2821 SPREADER BAR PILLAR KP HANG 1 5 15B 2012 ENDCAP 2 049 2 6 20G 2104 TRACK LAYFLAT CBAR APEX FUSION 1 7 10A 2251 BOLT AN4 25A 1 8 10T 3100 SPACER SS 313 028 390 1 9 10A 2321 BOLT AN4 32A 1 10 20G 1510 BRACKET VG PULLEY KEEL MOUNT 1 11 20P 1230 PULLEY HARKN SHEAVE TOP LEG VG 1 12 10B 1101 BOLT AN23 10A 1 13 40P 3301 WIRE SET BOTTOM REAR BAL...

Page 61: ...05 WIRE SPROG ASSY TGL JAW 25 5 2 5 10R 0366 RIVET AL 3 16 375 CHAAPQ6 4 2 6 10N 1740 CLINCH NUT 1 4 MS21042 4 4 7 10T 5101 SPACER NY 75 125 310 2 8 1 20G 2452 BRACKET LE SPROG HINGE 52 RIGHT 1 8 2 20G 2451 BRACKET LE SPROG HINGE 52 LEFT 1 9 10U 1140 WASHER STEEL AN960 416 2 10 10B 2460 BOLT AN24 46 2 11 10C 4081 BOLT NAS 623 3 8 2 12 20G 2448 SPROG FORK HINGE PILLAR 2 13 10b 2201 BOLT AN24 20A 2 ...

Page 62: ...Wills Wing 500 West Blueridge Orange CA 92865 Page A 10 Fusion Assembly Diagrams October 1998 83E09 VG Folding Base Tube ...

Page 63: ...Phone 714 998 6359 Fax 714 998 0647 Page A 11 Fusion Assembly Diagrams October 1998 80E08 VG Control Bar ...

Page 64: ...Wills Wing 500 West Blueridge Orange CA 92865 Page A 12 Fusion Assembly Diagrams October 1998 Fusion 150 Frame Plans ...

Page 65: ...Phone 714 998 6359 Fax 714 998 0647 Page A 13 Fusion Assembly Diagrams October 1998 Fusion 141 Frame Plans ...

Page 66: ...0 Stepped Spacer 20G 3010 Button Lock Apex Slider 20G 2204 Slider Control Bar Apex 4 15J 2004 Glide Notched Apex Slider 4 Note Replaces Item 5 and Item 6 Drawings 82E01 and 84E02 and Items 15 18 Drawing 80E06 500 BLUERIDGE AVE ORANGE CA 92865 PH FAX 714 998 6359 998 0647 Document ID TITLE DWG ID DATE REVISED BY na na 06 29 98 Pearson Button Lock Apex Slider Assembly Button Lock Apex Slider Assembl...

Page 67: ...Phone 714 998 6359 Fax 714 998 0647 Page A 15 Fusion Assembly Diagrams October 1998 Fusion Control Bar ...

Page 68: ...Wills Wing 500 West Blueridge Orange CA 92865 Page A 16 Fusion Assembly Diagrams October 1998 ...