Wills Wing Sport 2 155, Owner'S Service Manual

Page 1: ...Sport 2 155 Owner Service Manual June 1st 2004 First Edition...

Page 2: ......

Page 3: ...swing com E mail comments willswing com June 1st 2004 First Edition Copyright 1994 2004 by Sport Kites Inc dba Wills Wing Inc All rights reserved No part of this manual may be reproduced in any form w...

Page 4: ...htleadingedge Under the glider at the control bar At the nose Launching and Flying the Sport 2 20 Minimumcontrollableairspeedandminimumsinkairspeed Usingwingtuftstofindtheminimumsinkspeedofyourglider...

Page 5: ...ntheframe Glider Tuning 46 CGadjustment Turntrim Airframe Battens TipWandReceptacles rotationalalignment Sailtension Twistingatip Battentension Car Top Mounting and Transport 48 In Closing A Few Final...

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Page 7: ...rvice advisories and technical updates that relate to your glider You can do so most effectively by going to our web site at www willswing com The site features extensive information about Wills Wing...

Page 8: ...ted 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 airworthin...

Page 9: ...egative 150 degree angle of attack load test at a speed equal to at least the greater of 30 m p h or 50 of the required positive load test speed for at least 3 seconds without failure The required spe...

Page 10: ...able heading and attitude Recovery from a spin at low altitude or in the vicinity of terrain or other aircraft may involve a flight trajectory which intersects the terrain or another aircraft at a hig...

Page 11: ...fically designed and developed for recreational soaring to achieve the maximum level of performance possible at the minimum practical glider weight The stability controllability and structural strengt...

Page 12: ...rom the glider and unroll the sail part way 2 Identify the rear leading edges as to left and right in order to make sure you are mounting the correct rear leading edge into the correct front Check the...

Page 13: ...adjustment do not loosen this strap in order to install it on the rear leading edge See the section on Sail Tension in the Glider Tuning section of this manual for more information on the adjustment o...

Page 14: ...m the tang on the sail mount strap Reinstall the clevis pin in the leading edge tube and reinstall the safety ring 3 Check to see that the rear leading edges are labeled Left and Right If they are not...

Page 15: ...corner fitting and install the ball lock pin securing the plug to the basetube bracket c Repeat for the other side Thread the VG rope through the VG cleat Make sure that the small bushing that secures...

Page 16: ...the trailing edge at this time Insert the battens carefully so as to minimize stress and wear on the sail Do not hold the battens by the rear tips and do not apply significant force to the rear tips...

Page 17: ...ge insert the set up tool in the loop of leech line attached to the sweep wire keyhole tang Tension the sail by continuing to pull back on the sweep wire and secure the sweep wire by installing the ke...

Page 18: ...ls Wing Technical Bulletin TB20040424 available at www willswing com for more information Working from the front side of the leading edge facing the glider hold the end of the leading edge tube from u...

Page 19: ...el and then against the tip wand 11 After you cam the lever over check to see that the back label is properly aligned it should now lie directly under that cam lever Look into the sail from the tip an...

Page 20: ...g clasp Then pivot the lever tip upwards You should not feel any resistance to the lever rotating upwards if you do you haven t properly released the locking portion If you hear a click when pivoting...

Page 21: ...the tang on top If it will not remain aligned properly there is probably a twist in the sprog cable To fix this dismount the sprog from the leading edge and rotate the sprog around the cable until the...

Page 22: ...to the nose of the sail and stretch the top rear end of the nose cone back along the center line of the glider Press down to attach the velcro Then pull the bottom front end of the nose cone tight aro...

Page 23: ...e enters the sail and make sure that the bottom and top side wires are properly secured to the crossbar that the thimbles are not cocked on the tangs and that the nut and safety ring are in place Whil...

Page 24: ...at the bridle cables are not twisted Along the trailing edge right wing Same as for left wing At the right tip Same as for left tip Along the right leading edge Same as for left leading edge Under the...

Page 25: ...ossbar tube Check that the routing of all VG ropes and pulleys is clear and straight Check that the front keel pocket is secured to itself with the mating velcro surfaces and that all VG cables and ro...

Page 26: ...ch and ease the bar out for lift off 3 The flying characteristics of the Sport 2 are typical of a high performance flex wing Make your first flights from a familiar site in mellow conditions to give y...

Page 27: ...ts are useful for indicating the local reversal of the airflow which is associated with the onset of the stall in that portion of the wing You can use these tufts as described below to help determine...

Page 28: ...or your vario may tell you that although the glider has not stalled pitched nose down your sink rate has increased significantly In this mode the glider is mushing The VG rope is marked in 25 incremen...

Page 29: ...caution from time to time a tuft may tend to stick completely to the sail and fail to properly indicate the direction of local flow This may result from static buildup or from the fine threads of the...

Page 30: ...a nose line for platform towing Note that the line is cinched over the top of the tang in front of the tang handle and in front of the wires The two photos above both show INCORRECT methods for attach...

Page 31: ...ee this can be compensated for by pulling forward through the control bar to position the basetube below your shoulders and holding tight to the hold down rope This will cause the glider to raise the...

Page 32: ...actice 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 bes...

Page 33: ...you keep 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 maneuver...

Page 34: ...and increased pitch pressures at VG full loose you may find that total effective control is actually im proved in some conditions at slightly tighter settings up to VG 1 4 VG settings between VG loose...

Page 35: ...within a small field It will also ensure maximum control authority during the approach and especially when flying very slowly on final At VG full loose however there is some loss of aerodynamic effic...

Page 36: ...tion at the start of the approach to a semi upright position with one hand on a downtube and one hand on the basetube and complete the transition by moving the other hand to the downtube just a few se...

Page 37: ...nt begin your flare by smoothly accelerat ing the rate at which you push out on the bar At the same time draw one leg forward put a foot down and start to run as hard as you can This run should be ver...

Page 38: ...n speed to control the steepness of the descent Drogue chutes have been used which attach to the glider and others have been used which attach directly to the pilot s harness There are several signifi...

Page 39: ...period between round out and flare This reduces the opportunity that turbulence would otherwise have to lift a wing or yaw the nose away from your flight direction As a result timing the flare becomes...

Page 40: ...r tip battens remember to apply slight downward pressure on the top of the lever while squeezing the bottom portion so as to release the locking catch before pivoting the lever tip upwards 5 Open the...

Page 41: ...hen the glider is packed up 10 Pull the sail out away from the keel until it is even on top and bottom Place the bottom surface battens and tip wands on the sail and roll the sail gently and carefully...

Page 42: ...f the front keel pocket unzip the center zipper slightly if necessary and stow the nosecone under this velcro 14 Install the glider bag Flip the glider over onto the ground Remove both control bar cor...

Page 43: ...y components that provide pitch stability at low angles of attack outside the normal flight envelope The function of these sys tems is to support the trailing edge of the sail at low angles of attack...

Page 44: ...n the clevis fork You can usually loosen the jam nut by rotating the sprog counter clockwise before dismounting it and then spin the nut out of the way until you have readjusted the clevis fork as des...

Page 45: ...ment as listed above If the bridles are set too low it will not usually create a noticeable difference in flight characteristics If they are set too high they will at the point where they become tight...

Page 46: ...on a flat level floor against the batten diagram provided and correct any that deviate from the pattern by more than 1 4 3 If you fly in a dusty or sandy environment it will help to prolong the life...

Page 47: ...urface center zipper and inspect all of the batten pockets and batten pocket terminations 3 Replace bottom side wires and hang loops Note The bottom side wires are retained by a lightly press fit bush...

Page 48: ...line when all tension is removed must also be replaced immediately If it is not subsequent tensioning and de tensioning of the cable will induce fatigue and the cable will fail In tests we have conduc...

Page 49: ...ion on Breaking Down The Rear Leading Edges at the beginning of this manual 6 Unbolt the bottom side wires and top side wires from the crossbar and feed them through the holes and out of the sail Unbo...

Page 50: ...the leading edge pockets of the sail and don t get caught at the rear of the bottom surface near the root As you feed the frame slowly into the sail check periodically to see that none of the hardware...

Page 51: ...ailing edge Finish the assembly of the glider completely according to normal assembly procedures 17 Do a very careful and complete preflight of the glider according to the normal preflight procedure a...

Page 52: ...Receptacles rotational alignment The plastic plug which fits directly into the rear leading edge determines the rotational alignment of the tip wand This plug is secured against rotation by a small s...

Page 53: ...cap counter clockwise because doing so would rotate the wingtip downwards The aerodynamic effect is the same even though the direction of rotation appears at first glance to be opposite Adjustments ar...

Page 54: ...mmon manifestation of this is that a glider s trim speed often tends to slow down as the glider ages At some point it may no longer be possible to trim the glider at a speed above stall Because the ch...

Page 55: ...can be wrong is a bad decision The logical conclusion of this analysis of safety is that most pilots are making far too many bad decisions If they weren t we wouldn t see nearly as many accidents in t...

Page 56: ...ntial parts and without coverbags and non essential parts 60 2 Leading Edge Dimensions a Nose plate anchor hole to 1 Crossbar attachment hole 128 0 2 Rear sail attachment point 189 5 from end of LE tu...

Page 57: ...2 15 40P 3105 WIRE BOTTOM SIDE SLIPSTREAM 2 16 10N 1030 LOCKNUT 5 16 AN365 5 1 17 10N 1730 CLINCH NUT 3 16 MS20142 3 2 18 10G 1290 MS20392 2C29 4 19 40P 3203 WIRE SET BOTTOM FRONT SLIPSTREAM 1 20 40P...

Page 58: ...TH SLDPRT 2 11 10G 1290 MS20392 2C29 4 12 10P 1100 SAFETY RING AN 9491 SMALL 4 13 10N 1740 CLINCH NUT 1 4 MS21042 4 4 14 10U 5125 WASHER NYLON 75 X 316 X 020 3 15 10T 4114 BUSH SS 312 X 028 X 125 3 1...

Page 59: ...AN4 25A 7 1 20A 1511 A BUTTON SPRING HAULBACK LOCK 8 1 10R 0366 RIVET AL 3 16 X 375 CHAAPQ6 4 9 1 40P 3302 WIRE SET BTM REAR SLPSTR LTSTR 10 1 20E 2321 TANG 1 HOLE 2 SLOT 5 8 WEBBING 11 1 10U 1140 WA...

Page 60: ...WASHER STEEL AN960 416 1 4 THICK 4 22 30J 3301 ROPE 4mm SUPER PRE STRETCH 1 23 20P 1333 SHACKLE SM RONSTAN MOFIFIED 1 24 10C 0071 NAS623 2 7 1 25 10N 1220 LOCKNUT LOWPRO 0832 SS 1 26 20P 1250 PULLEY R...

Page 61: ...NG 1 8 10G 1710 MS20392 2C71 1 9 10M 1651 SCREW PAN 8 32 X 375 THRD CUT 1 10 40R 7601 Tip Wand 1 11 20G 3140 Wand Lever 1 12 20G 3130 Wand Cup 1 13 10C 4061 NAS623 3 6 1 14 10C 4121 NAS623 3 12 1 15 1...

Page 62: ...1 9 10N 1740 CLINCH NUT 1 4 MS21042 4 2 10 10R 0342 RIVET AL 1 8 X 25 2 11 45J 1411 A HANG LOOP INTGRL ASSY KP STOCK 1 12 40P 2301 WIRE TOP FRONT BALL SWG 3 32 1 13 40P 2401 WIRE TOP REAR BALL SWG 3 3...

Page 63: ...E UNIVERSAL 2003 1 8 10A 2301 AN4 30A 1 9 10A 2261 AN4 26A 3 10 40P 2301 WIRE TOP FRONT BALL SWEDG 3 32 1 11 20C 1638 NOSEPLATE UNIVERSAL 2003 1 12 20P 1237 PULLEY HARKN 16mm AIRBLOCK CHEEKBLOCK 1 13...

Page 64: ...1 20G 2441 C Sprog Fork Stainless 10 1 20G 2448 E Sprog Fork Hinge Pillar 11 1 10C 2361 NAS517 436 12 1 10T 4113 BUSH SS 312 X 028 X 240 13 2 10R 0605 MS20470 AD6 5 14 1 10C 4081 NAS623 3 8 17 1 10N...

Page 65: ...15C 6219 ENDCAP 62mm OD 58 2 ID 1 14 10P 1100 SAFETY RING AN 9491 SMALL 3 15 10G 2650 MS20392 3C65 1 16 20C 1740 XBAR PLATE RAMAIR 187 1 18 15D 2001 SADDLE 2 1 19 10U 1140 WASHER STEEL AN960 416 1 4 T...

Page 66: ...be 42mm x 0 9mm 7075 T6 98 13 2492 4 1 763 2 1 S2 155 keel front slv 44mm x 0 9mm 7075 T6 6 00 152 4 0 112 3 1 S2 155 keel middle slv2 44mm x 0 9mm 7075 T6 18 00 457 2 0 334 4 1 S2 155 keel rear slv 4...

Page 67: ...2 2 860 2 1 S2 155 Front LE front slv 52mm x 0 9mm 7075 T6 3 00 76 2 0 066 3 1 S2 155 Front LE middle slv 52mm x 0 9mm 7075 T6 24 00 609 6 0 536 500 BLUERIDGE AVE ORANGE CA 92865 PH FAX 714 998 6359...

Page 68: ...ENGTH mm WEIGHT lb 1 1 S2 155 rear le tube 50mm x 0 9mm 7075 T6 62 00 1574 8 1 332 2 1 S2 155 rear le slv 52mm x 0 9mm 7075 T6 3 00 76 2 0 067 500 BLUERIDGE AVE ORANGE CA 92865 PH FAX 714 998 6359 998...

Page 69: ...x 0 9mm 7075 T6 114 00 2895 6 3 051 2 1 S2 155 xbar slv 60mm x 0 9mm 7075 T6 6 00 152 4 0 154 500 BLUERIDGE AVE ORANGE CA 92865 PH FAX 714 998 6359 998 0647 PART NO TITLE SLDDWF ID 015 1 2 0005 003 DR...