GREAT PLANES Lancair ES, Instruction Manual

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6. Draw a 1/2" [13mm] circle onto the wheel pant
centered on the hole you have drilled. Use a high-speed
rotary tool and a small grinding wheel to open the hole to
1/2" [13mm]. If you have to use a drill, drill a series of
progressively larger holes until you get up to 1/2" [13mm]. If
you try to drill a 1/2" [13mm] hole without getting progressively
larger the bit
will tear the fiberglass.
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7. Locate one of the 1-1/8" x 1-1/8" x 1/8" [28mm x
28mm x 3mm] plywood landing gear mounting plates.
Mark the plate as shown in the sketch. Drill a 1/2" [13mm]
hole in the plywood plate.
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8. Roughen the inside of the wheel pant with 220-grit
sandpaper around the hole you have made. Clean the area
with rubbing alcohol. Glue the plywood plate to the inside of
the wheel pant, aligning the 1/2" [13mm] holes over each other.
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9. This step will probably require the help of another
person. Temporarily install the wing onto the fuselage. Put a
wheel on the left landing gear axle. Put the wheel and wheel
pant on the right landing gear axle. Align the pant with the
nose gear wheel pant. (This is where the other person can
help). When they are aligned with each other, press a T-pin
through one of the mounting holes in the landing gear,
making a mark on the wheel pant. Remove the wheel pant
from the axle. Drill a 1/16" [1.6mm] hole through the mark
the pin left on the wheel pant. Put the wheel and the wheel
pant back onto the axle. Insert a #2 x 3/8" [#2 x 9.5mm]
sheet metal screw through the mounting hole in the landing
gear and insert it into the wheel pant. Stand back and look
at the wheel pant again. If you are satisfied with the
alignment, drill another 1/16" [1.6mm] hole through the
other mounting hole in the landing gear and wheel pant.
Remove the screws and harden the holes with thin CA.
Insert #2 x 3/8" [#2 x 9.5mm] sheet metal screws through
the mounting holes in the landing gear, installing them into
the wheel pant.
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10. Remove the wheel and the wheel pant from the
axle. Locate two 5/32" [4mm] wheel collars and two 6-32 set
screws. Apply a small amount of thread locking compound
to the set screws. Insert the set screws into the wheel
collars. Slide the wheel pant partially onto the axle followed
by a wheel collar, the wheel and another wheel collar. Attach
the wheel pant onto the landing gear. Then, center the
wheel using the wheel collars. Once centered, tighten the
set screws in the wheel collar to keep the wheel centered in
the wheel pant.
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11. Repeat steps 5-10 for the remaining wheel pant.
Important! When repeating step 5, make sure you drill the
hole on the opposite side of the wheel pant than you did for
the previous wheel pant.
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