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Lancair International Inc., Represented by Neico Aviation Inc., Copyright 2008 Redmond, OR 97756

Chapter 1

Page  1.3

REV. 2nd Ed./08-15-06

Introduction to the Lancair ES FastBuild Kit

ES

1.3  The Manuals, Blueprints and the ES CD

Please read this manual! We encourage you to read this manual and then use it as your reference 

tool as you build your airplane. In this age of computers that are user friendly, cars that provide a 

warning light for every change in status, many people are out of the habit of reading manuals. 

That philosophy will not work here. While there really aren't any complex steps to building this 

aircraft, there are many that must not be overlooked. So, please do read this manual.
Each chapter should be read entirely and understood before beginning the work it describes. The 

equipment and supplies called for in each chapter should be on hand and ready for use.

1.3.A  Manual Layout

For ease of use and understanding, this assembly manual is laid out in a logical progression of 

assembly steps. This manual is organized as follows:
Chapter 1 – Provides an overview of the shop requirements and necessary tools to build your 

homebuilt airplane.
Chapter 2 – Describes safety considerations for building, general building procedures and how 

to prepare and join parts.
Chapter 3 and all following chapters contain the actual assembly instructions. The chapters are 

presented in the order your plane should be built. Assembly instructions are in a sequence that 

either is a convenient construction order or is necessary due to the kit design.

Chapter Organization

Each assembly chapter is organized in the same sequence.
1. Introduction – Briefly describes the work that will be completed in this chapter, and special 

construction requirements and if a pre-fit is necessary.

2. Parts List – Provides a complete list of the parts used in the construction procedures in the 

chapter. Parts lists may not match a kit. A parts list can include all or part of a kit plus other 

hardware from the H or K kit lists.

3. Construction procedures – this section is divided into specific areas of assembly. Each 

division is defined by an alphabetic prefix: A, B, C, etc.

4. Graphics, including drawings and photographs – each graphic is numbered within an 

alphabetic prefix: A.1, A.2, A.3, B.1, B.2, etc.

Symbols

The following symbols are used in the manual. 

Revisions

Occasionally revisions to the manuals may be necessary. Updates are posted on the Lancair web 

page. When updates are available, you need to immediately replace all outdated pages with the 

revised pages. Discard the outdated pages.
The lower right corner of each manual page contains a revision date. The final edition of this 

manual will have a zero followed by the date printed, for example, Rev. 0–06/12/2005. All 

subsequent revisions will have the revision number followed by the date of that revision. All 

revisions include a 

List of Revisions

 page for each chapter with updated pages When you receive 

List of Revisions

 page, you will need to inserted it in front of the first page of each revised 

chapter.

Click on this symbol to view the photograph of the procedure that has just been 

described.

 

Click on this symbol to view a series of photographs.

 

This symbol indicates a pre-fit is required.

 

This symbol indicates there is a detail view of the area covered by the magnifying 

glass.

Summary of Contents for ES

Page 1: ...ead the recommended books to familiarize yourself with glassworking if you are a newcomer to fiberglass construction techniques Always refer to the Glossary on page G 1 for definitions of unfamiliar terms 1 1 Introduction 1 1 1 2 Recommended Reading and Background Information 1 2 1 3 The Manuals Blueprints and the ES CD 1 3 1 3 A Manual Layout 1 3 1 3 B Blueprints 1 4 1 3 C The ES CD 1 4 1 4 Setti...

Page 2: ...tion Highly recommended Composite Construction for Homebuilt Aircraft by Jack Lambie This book is an additional source of useful construction information and goes into the theory of aircraft design as well Jack s Chapter 9 Safety in Working With Composite Construction is particularly worth reading This book would be a useful addition to the above Kitplane Construction by Ron Wenttaja This is a res...

Page 3: ...nization Each assembly chapter is organized in the same sequence 1 Introduction Briefly describes the work that will be completed in this chapter and special construction requirements and if a pre fit is necessary 2 Parts List Provides a complete list of the parts used in the construction procedures in the chapter Parts lists may not match a kit A parts list can include all or part of a kit plus o...

Page 4: ... version of the manual that you can view or print from your computer In addition the CD manual provides the following Includes color photographs of various construction processes and specific assembly techniques Ability to search the entire manual for a specific word or phrase Includes a linked table of contents and index All drawings and photographs are organized in a slideshow presentation in th...

Page 5: ...for your shop floor should be approximately 20 ft by 30 feet This will accommodate the building of your Lancair Figure 1 4 B 1provides an overview of the ES dimensions Since the wings are pre fit to the wing fairings and then removed for the remainder of the building process it is not necessary to have a shop that will accommodate the finished dimensions with the wings on You can temporarily move ...

Page 6: ...oll Mount the pipe through two plywood supports nailed to the sides of your table Figure 1 4 C 1 Fiberglass cutting table The cutting surface should be a hard plastic such as an 1 8 thick high density polyethylene HDPE Some home supply stores have similar sheets of this material called tileboards for use as shower liners Also check a plastic supply store After you have been using the cutting surfa...

Page 7: ...ing checking the weight and balance In addition the ES fuselage bottom may have optional jackpoints Steps 1 Cut two pieces of plywood one 8 x 8 and the other 4 x 4 2 Glue the two pieces of plywood together with the 4 x 4 centered on the larger piece 3 Drill a 1 deep and 3 8 diameter hole in the center of the 4 x 4 piece 4 Install the JP 325 jack point in the hole 5 Glue soft padding on the top of ...

Page 8: ...Tools Saber saw jig saw This saw is very handy for cutting out large or complex shapes from prepreg material You can use a manual saw but it won t be fun Always have plenty of sharp blades and change them often Dull blades create rough edges and create more sanding smoothing work later in the building process We use carbide tipped blades exclusively for the composite cutting Electric or cordless d...

Page 9: ... other parts in exactly the proper position Vise grip clamps These are useful for forcing pieces together Never use these on any fiberglass prepreg or carbon composite parts They grip with enough force to do great damage to these parts which may not be visible to the naked eye Buy several of these C clamps Buy an assortment of these and three or four in each size Again use caution when applying th...

Page 10: ... used to turn a tap for the cutting of screw threads They should only be used to remove small amounts of material This ensures a long life for the reamer and a superior finish to the hole 1 5 B Specialized Tools We refer to the following tools as specialized shop tools because it makes it a little easier to overlook their higher price tags Again the tools listed are not mandatory for your shop but...

Page 11: ...h the Dremel If these bits are available get one of each You can make a holder for the bits out of a piece of 2x4 with drilled holes for holding the bits Epoxy pump Sticky Stuff dispenser An epoxy pump pays for itself in saved epoxy With every pump of the handle you will receive the proper amount of resin and hardener without needing to weigh or measure With practice you ll know the proper number ...

Page 12: ...nd Cleco pliers are available from aircraft supply stores or catalogs ours included Digital level A digital level has an LCD readout instead of a bubble On some digital levels the center pops out to become a small six inch level that s extremely handy for measuring control surface throws seat back angles firewall angles engine thrust lines etc all with an accuracy of 1 10th of a degree KCI carries...

Page 13: ...t action for deburring holes and radii The curved blade automatically follows all contours Surveyor transit If you like gadgets this one is fun although a water level will work just as well for less money A surveyor transit can save you an hour or two in setup time and is usually available for rent from surveyor construction suppliers It is like the water level because it still takes two people to...

Page 14: ...aration of BID tapes and other fiberglass layups Thinner drop clothes are not as easy to handle and thicker ones are too hard to work Paper towels Buy paper towels by the case if you have the storage space Always keep at least three or four rolls on hand You ll be using paper towels for cleaning up drips as well as using them for absorbing excess resin Tongue depressors We supply tongue depressors...

Page 15: ...ld carry this item Cardboard We recommend using cardboard for rib or web templates Create cardboard templates to use as a pattern for prepreg Cotton flox Cotton flox is finely chopped cotton fibers which appear nearly as fine as micro balloons The difference is that flox is structurally stronger than micro when combined with epoxy Epoxy During aircraft assembly two types of epoxy are used Structur...

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