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Modification 16 – ENGINE FAIRINGS INSTALLATION 

 

NOTE:

 

Mounting engine cowling requires patience and attention to detail. While going through 

this manual make sure you take your time, ensuring each step is carried out properly. 

 

1.  Place upper and lower cowling on the workbench, fit them together and tape one to the 

other using masking tape. 

 

2.  Examine the halfway seam between the two cowlings. It should be a clean seam with no 

uneven gaps or wavy parts. Use sandpaper to even out any uneven seam gaps. 

 

 

Figure: 16-001: Measurements guide at engine cowlings installation 

 

3.  .. Once you’ve got a nice fit between the upper and lower cowling drill Ø3 mm holes 

through both, 11 mm above the connecting seam between the upper and lower cowling. 

Drill four holes according to the Figure 16-001. 

 

4.  Separate the upper and lower cowling and redrill the holes in the upper cowling with a 

Ø6.2 mm drill bit. 

 

5.  Fit the upper cowling with the quick connect bolt´s. 

 

NOTE:

  If you’ve been provided with two different types of quick connect bolt´s, be sure to fit the 

cowling’s seam with those with a smaller washer.  

 

6.  Check to see that quick connect bolt slides through the hole nicely and enlarge the hole 

with a file if necessary. When quick connect bolt is sliding nicely, fit the end of the quick 

connect bolt with the split washer, to ensure to it can’t fall out of place. 

 

 

 

Summary of Contents for LSA-MRA

Page 1: ...close to where the MRA was performed as this is something the manufacture cannot check This MRA has been generated based on the aircraft configuration data provided by the owner requester and is to be...

Page 2: ...thermometer that measures up to 60 deg C Allen key set Angled sander grinder Bit set Heat gun Boxcutter Canister or cart to drain fuel into Chisel Clean smooth and flat table partially covered with P...

Page 3: ...references 1 POM VARIO 00 65 001 Pipistrel VARIO propeller operators manual latest revision 2 AMM 100 00 60 001 LSA maintenance manual latest revision 3 Sinus 891 SN 912 Firewall repair 4 Sinus 891 S...

Page 4: ...the baggage compartment See 25 50 in 2 i Remove the fuel lines from under the seat pan See 6 44 40 j Detach any of the lines hoses components attached to the fuselage under the cabin floor and under t...

Page 5: ...ne which additional parts in the cabin need to be removed for the process to run smoothly Figure 00 002 Example of stretch wrap protection NOTE The picture above is for visual purposes only as the str...

Page 6: ...n its original form place the template on the firewall and mark all the bolts and holes on the firewall for later re installation See Modification 13 Figure 00 003 Measuring the distance between engin...

Page 7: ...a smaller amount of microbaloons compound through the hole in the fuselage belly over the support plate on seat pan and on seat backrest as shown in Figure 02 001 part 2 e Prepare some resin and cut...

Page 8: ...45 45 1x KK300T Pipistrel P N 5073003 45 45 1x 92110 Pipistrel P N 5071002 45 45 Seat backrest laminate plan from inner ply to outer 1x 92110 Pipistrel P N 5071002 45 45 1x Kevlar 200 g m2 twill Pipi...

Page 9: ...ALLATION NOTE Selection of appropriate drill bits is critical in order to drill the main holes in the undercarriage strut Please refer to the diagram in Figure 04 002 entitled Identification of drill...

Page 10: ...04 002 Identification of drill geometry and proper undercarriage strut orientation g Run the brake hoses from the undercarriage strut through the holes in the fuselage h Prepare the bottom cover plate...

Page 11: ...Drill 3 2mm holes on all four corners and in the middle too 6 holes in total Figure 04 004 step 5 m Drill a M4 thread into the 3 2mm holes with tap drill taps bit and fasten the M4 button bolts Figure...

Page 12: ...ng must lay at 200 220 mm from the ground Figure 05 002 Once the positioning is satisfactory temporarily fix the fairing in place with some adhesive tape e Obtain the fixing hole position as indicated...

Page 13: ...re 07 002 NOTE Cut made in the seat pan needs to be as accurate as possible for the seat pan insert to fit well Manufacturing a template of the seat pan insert can greatly reduce the margin of error F...

Page 14: ...irex foam P N 5079026 covered with resin non stick material for example heavy duty brown packaging tape j Secure the foam over the damaged area with firmly applied stretch wrap and with double sided T...

Page 15: ...Apply 1 50 taper to the fuselage edges and sand until whole repair surface Fuselage edges microbaloons and inner layers is smooth Figure 07 003 step 3 p Blow surface clean with compressed air wipe awa...

Page 16: ...fine polyester kit and grind sand down using sandpaper no finer than P600 x Paint the newly processed fuselage surfaces with white acrylic paint sand down with P2000 sandpaper and polish with polishin...

Page 17: ...trel P N 5072006 45 45 1x KK300T Pipistrel P N 5073003 45 45 1x 92110 Pipistrel P N 5071002 45 45 NOTE The first repair ply laid up is always the biggest Each ply that follows should be 7 mm smaller t...

Page 18: ...INDSHIELD REPLACEMENT and CABIN SUPPORT ASSEMBLY WITH BUSHINGS REPAIR a Assemble the cabin support assembly with bushing levelling tool Figure 09 001 as shown in the Figure 09 002 Figure 09 001 Cabin...

Page 19: ...the opposite direction by tightening the central bolt NOTE First bring the cabin support assembly with bushing to a levelled position and then apply slightly more force The rod needs to be slightly be...

Page 20: ...est See 51 10 2 2 in 2 Run a tap test with a smaller metal rod and if any hollow sounds can be heard the fuselage has been damaged Please contact support pipistrel aircraft com for information about h...

Page 21: ...he seat pan Figure 12 004 e Apply Loctite 406 on the PVC tube to insert joint wait for it to dry and cut the remain of the tube above the insert Figure 12 004 f Place the rudder pedals to its designat...

Page 22: ...Figure 12 005 k Mark 45 mm aft of the installed insert Figure 12 005 middle figure l Position the pedals to the fwd most position and run the braided cable through the lower PVC tube through spring a...

Page 23: ...he air intake diffuser See 8 following the process described on pages 6 10 in 10 NOTE Mind that 10 can be used only for illustrative purposes on specified pages since it is published for a different t...

Page 24: ...ee 6 1 01 27 Make sure to follow the guidelines in 7 x Install the water cooler See 6 1 22 10 and oil thermostat and the oil tank See 6 1 25 26 NOTE Secure electrical wires and fuel hoses to the engin...

Page 25: ...Once you ve got a nice fit between the upper and lower cowling drill 3 mm holes through both 11 mm above the connecting seam between the upper and lower cowling Drill four holes according to the Figur...

Page 26: ...t from the center of each insert Figure 16 002 10 Place the cowling on the workbench and mark the 8 cm wide and 20cm long outline for the nosewheel cut out Figure 16 003 Make sure the outline is cente...

Page 27: ...nner s profile blends into the cowling s profile NOTE Other tests to ensure the proper orientation of the cowlings 17 Measure the distance between cowling s halfway seam and the floor on both sides of...

Page 28: ...re you repeat step 22 as many times as needed do not rush this step 25 Temporary tape the cowling s to the fuselage with masking tape and repeat the step 9 Extend the lines marked on the fuselage just...

Page 29: ...and install the holes with the threaded inserts Figure 15 008 New drilled holes and threaded inserts installation 32 Use M4 bolts to fasten the lower cowling to the fuselage and quick connect bolt s t...

Page 30: ...reinstall it after drilling 37 Reinstall the Akrapovi tailpipe Try reinstalling the lower cowling and while pushing the cowling against the tailpipe gauge the location of the tailpipe opening in the...

Page 31: ...3 Determine the amount of adhesive foam tape needed to surround the entire oil cooler sides and bottom The tape must cover the whole surface but not overlap the oil cooler more than 1 cm 44 Apply prim...

Page 32: ...ling just above the oil cooler opening Figure 16 012 Line up the tape s lower edge with the opening s upper edge Apply a bead of black silicone along the outer edge of the tape Smooth it out with a st...

Page 33: ...r any signs of damage Notify your local Pipistrel dealer of all and any issues BLOCK 10 ENGINEERING DATA not applicable BLOCK 11 OPERATING INSTRUCTIONS to be filled out by the manufacturer Changes to...

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