Rans COYOTE II S-6ES, Technical Manual

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020220wg msw 09/01/05
022A-1
TRAILING EDGE SPAR ASSEMBLY
NOTE: Assemble both spars the same, but make a LH and RH.
1.
Select the necessary parts as shown in the parts drawing.
2.
The trailing edge spar comes with all holes pilot drilled. The final hole sizes are called out during
assembly.
NOTE: The tip of the spar has three (3) sets of holes around the spar. The fwd side of the
spar will have a single hole at 5.25” from the root. Mark spars “Left & Right”,” Tip & Root” and “Fwd &
Aft” for easier identification.
3.
Rivet a Long Wing Channel to the two (2) #11 holes at 5.25” and 6.75” from the root. Use 3/16”
Stainless Steel rivets.
NOTE: The root end of the Long Wing Channel will align with the thru hole at
3.75” from the root. Align, drill #40 and rivet a 3/16”side-by-side nut plate to the inner most hole of the
Long Wing Channel. Be sure the flange of the nut plate is orientated outboard.
4.
Rivet a Long Wing Channel to the three (3) #11 holes, 47.95" thru 50.95” from the root end. Rivet with
3/16” Stainless Steel rivets.
5.
Drill out the three (3) holes between 89.14” and 95.14” from the root to 1/4". HINT: For best accuracy,
lay the Strut Attach Plate against the spar holes and use it as a template. It is best to drill through with
a 1/4" drill bit, temporarily bolt the plate to the spar, then drill the other two holes out to 1/4". Remove
Strut Attach Plate and drill 1/4" holes to 3/8".
NOTE: Drill from each side, (not from one side) through to
the other. Do NOT drill the Strut Attach Plate!!! Debur and install the 3/8" x 2" bushings, 1/4" bolts,
Strut Attach Plate, and Long Wing Channel as shown in the parts manual. CAUTION: The 2” bushings
must fit tight in the holes. Test drill in a scrap piece of aluminum for proper fit. IMPORTANT: The
bushings may also need to be trimmed in length, if the Strut Attach Plate is held away from the spar
when bolted.
Be sure to make Right and Left Spars.
6.
Install the Trailing Edge Spar Tip Doubler into the tip of the spar. Push the doubler in with a block of
wood, until inserted half way into the tip. Transfer drill #11, the two (2) aft holes, through the spar and
doubler. Cleco as you drill. Rivet the two (2) holes with 3/16” Stainless Steel rivets.
7.
Slip the Trailing Edge Spar Tip over the Tip Doubler. Align the aft holes and transfer drill #11. NOTE:
Be sure the Spar Tip is tight against the Spar and straight. HINT: Clamp a piece of angle aluminum to
the tip and spar to make sure they are straight.
Rivet with 3/16” Stainless Steel rivets. Transfer drill #11
the remaining eight (8) holes of the Spar and Tip through the doubler. Rivet with 3/16” Stainless Steel
rivets.
8.
Collect the parts shown in the Universal Hinge drawing. Make and insert the bushings into the bushing
fittings. Press the bushings into the ends of the bushings on the spar fitting. If the bushings do not
press in, glue them in using a dab of J & B Weld Epoxy. Test fit the fitting into the end of the spar. Grind
to contour the spar's inside diameter.
CAUTION: Do NOT grind too much, as a slip fit is desirable.
Assemble the hinge into the trailing edge spar's inboard end. Use the first and second bolts at the
spar's root to attach the fitting. The bolt that attaches the hinge cube is used to attach one "L" bracket.
The "L" bracket is used for the Root Rib tensioning system. Only finger tighten the bolt at this time.
9.
From the parts drawing, determine the location of the remaining hinge bolts. Rivet 3/16” nut plates to
the fwd side of the spar. Align the nut plates parallel with the spar, drill #40 and rivet.