Rans N512DT Text Manual Download

Page: 9 / 202

09/11/2018

RANS S-21 OUTBOUND

TEXT MANUAL

FUSELAGE INTERNAL _______________________________________________ 102

FLOORBOARD INSTALLATION __________________________________ 102

RUDDER PEDAL ASSEMBLY - (FINISHING KIT) _____________________ 102

RUDDER SYSTEM ASSEMBLY AND INSTALLATION - (FINISHING KIT) _ 103

HYDRAULIC BRAKE INSTALLATION _____________________________ 104

SLIDING SEAT ASSEMBLY ______________________________________ 106

OPTIONAL HEADREST ASSEMBLY ______________________________ 107

SEAT FINAL ASSEMBLY________________________________________ 108

OPERATION OF SLIDING SEAT __________________________________ 110

SEAT BELT INSTALLATION - (FINISHING KIT) ______________________ 111

FUSELAGE - CONTROLS AND EXTERNAL ______________________________ 112

CONTROL STICK ASSEMBLY & INSTALLATION - (FINISHING KIT) _____ 112

CONTROL STICK PUSH-PULL TUBE - (FINISHING KIT) ______________ 113

ELEVATOR PUSH-PULL TUBE - (FINISHING KIT) ___________________ 115

AILERON CABLE SYSTEM INSTALLATION - FUSELAGE (FINISHING KIT)
____________________________________________________________ 116

FLAP LEVER - (FINISHING KIT) __________________________________ 117

BELLY FAIRING INSTALLATION

– (FINISHING KIT) __________________ 119

VENT SYSTEM - (FINISHING KIT) _________________________________ 119

INSTRUMENT PANEL INSTALLATION _____________________________ 120

SUB-PANEL & RADIO MOUNT PLATES ___________________________ 121

WING INSTALLATION __________________________________________ 123

WING TIP ____________________________________________________ 126

OPTIONAL STROBES INSTALLATION ____________________________ 128

AILERON AND FLAP ATTACHMENT ______________________________ 128

FORMED WINDSHIELD & SKYLIGHT INSTALLATION _____________________ 129

WING CUFF INSTALLATION _____________________________________ 136

DOOR ASSEMBLY - LEXAN AND TRIM - (FINISHING KIT) __________________ 138

DOOR LATCH ASSEMBLY - (FINISHING KIT) _______________________ 140

HYDRAULIC DOOR LIFT - (FINISHING KIT) _________________________ 141

FORWARD BAGGAGE COMPARTMENT - (FINISHING KIT) ____________ 142

BAGGAGE COMPARTMENT & CARGO NET INSTALLATION __________ 143

(FINISHING KIT) _______________________________________________ 143

INSTRUMENTS AND ELECTRICAL _____________________________________ 144

Summary of Contents for N512DT

Page 1: ...09 11 2018 S 21 OUTBOUND TEXT MANUAL Serial Number Registration Number COPYRIGHT RANS DESIGNS 4600 HWY 183 Alt HAYS KANSAS USA 67601 785 625 6346 www rans com...

Page 2: ...TARTED 02 RUDDER 02 RUDDER 03 VERTICAL STABILIZER 03 VERTICAL STABILIZER 04 HORIZONTAL STABILIZER 04 HORIZONTAL STABILIZER 05 ELEVATOR 05 ELEVATOR 06 141 WING 06 141 WING 07 FUSELAGE TAILCONE 07 FUSEL...

Page 3: ...141 WING 07 FUSELAGE TAILCONE 07 FUSELAGE TAILCONE 08 LANDING GEAR 08 LANDING GEAR 09 FUSELAGE 09 FUSELAGE 10 FUSELAGE 10 FUSELAGE 11 ENGINE INSTALL 11 ENGINE INSTALL 12 WEIGHT BALANCE 12 WEIGHT BALAN...

Page 4: ...09 11 2018 RANS S 21 OUTBOUND TEXT MANUAL 3 REVISION FORM Revision Pages Affected Description Date Original all Original Issue 09 11 2018...

Page 5: ...Engine Model Parts Number Needed Parts Department Only Your Aircraft Assembly Manuals NOTE Please make your questions precise and to the point so that we may assist as many customers as possible Phon...

Page 6: ...SYSTEM SYSTEM SYSTEM SYSTEM SYSTEM SYSTEM SYSTEM CV COVERING CW COWLING DR DOOR EL ELEVATOR EM EMPENNAGE ES ELECTRICAL SYSTEM EX EXHAUST SYSTEM SYSTEM SYSTEM FL FLAP FS FUEL SYSTEM FU FUSELAGE FW FIRE...

Page 7: ...42 VERTICAL STABILIZER _______________________________________________ 43 VERTICAL STABILIZER ASSEMBLY _______________________________ 43 OPTIONAL TAILDRAGGER PULL HANDLE ASSEMBLY ______________ 43 V...

Page 8: ...________ 78 TAILCONE__________________________________________________________ 79 INITIAL ASSEMBLY_____________________________________________ 79 TAILCONE CAGE ATTACHMENT_____________________________...

Page 9: ...________________________________________________ 116 FLAP LEVER FINISHING KIT __________________________________ 117 BELLY FAIRING INSTALLATION FINISHING KIT __________________ 119 VENT SYSTEM FINISHI...

Page 10: ...IRPLANE WEIGHING PROCEDURES ____________________________ 154 WEIGHT AND BALANCE________________________________________ 156 POST FLIGHT RIGGING______________________________________________ 157 DETERM...

Page 11: ...state that you must build 51 of the total In essence we are your parts supplier You have the final say concerning every single item that goes into your project The responsibility of making a safe airc...

Page 12: ...labels these will match the pack list in numeric order Go through the list item by item If anything is not there that should be please contact our parts department immediately HINT Use sections of ply...

Page 13: ...an glazing These and some other solvents will destroy the Lexan STEEL PREPARATION All steel parts have been powder coated to provide a lasting durable surface Even though care is taken to assure a saf...

Page 14: ...d grinders Edges of certain parts also need deburring a good file works here CLECOS These are temporary fasteners that will be used to hold things together while fitting and drilling A pair of cleco p...

Page 15: ...nd side part is called out this means the planes left or your left if you were sitting in the cockpit looking forward This rule excludes ribs SERIAL NUMBER Refer to FIGURE 00 03 for the serial number...

Page 16: ...Socket Set SAE Metric Ruler Tape Measure 2 or 4 ft Level Utility Knife Hole Saw Digital Protractor Hack Saw Fluting Pliers Edge Forming Tool Scotch Brite Pads Files 1 2 3 4 Uni Bit Step Drill Dimple D...

Page 17: ...or PVC Glue Slow setting Epoxy 1 2 X 3 32 Black Foam Tape 1 2 3M VHB Tape DRILL BIT SIZES A full set of fractional drill bits ranging from 3 32 to 5 8 is strongly recommended In addition to these the...

Page 18: ...IN G3X WITH G5 BACKUP Comm Radios GARMIN GTR 200B Transponder GARMIN GTX 335 Encoder GARMIN GAE GPS for non digital display systems GARMIN AERA 660 ELT ACK Technologies E 04 Push to Talk Switch RADIO...

Page 19: ...ration In order to register your plane it will be necessary to obtain an identification number for the plane This is referred to as an N number Information and on line registration can be done by visi...

Page 20: ...o complete your kit within a very short time it is recommended that you obtain your N number right away If your project will be fairly lengthy you will not need to obtain your number until the last se...

Page 21: ...of the local EAA chapter or a local flying service may be able to help direct you to this office The purpose of such an early contact would be to discuss with the FAA representative your proposed hom...

Page 22: ...gibility Statement 3 Form 8130 6 Application for Airworthiness Certificate 4 A 3 view drawing of the aircraft or photos of top front and side view Include with this the following Horsepower rating of...

Page 23: ...components for improper installation apparent defects and unsatisfactory operation 3 Envelope gas bags ballast tanks and related parts for poor condition c Each person performing an annual or 100 hour...

Page 24: ...Cowling for cracks and defects e Each person performing an annual or 100 hour inspection shall inspect where applicable the following components of the landing gear group 1 All units for poor conditio...

Page 25: ...3 Anti icing devices for improper operations and obvious defects 4 Control mechanisms for improper operation insecure mounting and restricted travel i Each person performing an annual or 100 hour insp...

Page 26: ...N PLATES INSTALLED EXPERIMENTAL PLACARD INSTALLED WEIGHT AND BALANCE EQUIPMENT LIST WINGS REMOVE INSPECTION PLATES FAIRINGS GENERAL INSPECTION OF THE EXTERIOR INTERIOR WING FLIGHT CONTROLS BALANCE WEI...

Page 27: ...T AND OPERATION PERFORM FLOODLIGHT CARBON MONOXIDE TEST ENSURE THE COCKPIT INSTRUMENTS ARE PROPERLY MARKED INSPECT INSTRUMENTS LINES FOR SECURITY CHECK CLEAN REPLACE INSTRUMENT FILTER INSPECT COCKPIT...

Page 28: ...ECK ANTI COLLISION LIGHT FOR OPERATION INSPECT ALL ANTENNA MOUNTS AND WIRING FOR SECURITY CHECK ALL GROUNDING WIRES ENGINE TO AIRFRAME WING TO AILERON FLAP ETC INSPECT RADIOS LEADS WIRES FOR ATTACHMEN...

Page 29: ...BOUND TEXT MANUAL 28 ELECTRICAL SYSTEM CHECK COOL DOWN PERIOD ENGINE SHUT DOWN PERFORM OIL HYDRAULIC AND FUEL LEAK CHECK PAPERWORK AIRWORTHINESS DIRECTIVES RECORD FINDINGS AND SIGN OFF INSPECTION AND...

Page 30: ...ch entrance to the cabin or cockpit in letters not less than 2 not more than 6 in height the word EXPERIMENTAL LOCATION OF MARKS ON FIXED WING AIRCRAFT Reference FAR Part 45 25 b 1 If displayed on the...

Page 31: ...ation number to the sides of the fuselage the builder must also identify his aircraft by attaching an identification plate to the aircraft s structure This identification data required to be inscribed...

Page 32: ...for complying with these requirements MARKINGS AND PLACARDS The markings and placards necessary for the safe operation and handling of the aircraft should be displayed in a conspicuous place and may...

Page 33: ...ting speed if applicable LANDING GEAR If a retractable landing gear is used an indicator should be marked so that the pilot can at any time ascertain that the wheels are secured in their extreme posit...

Page 34: ...ed acrobatic maneuvers and the recommended entry airspeed for each If inverted flight maneuvers are not approved the placard must have a notation to this effect BAGGAGE PLACARD The maximum baggage loa...

Page 35: ...the FAA inspector will acquaint you with the requirements for a mandatory flight test and proving period This flying will be confined to an assigned flight area approved by the FAA Inspector The prese...

Page 36: ...The FAA Inspector will authorize the flight tests to be carried out in a designated and limited test area usually within a 25 mile radius of the aircraft s base of operations He will insure the area s...

Page 37: ...eriod they only may be modified After the mandatory flight test period then what REPAIRMAN S CERTIFICATION The Repairman s Certificate is applied for using the application form 8610 2 available from t...

Page 38: ...e all of the information without having to turn many pages Here are some important points to remember when completing any assembly 1 Open your manuals to the correct pages before starting an assembly...

Page 39: ...h it may have the same size and grip length 12 When placing rivets through steel structures dip the rivet in primer first This will seal the hole and prevent corrosion Don t forget the most important...

Page 40: ...ru 68 11 AACQ 42 30 CCC 42 30 AVEX 1691 0410 30 AN3 Bolt 11 AN4 Bolt 1 4 AN5 Bolt 5 16 AN6 Bolt 3 8 AN7 Bolt 7 16 1 4 Quick Pin 1 4 4 Machine Screw 30 6 Machine Screw 20 8 Machine Screw 21 10 Machine...

Page 41: ...rface of the parts using fine sandpaper or Scotch Brite pads 3 Hang the parts from a simple scaffold using wire 4 Apply the paint in several light coats allowing drying between coats 5 Let the parts c...

Page 42: ...tube outside diameter and insert a screwdriver or anything handy to be used for leverage 8 This will probably take 2 people Force the tube down toward the table and rotate the tube to roll the skin t...

Page 43: ...ly bend the edges of the skin around the spar at the very bottom near the hinge The purpose is to ensure the edge of the skin does not contact the vertical stabilizer skin and to reduce drag slightly...

Page 44: ...time 6 Use an edge forming tool to form the aft edges of the leading edge skin 7 Cleco the leading edge skin to the frame assembly overlapping the side skins 8 Check the vertical stab for twist by pla...

Page 45: ...doubler Place a mark flush with the opposite doubler Remove handle from Vertical Stab 12 Refer to FIGURE 003 05 and locate a 1 4 hole for the Quick Release Button to protrude through The Button will l...

Page 46: ...ll the rubber trim onto the bottom edge of the vertical stabilizer Remove and trim to fit Use a very small amount of Cyanoacrylate Superglue to secure the rubber trim onto the bottom edge of the verti...

Page 47: ...aircraft Ensure the pre drilled holes in the spars and doublers match with each other and the pre drilled holes in the spars are on one side This will orientate the spars so that both undrilled flang...

Page 48: ...ars 6 Remove the skins and de burr the transfer drilled holes 7 The center section of the horizontal stabilizer is cut out to allow it to fit over the fuselage The rivets in the area are flush to allo...

Page 49: ...tach the aft spar to S 11 The hole for the other bolt is left out of the rear spar of the horizontal stabilizer This will be drilled out after the wings are attached to the fuselage IMPORTANT Secure t...

Page 50: ...al stabilizer 3 Remove the tape and place the fairing in place up against the tailcone 4 Trim to fit tightly around the tailcone 5 Use a small amount Cyanoacrylate to secure the rubber edging to the f...

Page 51: ...he 1 1 4 O D tube outside diameter and insert a screwdriver or anything handy to be used for leverage 17 This will probably take 2 people Force the tube down toward the table and rotate the tube to ro...

Page 52: ...to the additional ribs 2 The outer 4 rib flanges point inwards On the ribs at the horn and the ribs at the center of the trim tab the flanges point away from each other Rivet the ribs to the spar 3 C...

Page 53: ...spar at each hinge to retain the hinge pin as shown in FIGURE 05 02 Safety wire the hinge pins in place upon final assembly of the trim tab to the elevator ELEVATOR FINAL RIVETING 1 Check the assembl...

Page 54: ...de elevator with nut plates 1 The Servo Ribs should have been drilled to 11 and nut plates installed during elevator assembly If not do so now 2 Drill the 4 servo mounting holes to 20 Attach servo to...

Page 55: ...Precautions Do NOT eat drink use tobacco products or apply cosmetics in work areas Wash shower thoroughly after handling and before eating drinking or using tobacco products Dispose of water in compl...

Page 56: ...t in either side varies but it should not be all on one side 8 When satisfied with the balance of the elevator tip the trailing edge up slightly balance arm down while the epoxy cures This will preven...

Page 57: ...or similar to insert the bolts into the hinges Take care not to ding or mar the skins 3 Use the appropriate hardware to secure 4 Once the horizontal stabilizer elevator is mounted to the tailcone bolt...

Page 58: ...there is an up and down to the doubler due to mounting hole alignment d The AFT Spar Truss Doubler is on the forward side of the Rear Spar e On the FWD Spar FWD Doubler the notch in the doubler points...

Page 59: ...lines This will allow final trimming during fit up 4 Slip Lens into Spar Center raised area within cut out in spar The top edge will rest against the spar radius 5 The lower edge will need to be trimm...

Page 60: ...holes Note that the mounts have slots which allow the light to be angled as necessary for proper light beam convergence After adjusting tighten bolts AILERON BELLCRANK ASSEMBLY 1 Press the bearing int...

Page 61: ...llcrank orientation Notice the snap ring is up the long arm of the bellcrank and bellcrank mount point in the same direction and the short arm of the bellcrank points opposite of the rear spar 5 Slide...

Page 62: ...line up and drill the opposite hole through the fitting and the truss Put another bolt in the freshly drilled hole e Drill out the remaining 2 holes f The fitting that was just drilled is now matched...

Page 63: ...nge arms aileron bellcrank outer rib support and flap teleflex and bellcrank mount to the ribs 13 Rivet only the bottom holes of the rib AFT attach angles through the rear spar The top hole is used to...

Page 64: ...groove on the teleflex cable onto the flap bellcrank mount rib support 27 Position the flap bellcrank so that the longer arm of the bellcrank points toward the root of the wing while the shorter arm...

Page 65: ...proper location using blue thread lock safety wire and lock washers where necessary Flap bellcrank is assembled and bolted into the wing in the proper location using blue thread lock safety wire and...

Page 66: ...ing spanning from the front and rear spar 6 Make sure the wing structure is square Lightly clamp down the wing in a way as to not interfere with the top skin 7 Place a couple of straight pieces of ang...

Page 67: ...p and aileron to check for clearance through the range of motion If any rivet heads contact the aileron or flap the bottom surface of the gap seal may be formed to clear by using a round object such a...

Page 68: ...similar to remove material from the stringer to create a notch NOTE Smooth any sharp corners cutting marks etc from the stringer to avoid stress concentrations 5 Use shears or a Dremel to remove the...

Page 69: ...wing ribs and go on the inside of the ribs flange 15 Double check to be sure there is 0 of twist in the wing 16 Match drill the leading edge holes through the D spar using a 30 drill Start in the mid...

Page 70: ...d rivet to Cover 5 Push a Union Elbow over the upper end of the Pitot Tube Pull on the elbow body while holding the inner sleeve to seal Connect to Pitot line in wing Pull on tubing to seal Attach Pit...

Page 71: ...the drill guide at the center of the hole in the top skin for the cap Mark the hole in the top skin to the top of the tank using a marker 7 Remove the tank from the wing 8 Cut a 3 hole for the wing t...

Page 72: ...upport with shorter side orientated to the AFT Refer to FIGURE 06 14A The outboard v shaped cut out should align with the Fuel Vent opening 21 The underside of the fuel cap assembly is cone shaped and...

Page 73: ...get to them once the root rib is in place Once in place pull the string out through the exit hole in the Inside Root Rib 31 Install the sight gauge tube and hose clamps 32 Rivet the Inside Root Rib to...

Page 74: ...p of the tube pretty well 5 Transfer drill and cleco the rest of the holes in the skin to the tube 6 Clean the table to be used from debris and chips Flip the skin tube over and place it on the edge o...

Page 75: ...er to FIGURE 06 16 for typical orientation Use a bench vice or similar to press in the bronze flange bushings Ream the bushings to 11 if a 3 16 bolt will not insert into the bushings NOTE If any of th...

Page 76: ...ere is any play detectable between the bronze flange bushing and the hole the damaged hinge must be replaced This may have been done in a previous step 6 Double check the location and orientation of t...

Page 77: ...rk forward 17 Match drill and debur the spar using the holes in the skin and a 30 drill 18 Finish riveting the skin to the spar AILERON BALANCING The plugs for the mass balance are created using spray...

Page 78: ...at for the remaining 3 strut doubler plates 5 Slide the Strut Fitting Doublers inside the ends of the strut and cleco in place Drill the 30 holes out to 11 Rivet the doublers to the strut using the ap...

Page 79: ...e fairing and drill to 30 Slip fairing over upper end of lift strut NOTE The fairing may be split to the cut out at the top to aid in removal without removing the strut If this is the case you may wan...

Page 80: ...of bending should be minimized The angles should be close but do not bend them back and forth to get them perfect This will weaken the flange at the bend 5 Set the bulkheads aside 6 Cut out the slot...

Page 81: ...and rivet starting the fourth hole back from the front 13 Refer to FIGURE 07 02A and cut the shorter forward stringer for the Top Skin Notice the AFT end will lap onto the bulkhead Do NOT transfer dr...

Page 82: ...be parallel to the tube on the rear of the cage Slide them together until the gussets fit with the lower longerons NOTE Front edges of the side skins may not be perfectly parallel to the cage due to...

Page 83: ...ort angle as shown in FIGURE 07 03 16 Fabricate and install the lower longeron support angle and S 3 to S 4 Support as shown in FIGURE 07 04 and the PARTS MANUAL DRAWING 17 Fabricate and install the t...

Page 84: ...un the rudder cables as shown in PARTS MANUAL DRAWING 009B 01 The cable will have to be fed through the hole in the S 4 bulkhead from the back working forward Mount the pulleys as you go with the rudd...

Page 85: ...the right baggage floor in place first and then the left Line up the aft edge with the aft flat surface of the S 4 bulkhead Press the front and rear corners of the floor tightly into the corners on S...

Page 86: ...trimmed at a later time c Use RTV Silicone or hot glue to adhere the wire to the longeron every 12 inches or so d To keep the rudder cables from being damaged coil and tape them to the cage at statio...

Page 87: ...to the tailcone top skin 6 Trim conservatively and test fit Repeat until satisfied with fit 7 Transfer drill 11 through the Closeout at the bushing locations into the S 4 bulkhead Remove the S 4 clos...

Page 88: ...t skin 7 Cleco the tailcone top front skin to the side of station 4 Ensure the front bend fits snug around the tube at S 3 Lightly clamp in place if needed 8 Position the window support angle to mate...

Page 89: ...t from S 3 to the aft section of the tailcone Transfer drill and cleco Trim the stringers to the next hole in the stringer closest the tube on the cage The last rivet on the stringers should catch the...

Page 90: ...ark left and right 5 Fit up the AFT and FWD fuselage side skins to the cage The bottom flange of the side skins slips between the cage and the belly skin Hold pressure rearward while transfer drilling...

Page 91: ...ge of the side skins Refer to FIGURE 10E 31 for dimple locations for countersunk rivets for gear clamp plate clearance 11 Drill the 5 16 and 3 8 holes for gear attach bolts 12 Deburr all skins prior t...

Page 92: ...E 08 05 Be sure the Top Main Gear Clamp Plate fits tight against the Fuselage Longeron File upper side of clamp plate if required NOTE Oval hole will be orientated fwd or aft depending on whether on l...

Page 93: ...g grease without first removing the oil will dilute the wheel grease causing it to run out past the seal and not lubricate properly 6 Slip the bearings and wheel tire assembly back onto the axle Insta...

Page 94: ...ied greased and inserted in the wheel the axle nut should be tightened until all play is out of the assembly Rotate the wheel back and forth while tightening the nut to help seat the bearings When all...

Page 95: ...on the firewall side for support when drilling Cleco as you drill Remove debur and apply Truck Bed Liner Spray to the backside of the Firewall 4 Pin and cleco the firewall back in place Bend the smal...

Page 96: ...ded tabs and Side Skin Cut to length notch and trim as require to clear fuselage tubes Refer to FIGURE 10E 13 Transfer drill 30 through the tabs into the stiffeners Remove and layout 30 holes approxim...

Page 97: ...30 through tabs at firewall Make sure the tabs are flush with or slightly behind the Top Skin edge Check for flushness of Spacer Strips Cleco as you drill 27 Transfer drill 40 through pre drilled hole...

Page 98: ...e PARTS MANUAL DRAWING NOTE It may be necessary to lightly file or grind the tail spring to fit within the spring mount channel Do NOT modify the channel to obtain the proper fit as rotation of the ta...

Page 99: ...tight in the Socket 4 Mark a ring 3 8 from the top end of the Nose Gear 5 Insert the Nose Gear into the Gear Leg Socket until the line is visible in the hole NOTE To verify that the Nose Gear is in t...

Page 100: ...Drawings and FIGURE 08A 21 17 Using a fish scale adjust the nut until the required pull is attained at the Axle Attachment on the Fork to move it See FIGURE 08A 22 18 Drill the Nose Gear 30 from each...

Page 101: ...bottom skin of tailcone and FWD Attach Block on AFT side of Station 9 Bulkhead 2 Orientate Ring fore and aft and tighten nut OPTIONAL TOW BAR INSTALLATION STANDARD NOSE GEAR 1 Modify Nose Gear Tow Pla...

Page 102: ...proper alignment of Closeout Trim as needed 5 Transfer drill 30 thru the tailcone skins to the aft closeout Cleco as you drill Be sure the aft closeout is tight against the tailcone skins when drilli...

Page 103: ...orboard to be final installed after Boot Cowl fit up AFTER FIT UP OF BOOT COWL 5 Position the floorboard in place and mark where it interferes with Boot Cowl Skin Stiffeners Mark as needed for clearan...

Page 104: ...the Rudder Cables through their respective holes Slip grommets over Rudder Cables and install into Station 4 4 Route the Rudder Cables forward to Station 3 Roll up Rudder Cables bag and tape to a fus...

Page 105: ...STALLATION OF FIREWALL 1 Rudder pedals and floorboards must be installed and the airplane should be on the main gear with wheel assemblies mounted 2 Drill the arm of Parking Brake to 1 4 3 Locate the...

Page 106: ...oil pump Refill the oil pump attach it to the right side bleed valve and follow the same procedure Continue to fill the system and alternate sides until the system is free of all air bubbles Do NOT ov...

Page 107: ...t Nuts If you do not have a Rivet Nut puller refer to FIGURE 09D 02 for the procedure to install them 3 Fabricate Seat Stop Tubes from raw stock Using loc tite bolt Stop Tubes and Sliding Seat Positio...

Page 108: ...be if it does not set well over the 1 4 shear nut Refer to FIGURE 09D 13 12 Complete Sliding Seat Bottom Frame by placing Seat Bottom Pan on top of Sliding Seat Bottom Frame Refer to FIGURE 09D 06 Be...

Page 109: ...f the Internal Tube SEAT FINAL ASSEMBLY 1 Pull Seat Back Cushion over Seat Back Frame Slide Seat Back Tube through sewn loop of aft flap at bottom of Seat Back Cushion Pull Seat back Cushion down unti...

Page 110: ...09 11 2018 RANS S 21 OUTBOUND TEXT MANUAL 109...

Page 111: ...notches under the square seat rail Check to be sure seat has locked in position 3 To aid exiting and entering the aircraft adjust seat to aft most position 4 The seat is also adjustable in recline by...

Page 112: ...AL DRAWING 3 Use the elastic bands on the lap belts and lower shoulder belts to hold the tail of the belts after adjustment has been made 4 This seat belt design allows for quick exit out of both lap...

Page 113: ...causing binding 5 Assemble the control stick link tube as per FIGURE 10 05 Assemble the unit to the control stick connector tubes 6 Adjust the control sticks to parallel using the rod end IMPORTANT M...

Page 114: ...arts catalog and select the required components for assembly 2 Fabricate elevator stop sleeves from raw stock per FIGURE 10A 02 Slip one sleeve onto 35 push pull tube before inserting tube through Sli...

Page 115: ...ate the small cable keepers to the bottom of the pulleys and tighten the bolt to prevent rotation Insert cotter pins after rudder cables are installed 10 Lubricate the sliding block and 35 Push Pull T...

Page 116: ...ly on a flat bench or floor Insert a long 1 4 rod or bolt through the 1 4 holes in the forward end and aft end of Push Pull Tube Fitting b Support each side of the 1 4 rods with scrap lumber of equal...

Page 117: ...station 3 and down to the Pulley Assembly at lower station 3 7 Route the cable forward and connect to the turnbuckle attached to end of Aileron Control Stick Cable Refer to FIGURE 10C 06 for a control...

Page 118: ...elease tube with end caps installed 6 Depress and rotate the flap release tube until the 1 4 hole is lined up with the slot in the Handle Install the 1 4 bolt and 3 8 diameter bushings into the flap l...

Page 119: ...ON CABLE SYSTEM INSTALLATION FUSELAGE 16 Route toward the center of the fuselage under the baggage compartment area and forward through hoops welded to Station 2A 17 Disconnect the rod ends from the f...

Page 120: ...with Truss Head Screws VENT SYSTEM FINISHING KIT BEFORE SKINNING AND PAINTING 1 Refer to the parts catalog and select the required components 2 Position NACA scoop of Vent System centered on Side Skin...

Page 121: ...Panel Frame NOTE Instrument Sub panel will also rivet to lower center frame hole with nut plate rivets 5 The 5 16 holes in the Panel perimeter are to allow the rubber grommets vibration isolators to b...

Page 122: ...nel oval cutouts and trim to the edge of the cutout Spray and glue a small area at a time from center out to aid in a smooth wrinkle free application of the Fabric When gluing in place carefully match...

Page 123: ...rom raw stock Cut to length to allow to overlap onto sides of Mount Plates and extend upward to fuselage crossing tube 9 Locate and drill a 11 hole in each support angle and cleco with cushion clamps...

Page 124: ...ounting holes drilled to 3 8 thru spar 5 16 bolt head side inboard at top of Station 3 installed with washer on both sides It is recommended to hang both Wings at the same time one at a time You will...

Page 125: ...f the correct hardware should now be in place and can now be tightened This includes the front spar attach bolt 5 16 bolt retaining the Aft Attach Fitting the bolts at the top and bottom of the strut...

Page 126: ...USELAGE NOTE Fuselage section of the fuels system is dependent on engine selection 16 Refer to FIGURE 06I 19 Position the Wing Root Bottom Gap Seal on the bottom side of the Wing so that the flange is...

Page 127: ...e very outside edge Carefully stick the tape down with the very edge of the tape to the very edge of the skin of your wing This tape can be or wider tape Note the width of the tape It will be used for...

Page 128: ...pport rib at the bottom g Place weights on top of the wing tip and let the glue cure INSTALLATION 11 Position the tip on the wing and tape in place Ensure a proper fit as this will be the wing tips fi...

Page 129: ...opening 4 After painting of Wing Tip mount Strobes to Wing Tip and connect wiring Route wire into fuselage when installing Wing to Fuselage AILERON AND FLAP ATTACHMENT 1 Make sure all the bronze flan...

Page 130: ...d and will probably break your windshield A tool that grinds the windshield is best Mark your windshield with a grease pencil or a Sharpie Allow the windshield to warm to room temperature Do NOT allow...

Page 131: ...500 500 1000 750 500 800 1 000 500 How should I clean my windshield Use cleaners specifically for Acrylic A damp cloth or an air blast will clean the dust away To achieve the best results use fore and...

Page 132: ...SikaFlex 295 UV with appropriate primers and cleaners Use each at your own discretion DO NOT USE LOCTITE It crazes the Acrylic One source for more information may be found at https www plexiglas com...

Page 133: ...us the top front end of the each rib as per FIGURE 10G 02 Center all three ribs on the S 2 carry thru tabs and drill and cleco 30 These holes will be counter sunk for 30 flush rivets in a later step R...

Page 134: ...o each other Use 2 wide masking tape to secure the parts Place and transfer drill 30 Cleco as you drill See FIGURE 10G 12 14 To fit and trim the skylight remove outer trim strip Re cleco hold down str...

Page 135: ...strip spacer to the windshield Z strip Verify a good fit along the door tube center line Refer back to FIGURE 10G 20 Trim if required 23 Sand the upper and lower edges of the fiberglass windshield hol...

Page 136: ...ly using a 1 4 diameter tube sharpened on the end to act as a punch 33 Apply 1 2 black foam tape across top of fuselage at station 3 where the skylight and AFT trim strip attaches 34 Place skylight on...

Page 137: ...for cuffs and windshield hold down strip Paint with an Acrylic paint black is an excellent choice This will hide glue used to bond the on the cuffs and hold down strip 42 Paint wing cuffs as desired F...

Page 138: ...p Gap Seal Refer to FLAP RIGGING for proper neutral positioning of flap 47 Apply tape outside of marked perimeter of wing cuff on windshield Scuff inside of Wing Cuff with Scotch brite Apply 3M 2216 A...

Page 139: ...ame fwd or aft as needed for clearance Door should open and close without hitting the Fuselage tubes The Door Frame may be painted or powder coated AFTER PAINTING OF DOOR FRAMES Re check Door Frame fo...

Page 140: ...frame Mark and trim upper edge to center of door bow tube Refer to FIGURE 10H 13 Position Upper Door Lexan on Door Frame flush with top of door frame at FWD and AFT edges Refer to FIGURE 10H 14 Cente...

Page 141: ...the Windshield Boot Cowl 21 Paint Door Assemblies as desired 22 Glue Rubber Edging to top edge of Upper Trim Strip Open the Edging and apply a small amount of Cyanoacrylate glue Permabond Superglue et...

Page 142: ...for tight closing of Door Assembly against Fuselage Adjust washers under Pivot Bushing and Aluminum Bushing on Handle Plate until a tight seal is obtained Transfer drill 30 through fabricated Aluminum...

Page 143: ...ll align to center of fuselage diagonal tube Forward edge will set on large tabs at Station 2B Refer to parts page drawing for proper orientation Transfer drill 11 through all tabs and cleco 2 Set For...

Page 144: ...rtment into place Cleco then rivet or install screws as shown in parts manual 3 Position Station 4 Closeout The upper straps of the Cargo Net will attach to the upper corners 4 Cleco Sides of Forward...

Page 145: ...AND ELECTRICAL Due to the different instruments and flight systems that builders are choosing RANS does not supply gauges with the kit Refer to ENGINE INSTALLATION and Engine Manufacturer s documentat...

Page 146: ...f the rod end for the bushing Refer to the part manual drawing for hardware and bushing material used Cut the bushing material to 1 16 shorter than the gap measured This is to allow for the thick wash...

Page 147: ...Hinge Up 24 Tolerance is 2 0 1 0 Down 14 Tolerance is 2 0 1 0 SURFACE CLEARANCE The minimum clearance between aileron and wing tip is 0 13 The minimum clearance between aileron and flap is 0 2 OPERAT...

Page 148: ...n measurement move flap lever all the way up fourth notch Measurement is taken on top surface of flap at approximate half span on top of flap rib NOTE Press lightly up on the Flap trailing edge to rem...

Page 149: ...sen the top 4 cap screws 4 Use the bottom 2 cap screws to set the desired incidence Press down on the front of the horizontal stabilizer to ensure the bushings are against the bottom cap screws 5 Chec...

Page 150: ...er adjust the incidence using the method above to raise the nose of the horizontal stabilizer Lower the nose of the horizontal if the elevator balance can be seen below the horizontal NOTE Replace thr...

Page 151: ...utral position of elevator as reference for deflection measurement Use of a Digital Protractor with a zero function works well 4 Set Elevator to neutral position Set digital protractor on top of Eleva...

Page 152: ...full range of deflection Check for Correct deflections of control surfaces Interference of controls linkages surfaces with other components Excessive friction ELEVATOR TRIM TAB 1 The elevator trim ta...

Page 153: ...MANUAL 152 OPERATIONAL CHECK 6 Operate trim tab through full range of motion Correct deflections of trim tab Visual check trim tab for twist Check free movement of trim tab through full motion and li...

Page 154: ...st by feel 6 Reconnect the tailwheel cables and adjust tension by removing links in the tailwheel chain DEFLECTIONS 7 For deflection measurements move rudder pedal in cabin hold at full travel positio...

Page 155: ...ing your pre flight planning It is recommended to check the data for landing and takeoff due to fuel weight change It is the responsibility of the pilot to ensure that the airplane is loaded properly...

Page 156: ...lb minimum capacity is recommended 3 Weighing With the airplane level record the weight shown on each scale Subtract the weight of the leveling device from the weight indicated at the tailwheel Make...

Page 157: ...uld be secured securely for flight To figure the weight and balance enter the following data on the chart Refer to FIGURE 13 02 FIGURE 13 02A or FIGURE 13 03 Weight of Main Gear Left Weight of Main Ge...

Page 158: ...o hands off Release both the hands and feet from the controls and observe the slip indicator Gross weight will impact the pitch attitude of the plane and introduce P Factor Plane slowly rolls ball sta...

Page 159: ...trim bulb will be more effective on the bottom side due to dynamic pressure Start with 4 to 5 of bulb and shorten as required If not totally corrected with roll trim try adding rudder trim Plane Flie...

Page 160: ...09 11 2018 RANS S 21 OUTBOUND TEXT MANUAL 159 D shaped weather strip makes a fine bump trim Permanent bump trim using 1 4 Aluminum tubing...

Page 161: ...se where an engine of greater than flight tested weights is installed The S 21 was designed to accommodate a wide range of engines from the 100 HP Rotax up to Lycoming 360 s with constant speed props...

Page 162: ...erons Place trim on the bottom of ailerons for best results Summary Take your time on post flight rigging the end result will be a plane that flies in perfect trim This will enhance performance and fl...

Page 163: ...09 11 2018 RANS S 21 OUTBOUND TEXT MANUAL 162 RANS S 21 OUTBOUND THREE VIEW...

Page 164: ...at back near the bottom Lean back and check that seat back locks into place If a different recline setting is desired exit the aircraft and lift the seat bottom and move the pins to the desired reclin...

Page 165: ...own with 1 or both doors removed up to 100 mph A loss in lift climb and cruise speed is to be expected with the doors open or off STEERING AND BRAKING Proper steering and braking procedure is importan...

Page 166: ...maximum takeoff weight Speeds are given in MPH and KNOTS Airspeed IAS Remarks VNE Never Exceed Speed 215 187 DO NOT exceed this speed in any operation VA Maneuvering Speed at maximum gross weight 170...

Page 167: ...landing configuration Upper limit is maximum speed permissible with flaps extended Green Arc 49 170 43 148 Normal Operating Range Lower limit is maximum weight VS at most forward CG with flaps retrac...

Page 168: ...artment 180 lbs MANEUVER LIMITS This aircraft is intended for non acrobatic operations The angle of bank should not exceed 60 and the pitch attitude may not exceed 30 Stalls except whip stalls are app...

Page 169: ...prohibited FUEL LIMITATIONS Approved Fuel Grades Dependent on engine used Fuel Capacity with 2 75 gallon header tank Total Capacity 45 85 U S GAL Total Capacity each Wing Tank 21 55 U S GAL Header Tan...

Page 170: ...are therefore not correct The fuel remaining in the tanks after the fuel quantity indicator reads zero in level flight attitude in cruise condition cannot be safely used in flight OTHER LIMITATIONS Fl...

Page 171: ...e data for landing and takeoff due to fuel weight change It is the responsibility of the pilot to ensure that the airplane is loaded properly AIRPLANE WEIGHING PROCEDURES 4 Preparation Inflate tires t...

Page 172: ...AL 171 Place scales under each wheel 500 lb minimum capacity is recommended 6 Weighing With the airplane level record the weight shown on each scale and subtract the weight of the leveling device from...

Page 173: ...nd balance use the Sample Loading Problem and Center of Gravity Envelope as follows Enter the following data on the chart Refer to FIGURE 13 02 FIGURE 13 02A or FIGURE 13 03 Weight of Main Gear Left W...

Page 174: ...er pre flight planning However should an emergency arise the basic guidelines described in this section should be considered and applied as necessary to resolve the problem In any emergency fly the ai...

Page 175: ...f Fly the Airplane 1 Airspeed 66 MPH Flaps up 59 MPH Flaps down 2 Brakes APPLY As Needed 3 Ignition Switch OFF 4 Master Switch OFF Engine Failure During Flight Fly the Airplane 1 Airspeed 68 MPH for b...

Page 176: ...cabin doors prior final approach 5 Touchdown MINIMUM FLIGHT SPEED 6 Brakes APPLY As Needed Precautionary Landing With Engine Power Fly the airplane 1 Select Field FLY OVER noting terrain obstructions...

Page 177: ...ants obtains fire extinguisher when ready to extinguish fire 5 Ignition OFF 6 Master Switch OFF 7 Fuel Selector Valve OFF 8 Fire Damage INSPECT repair damage or replace damaged components or wiring be...

Page 178: ...ing coordinated aileron and rudder in opposite direction of Spiral dive 3 Cautiously apply elevator back pressure to slowly reduce the airspeed to below maneuvering speed SPINS Intentional spins in th...

Page 179: ...hould be planned straight ahead with only small heading corrections to avoid obstructions Of course the number one priority is to land the aircraft as smoothly and accurately as possible CAUTION Altit...

Page 180: ...ter vessel as possible Transmit Mayday message on 121 5 MHz giving location and intentions RECOVERY FROM A SPIRAL DIVE If a spiral dive is encountered proceed as follows 1 Retard Throttle to IDLE 2 St...

Page 181: ...roughness or loss of rpm could be carburetor ice problems Actuate the Carburetor Heat switch As soon as the engine roughness or suspected carburetor ice is gone turn off the Carburetor Heat Repeat as...

Page 182: ...ion during the walk around In addition to the items listed on the pre flight checklist look for signs of visible ice if applicable The presence of ice on the aircraft wings and tail will adversely aff...

Page 183: ...09 11 2018 RANS S 21 OUTBOUND TEXT MANUAL 182 FIGURE 14D 01...

Page 184: ...EMENT free Seats ADJUST POSITION CHECK PINS Control Sticks MOVEMENT free and correct Flap lever Operation free correct Cabin CHECK FOR FOREIGN ARTICLES Baggage SECURE For Solo flight SECURE passenger...

Page 185: ...Engine cooling air inlets and oil cooler CHECK of obstructions Engine cooling air outlet radiator CHECK of obstructions Exhaust CHECK loose or damaged TRIKE NOSEWHEEL CHECK 7 Main Gear CHECK Main whe...

Page 186: ...AILWHEEL CHECK Rudder cable and springs SECURE TRIKE CHECK Rudder cable CHECK SECURE Rudder CHECK and SECURE Tail tie down DISCONNECT 15 Control surfaces CHECK free movement and SECURE Hinge points SE...

Page 187: ...eter SET Communication radio SET Transponder SET Fuel CHECK QUANTITY Hour meter Note reading and time Engine controls SET throttle closed ROTAX 912ULS Choke on Titan X340 Mixture Rich CLEAR AREA Ignit...

Page 188: ...CHECK IN Fuel Selector Valve ON STARTING THE POWERPLANT COLD START Throttle CLOSED Master Switch ON Propeller Area CLEAR Ignition Switch START release when engine starts Throttle adjust IDLE smooth O...

Page 189: ...OFF Cabin Doors CLOSED and SECURED Parking Brake SET Flight Controls FREE and Correct Flight Instruments SET Elevator Trim SET FOR TAKEOFF center of indicator Fuel Selector Valve ON Fuel Quantity CHEC...

Page 190: ...RAISE NOSE WHEEL Climb Speed 65 70 MPH Short Field Takeoff Flaps 3rd notch Carburetor heat COLD Fuel pump ON Brake APPLY Elevator Control FULL BACK Throttle FULL OPEN Brake RELEASE Elevator Control Ta...

Page 191: ...Throttle up to MAX Continuous RPM Elevator Trim adjust Fuel pump OFF APPROACH Throttle AS DESIRED Engine temperatures MONITOR Carburetor heat ON AS REQUIRED BEFORE LANDING Seat Belts Shoulder Harness...

Page 192: ...Taildragger LOWER TAILWHEEL GENTLY AFTER MAIN WHEEL TOUCH DOWN Trike LOWER NOSE WHEEL GENTLY AFTER MAIN WHEEL TOUCH DOWN Brake MINIMUM REQUIRED Short Field Landing Airspeed approach 66 70 MPH flaps UP...

Page 193: ...ng Flaps RETRACT TO HALF Slowly Airspeed 60 MPH Wing Flaps RETRACT Slowly AFTER LANDING Wing Flaps UP Taxi SLOWLY Carburetor Heat OFF Fuel pump OFF SECURING THE AIRCRAFT Parking Brake SET Throttle IDL...

Page 194: ...llustrated NOTE This suggested outline for a pre flight inspection generally covers the critical areas that MUST be checked prior to each flight In addition EVERY component should be examined properly...

Page 195: ...s not moving Refer to FIGURE 14D 02 When taxing in strong crosswinds a little extra throttle will help the aircraft turn due to the increased airflow over the rudder Use caution not to use excessive t...

Page 196: ...g flaps reduces the ground roll and the total distance to clear an obstacle If flaps are used for takeoff they should be left in that position until all obstacles are cleared and a flap retraction spe...

Page 197: ...horizontal stabilizer The aircraft has a 360 degree full swivel tailwheel which is connected to the rudder by a centering cam You can disengage the tailwheel through pushing sideways on the rear fuse...

Page 198: ...ghly and dry with a clean soft cloth or towel RANS recommends Brillianize for windshield care Brillianize is available through RANS Parts Department CAUTION Never use gasoline benzene alcohol acetone...

Page 199: ...pot removers or upholstery cleaner may also be used for the seat upholstery Always test it on an obscure place on the fabric to be cleaned The plastic baggage enclosure and Station 3 Closeout sides ca...

Page 200: ...110 35 96 Full Flap Operating Range Lower limit is maximum weight stalling speed in landing configuration Upper limit is maximum speed permissible with flaps extended Green Arc 49 170 43 148 Normal Op...

Page 201: ...g root enclosure in clear view from the pilot seat 8 Inside of oil check door cowling 9 Near fuel caps of both fuel tanks 10 On both door top longerons in view of pilot 11 On left and right wing root...

Page 202: ...o experience in light aircraft additional the special characteristics of such shall be reviewed PILOT OPERATING ADVISORIES The S 21 OUTBOUND shall only be operated by pilots with proper training Alway...

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