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K

IT

: P/N 938-02000-01 

K

IT 

I

NSTRUCTIONS

: P/N 063-09019-01

 

 

R

EVISION

D

ATE

8/28/08  

P

AGE

1

 

2008

©

 Copyright Glasair Aviation LLC, Arlington, Washington All rights reserved 

 

G

LA

S

TAR 

/ S

PORTSMAN

 

C

ABIN 

A

IR 

V

ENT 

K

IT

 

O

RIGINAL 

E

QUIPMENT 

I

NSTRUCTIONS

 

 

P

ARTS 

L

IST

: P

LEASE 

R

EFER TO THE 

P

ACKING 

L

IST

 

 

This kit provides all the necessary parts and hardware for installing pilot-
and passenger-side cabin air vents.  The system draws fresh air into the 
cabin through two small but very effective NACA-style scoops on the 
fuselage sides.  Airflow can be controlled by the pilot and passenger using 
two adjustable eyeball ventilators.  These ventilators are oversized to 
provide ample airflow in hot climates, even at the slower end of the 
GlaStar / Sportsman’s wide performance envelope. 

 

The cabin air vent system can be installed in a GlaStar / Sportsman at any 
stage of completion, but it is most easily accomplished immediately after 
the fiberglass fuselage shells have been bonded together and fastened to 
the welded steel-tube cage structure. 

Summary of Contents for GLASTAR

Page 1: ...s fresh air into the cabin through two small but very effective NACA style scoops on the fuselage sides Airflow can be controlled by the pilot and passenger using two adjustable eyeball ventilators Th...

Page 2: ...tubes and the cabin air vent boxes Therefore treat this location as provisional until you have verified clearance as described below Tape the template in position on the exterior of the fuselage shell...

Page 3: ...938 02000 01 KIT INSTRUCTIONS P N 063 09019 01 REVISION C DATE 8 28 08 PAGE 3 2008 Copyright Glasair Aviation LLC Arlington Washington All rights reserved FIGURE 1 POSITIONING THE AIR BOX FOR INSTALL...

Page 4: ...the aircraft to receive the air drawn into the system through the NACA scoops The air box in turn provides mounting surface for the eyeball ventilators Prepare the air box for installation by first tr...

Page 5: ...all ventilator in the square aft face of the box Find the center of the face by marking diagonal lines from the corners and then use a 2 hole saw to cut a circle centered on that point Finally fit the...

Page 6: ...08 Copyright Glasair Aviation LLC Arlington Washington All rights reserved Position 10 nutplate jig 45 to corner Countersink 40 holes for AN426AD3 3 rivets Using standard procedures install a K1000 3...

Page 7: ...TIONS P N 063 09019 01 REVISION C DATE 8 28 08 PAGE 7 2008 Copyright Glasair Aviation LLC Arlington Washington All rights reserved Cleco K1000 3 nutplates in position Completed Left Right Use hand riv...

Page 8: ...layout of the air box relative to the cage Align the pre molded NACA scoop section of the air box with the cutout you made in Step 1 Verify that the air box clears the cage structure and relieve the...

Page 9: ...batch of thick resin milled fiber mixture and spread it evenly over the air box mounting plate Position the box against the fuselage side and use four clecos to pin it in place Then using the NACA sco...

Page 10: ...l the way around the cutout At the aft edge of the cutout increase the depth of this trough to about Once you have removed the foam core as described above fill the resulting troughs back in with Bond...

Page 11: ...T P N 938 02000 01 KIT INSTRUCTIONS P N 063 09019 01 REVISION C DATE 8 28 08 PAGE 11 2008 Copyright Glasair Aviation LLC Arlington Washington All rights reserved FIGURE 4 FINISHING THE NACA SCOOP EDGE...

Page 12: ...hown in Figure 5 use NAS603 8P round head machine screws to install the eyeball ventilator in the air box Note If you intend to upholster over your air boxes you will want to do so before installing t...

Page 13: ...N 938 02000 01 KIT INSTRUCTIONS P N 063 09019 01 REVISION C DATE 8 28 08 PAGE 13 2008 Copyright Glasair Aviation LLC Arlington Washington All rights reserved FIGURE 6 NACA SCOOP TEMPLATE FULL SIZE 6 0...

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