Wills Wing Ultra Sport 135 Owner'S Service Manual Download

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Ultra Sport 135,147,166

Owner / Service Manual

July 1998 - Third Edition

Summary of Contents for Ultra Sport 135

Page 1: ...Ultra Sport 135 147 166 Owner Service Manual July 1998 Third Edition ...

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Page 3: ...E mail comments willswing com July 1998 Third Edition Copyright 1994 1995 1996 1997 1998 by Sport Kites Inc dba Wills Wing Inc All rights reserved No part of this manual may be reproduced in any form without the express written permission of Sport Kites Inc dba Wills Wing Inc Ultra Sport 135 147 166 Owner Service Manual ...

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Page 5: ... Sail from the Airframe and Re Installing 31 Glider Tuning 33 Car Top Mounting and Transport 36 In Closing 36 Ultra Sport 135 147 166 Assembly Diagrams Table of Contents A 1 Ultra Sport 147 Middle Rear Keel A 2 Ultra Sport 147 VG Assembly A 3 Ultra Sport 147 Crossbar Assembly A 4 Ultra Sport 147 Noseplate Assembly A 5 Ultra Sport 147 Kingpost Assembly A 6 Ultra Sport 135 and 166 Rear Keel A 7 Ultr...

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Page 7: ...free to give us a call If you have access to the Internet please visit us at http www willswing com The site features extensive information about Wills Wing gliders and products a Wills Wing Dealer directory our complete retail price list a site search engine and more The most important contents of our internet site are the service and technical bulletins and the latest editions of owners manuals ...

Page 8: ... certified to any state or federal government airworthiness standards or requirements FederalAviation Regulation Part 103 states in part ultralight vehicles are not required meet the airworthiness certification standards specified for aircraft or to have certificates of airworthiness and operators of ultralight vehicles are not required to meet any aeronautical knowledge age or experience requirem...

Page 9: ...ees below zero lift angle at 37 m p h and from 10 degrees above zero lift angle to zero lift angle at 53 m p h 5 Flight maneuvers which show the glider to be adequately stable and controllable throughout the normal range of operation NOTE The Ultra Sport has been designed for foot launched soaring flight It has not been designed to be motorized tethered or towed It can be towed successfully using ...

Page 10: ...be exceeded in anything other than smooth air No abrupt maneuvering or control inputs should be made at anything above this speed The stability controllability and structural strength of a properly maintained Ultra Sport have been determined to be adequate for safe operation when the glider is operated within all of the manufacturer specified limitations No warranty of adequate stability controlla...

Page 11: ...mitations stated herein Please be aware that the fact that some pilots have exceeded these limitations in the past without dangerous incident does not imply or insure that the limitations may be exceeded without risk We do know that gliders which meet all current industry standards for airworthiness can and do suffer in flight structural failures both as a result of turbulence and as a result of v...

Page 12: ... oversleeve junction This will help to align the rear leading edge during reassembly 4 Pull the rear leading edge straight aft to disengage it from the front Put tape or padding on the sharp edges of the front end of the rear leading edge tubes 5 Carefully fold the rear of the sail over against the front and replace the bag on the glider Remounting the rear leading edges 1 Make sure you are mounti...

Page 13: ... with a folding basetube i Straighten the fold in the folding basetube ii Preflight the folding basetube center hardware at this time checking that the nuts and coil spring pins are secure and that the tangs are straight and in good condi tion iii Slide the basetube center sleeve over the center joint until it is positioned between the button spring pins Note If you plan to clamp instruments to th...

Page 14: ...cro ties Do not remove the leading edge tip protector bags at this time but do loosen the velcros on the tip bags If there is more than eight m p h of wind or if the wind is gusty turn the glider 90 degrees to the wind direction 5 Spread the wings almost all the way If you have left the bridles attached this will automatically stand the kingpost upright If not lift on the top side wire as you spre...

Page 15: ...ad the wings all the way and check all cables for any twisted thimbles or tangled cables Check at this time that no bridle line is caught under the end of an adjacent batten 10 At the rear of the keel tension the crossbar by pulling on the top portion of the 4mm accessory cord which passes through the white pulley on the rear of the sweep wire keyhole channel Drop the keyhole channel all the way d...

Page 16: ...order to attach or remove the keyhole tang from the collared bolt the aluminum anchor lock must be rotated into the position shown below left Once this is done install the keyhole tang over the collared bolt by pulling down on the nose of the glider while pressing the tang upwards over the collared bolt Remember it is the pulling down of the glider s nose rather than the upward pressure on the tan...

Page 17: ...ake special care that there is no way that the nose line can disengage the bottom front wire keyhole tang Specifically make sure the anchor lock is installed properly and that any nose line is routed outside of and or forward of the V of the bottom front wires 16 By lifting up and back on the nose batten strings push the nose battens fully back into the sail so that the tips rest on top of the nos...

Page 18: ...de wire with about 75 lbs of force This is a rough field test of the structural security of the side wire loop the control bar the kingpost and the crossbar and may reveal a major structural defect that could cause an in flight failure in normal operation Open the crossbar junction access zipper and look inside making sure that the safety ring on the junction bolt is in place and that the wires ar...

Page 19: ...idles Check again that the keyhole channel is fully engaged and locked to the keyhole bolt Along the trailing edge right wing Same as for left wing At the right tip Same as for left tip Along the right leading edge Same as for left leading edge Under the glider at the control bar Sight down the downtubes making sure that they are straight Check the cables at the control bar corners making sure the...

Page 20: ...he nose Check that the front keel pocket is secured to itself with the mating velcro surfaces and that all VG cables and ropes are inside the keel pocket Whenever you undo the velcro attaching the two sides of the front keel pocket to one another you must be sure when reattaching them that the sweep wires are fully inside the keel pocket Otherwise the keel pocket can be ripped away from the sail P...

Page 21: ...Setting the Glider Up Flat on the Ground In areas where the ground is not rocky and when there are strong winds you may wish to set up the glider flat on the ground This is easy to do and relatively few parts of the set up procedure are different from what has been described 1 After unfolding the control bar and securing the basetube center sleeve disengage the spring loaded apex slider lock from ...

Page 22: ... will give you lighter control pressures and better control Minimum controllable airspeed and minimum sink airspeed There are two important airspeeds with which all hang glider pilots should be intimately familiar minimum sink airspeed hereinafter referred to as MSA and minimum controllable airspeed MCA The more important of these two is MCA Minimum sink airspeed is that speed at which your descen...

Page 23: ...ds the root If you wish to observe the stall propagation across the whole wing on your glider you can cut some more tufts from knitting yarn about 3 4 long and tape these to the top surface of your sail across the rest of the span During normal flight the flow will be chordwise along the wing and the tufts will point towards the trailing edge When the wing stalls the tufts will reverse direction i...

Page 24: ...icate angle of attack without regard to airspeed Therefore if you practice flying various bank angles in smooth air while well away from any terrain or other gliders and watch your tufts on the inside wing which will be at the highest angle of attack you will get a feel for the way your minimum sink speed varies at varying bank angles Also be aware that in some thermalling situations such as when ...

Page 25: ...iddle and Rear Keel in the back of this manual We recommend that you not stow your glider bag or any other cargo on the glider The practice of putting your glider bag inside the sail for example can drastically alter the pitch trim and static balance of your glider and adversely affect its flying and landing characteristics The best place to carry your glider bag or other cargo is in your harness ...

Page 26: ...ed in the green for best control and stability and best structural margin at all times Yellow This region represents the upper speed range between maximum rough air maximum maneuvering speed and the speed never to exceed You should fly in this range only in smooth air as described above Red Line This is your never to exceed speed At no time should you fly faster than this speed The design of the H...

Page 27: ...like some other makes of gliders the full loose setting of the VG on the Ultra Sport is intended to be used This setting does not represent a degraded performance tuning configuration VG full loose is a very useful configuration for maximizing control ease and response while retaining excellent performance It is the recommended VG setting for working lift when any significant degree of turbulence ...

Page 28: ... The glider in this case will way overshoot the desired heading and the oscillation process has begun and will continue to get worse as long as the pilot continues to input corrections in response to what the glider has already done instead of what it is about to do The other thing pilots often tend to do is to respond to any perception of loss of control by gripping the bar more tightly and pulli...

Page 29: ...ur entire approach at a constant airspeed and to control your touchdown point by making adjustments to the shape of your pattern In particular you should avoid the technique of making a diving turn onto final This maneuver sometimes called a slipping turn is often taught to hang glider pilots as a way to lose altitude during the approach It works reasonably well with low performance low aspect rat...

Page 30: ...d inclined body position c Slowing too much prior to flare so that your arms are too much extended to allow enough flare amplitude Note One other technique you can try that will increase your landing flare authority is to land with some amount of VG on With more VG on the glider stalls more abruptly and an abrupt stall is crucial for an effective landing flare A failure to fully stall the glider i...

Page 31: ...ward to cover the keyhole bolt at the aft wire junction 6 If you leave the bridles attached make one more fold in the sail bringing the trailing edge towards the keel Roll the sail gently and carefully and install the velcro sail ties Do not attempt to stuff the sail between the mylar pocket and the leading edge tube at any point behind the kingpost base The internal fabric ribs prevent this Becau...

Page 32: ...system on the Ultra Sport 147 functions by moving the center hinge connection of the crossbar assembly aft along the keel thus pushing the leading edges outward and increasing the airframe nose angle The variable geometry system on the Ultra Sport 166 functions by activating levers mounted at the outboard end of each crossbar to achieve the same result Both mechanisms result in increased spanwise ...

Page 33: ...ear quite slack The Ultra Sport 135 and 166 do have a bridle compensation system however the bridles will still be slacker at looser VG settings Outer Mid Outer Mid Inner Inner Inner 166 VG Setting 4 Batten 5 Batten 6 Batten 7 Batten 8 Batten Tight Just Slack Just Slack Snug Snug Snug In order to sight the bridles use the following procedure For each VG setting check the bridles by flying multiple...

Page 34: ...ept that the wire you are replacing is the upper compensator wire instead of the bridle pigtail Bridle Adjustment For Older Gliders The above adjustment methods are adequate to correct for minor bridle misadjustment caused by stretching of the various cables and seating of the hardware There is another mechanism by which bridle adjustment changes for which the normal adjustment of the bridles will...

Page 35: ...enance None of the items in this section are a substitute for the continual and consistent practice of proper pre flight inspections and immediate maintenance of any items on the glider which require it Safety requires that your glider be fully airworthy for every flight Nuts and bolts must always be secure safeties must always be in place and damage to any part which could compromise the airworth...

Page 36: ...rn 2 Replace bottom side wires and hang loops 3 Replace the VG ropes 4 Replace and re adjust all batten strings see the tuning section on batten string tension Special circumstances 1 Cleaning Your Sail Keeping your sail clean will extend the life of the cloth When cleaning the entire sail you should generally use only water and a soft brush You may clean small spots or stains with any commercial ...

Page 37: ...assembled in the proper order and orientation Use the exploded parts diagrams in this manual to help you 5 Undo the velcro which holds the front part of the keel pocket together Disconnect the front VG pulley from the retaining bungee keyring 135 166 only Untie the VG activation rope from the becket on the rear triple block and unthread the VG activation rope from the two triple blocks Unthread th...

Page 38: ...aps in the proper direction to follow the sail around the leading edge as it enters the pocket 2 Position the sail on the floor with the keel pocket up and the wings folded over so that the leading edges lie along the length of the root line with the mylar pockets lying on top 3 Prepare the frame making sure that the side wires are pulled forward from the crossbar leading edge junction and are not...

Page 39: ...s explained earlier in this manual Glider Tuning Dismounting and remounting the sail at the tip A number of tuning procedures require you to dismount the sail at the rear leading edge This can be most easily accomplished by using a large flat bladed screw driver to pry the sail mount webbing off of the end of the leading edge The same technique can be used to reinstall the sail Take care not to da...

Page 40: ... too much the wedge will fall off inside the leading edge tube and you will have to dismount the sail to retrieve it Sail tension Check for symmetrical sail tension on the leading edges In order to check this sight the hem of the sail at the bottom of the leading edge tube relative to the noseplate on each side Sail tension is adjusted by adding or removing shims in 1 8 or 1 4 increments to or fro...

Page 41: ... against rotation When the screw is properly tightened there will be a slight bulge less than or equal to the wall thickness of the tube in the rear leading edge tube adjacent to the screw Batten tension All battens are tensioned by looping the batten string over the notched end of the batten twice The inboard batten strings should be slightly on the loose side You should be able to pull the strin...

Page 42: ...against the top of the leading edge tubes and the kingpost sits on top of the keel Some extra padding inserted in this area will save wear on your airframe and sail In Closing With proper care and maintenance your glider will retain a high level of airworthiness for some years Because of the relatively short history of hang gliding and the rapid advances in new designs we do not have a lot of info...

Page 43: ...and without coverbags and non essential parts 60 2 Leading Edge Dimensions a Nose plate anchor hole to 1 Crossbar attachment hole 114 0 2 Rear sail attachment point 203 204 b Outside diameter at 1 Nose 2 05 2 Crossbar 2 05 3 Rear sail attachment point 1 97 3 Crossbar Dimensions a Overall pin to pin length from leading edge attachment point to load bearing ball center at glider centerline 104 25 10...

Page 44: ...ll essential parts and without coverbags and non essential parts 65 2 Leading Edge Dimensions a Nose plate anchor hole to 1 Crossbar attachment hole 120 0 2 Rear sail attachment point 215 25 216 25 b Outside diameter at 1 Nose 2 05 2 Crossbar 2 05 3 Rear sail attachment point 1 97 3 Crossbar Dimensions a Overall pin to pin length from leading edge attachment point to load bearing ball center at gl...

Page 45: ...sential parts and without coverbags and non essential parts 70 2 Leading Edge Dimensions a Nose plate anchor hole to 1 Crossbar attachment hole 132 0 2 Rear sail attachment point 227 5 228 5 b Outside diameter at 1 Nose 2 05 2 Crossbar 2 05 3 Rear sail attachment point 1 97 3 Crossbar Dimensions a Overall pin to pin length from leading edge attachment point to load bearing ball center at glider ce...

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