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1.3 General Assembly Notes
Before starting to assemble anything, read the whole of this manual to get an overall
impression of the order and methods of assembly. The sequence of construction is
the one used to build the importer‟s aircraft, and should be adhered to. If you wish to
change the sequence, you may find difficulty in fitting other parts later, so read ahead
carefully to determine the effects of your changes. Flylight Airsports cannot advise
on, nor be responsible for, the consequences of not following the instructions, as if
we have not tried something we cannot comment upon it with any experience.
Unpacking
To familiarise yourself with the kit components it is useful to unpack the kit and sort it
into groups for each assembly stage, such as wing parts, fuselage parts,
undercarriage etc.. Do this in conjunction with the packing list and the instruction
manual to determine that you have all the required parts.
If you cannot find a part, check under the packaging on related assemblies,
and make sure you know what it is that you are looking for, as parts may be
rolled up or transported inside other parts.
For instance smaller tubes may be slid
inside larger ones.
Don‟t forget to check
all
the boxes, in case you‟ve put a box aside somewhere. Some
small parts may be hidden within packaging foam „snow‟ in the bottom of boxes, so
don‟t throw any boxes or packaging away until you have ascertained for certain that
you have all the parts
– we have stories of unloading skips to retrieve parts that have
gone with the rubbish!
We also pack some parts in the engine box
– so remember to look in there.
This may all sound obvious, but we know from past experience that even big parts
like propellers can be thought missing when they are there all the time!
Initial assembly with non locking nuts
During initial assembly it may be helpful to use wing nuts or normal nuts (wing nuts
are preferred as they are more obvious and less likely to be forgotton!) rather than
Nyloc nuts for test fitting pieces, or on pieces which need to be removed later to fit
the coverings or other parts. Alternatively, only tighten the Nyloc nuts up to the Nyloc
section until ready to apply threadlock and tighten properly.
Assembly
If in doubt about a part, or an assembly, read ahead and pay particular attention to
drawings and photographs. Note that the direction of bolts (up/down, pointing
forwards/backwards) may differ between drawings and photographs. Normally, the
bolts will be inserted from the top or the front, unless other considerations apply,
such as coverings or access.
Remember to replace any non locking nuts with Nyloc nuts before final assembly,
and also:
REMEMBER TO USE LOCTITE 243 ON ALL NUTS.
This is usually available from your local fastenings company, look them up in the
Yellow Pages under “Fixings and Fasteners”, and you will never be stuck for nuts
and bolts again!