SERVICE INSTRUCTION SI-57-01 Revision 2 TITLE: VG/Swept Wing Tip Installation (Mod 1215) SUBJECT / REASON / DESCRIPTION: This Service Instruction describes the installation of the Full Span Vortex Generators and Swept Wingtip Extension Mod (VG/Wingtip Mod). This modification includes the installation of 72 small VGs on the leading edge of the main wing and the replacement of the standard wingtips with the swept wingtips. This modification will enhance the slow speed handling qualities of the aircraft. It also allows the removal of the ventral fin on float equipped aircraft. Revision 1 allows the use of a generic laser level instead of a specific Craftsman laser level. Revision 2 allows using water rudders for aircraft trimming. Applicable parts were added and figures were updated. Changed stick-on template number from TF1700 to TF1833. Corrected p/n from U1081 to U1079 on page 25. COMPLIANCE: Compliance is optional. EFFECTIVITY: FBA-2C1 (equipped with Mod 1043): S/N 28, 31, 33 to 59. FBA-2C2: S/N 100 and on. APPROVAL: This modification has been approved by FAC Engineering and TCCA where applicable. MANPOWER REQUIREMENTS: It is estimated that the modification will take approximately 20 hours. This excludes labor necessary to open and close the aircraft, and work is performed by experienced personnel. SPECIAL TOOLS / EQUIPMENT: None www.foundair.com Page 1 of 27
PARTS LIST (BILL OF MATERIALS): Kit FAC-SI-57-01 Rev 2 This service instruction kit consists of the following: VG Installation Package BOM (FAC-SI-57-01 VG) Qty P/N Description 75 RAP-VG-10C12 1.0 Wing VGs 18 TF1709 Stick-on Template 2 TF1699 Stick-on Template 2 TF1833 Stick-on Template 1 syringe Loctite 330 Adhesive 1 spray Loctite 7387 Activator 1 Spare Kit 5 spare VGs, Mini glue kit Swept Wingtip Installation Package BOM (FAC-SI-57-01 Wingtip) Qty P/N Description 1 W1109 Swept Wingtip - Port 1 W1110 Swept Wingtip - Stbd 2 W1113 Shear clip (3.25 ) 4 W1115 Nut plate strip (16.75 long) 1 TF1802 Wingtip Positioning Plate 2 L949 Extension Cord 2 L951 Extension Cord 2 L45 Bonding Wire 1 Laser Level Laser level with laser beam height = 0.75 and horizontal beam splitter capability (e.g. Craftsman, Catalogue # 092892533 ) 30 MS21059L08K Two Lug, Floating Nut plate 32 AN525-832R6 Screw 2 MS21059L08 Two Lug, Floating Nut plate for W1113 6 MS21061L06 One Lug, Floating Nut plate for Position Lights 15 CCR264SS-3 Cherry Max Flush Head Rivets 6 MS24693-S28 Screw 8 CR3213-4-2 Cherry Max Rivets Miscellaneous Items 1 M400-S14 Flight Manual Supplement 1 X969 VG Placard www.foundair.com Page 2 of 27
For floatplanes with this modification installed, the following water rudder stops must be installed. The ventral fin can be removed once this kit is installed. For removal of the ventral fin, see appropriate sections (32.72 and 32.73) in FAC2-M200 (ICA or Maintenance Manual) or Figure 25. Wipline Floatplanes Water Rudder Stop Installation (FAC-SI-57-01 WWRS) Qty P/N Description 4 U1081 Water Rudder Stop 4 U1087 Water Rudder Stop 8 AN960-10 Washer 8 MS21042-3 Nut 8 AN525-10R12 Screw Aerocet Floatplanes Water Rudder Stop Installation (FAC-SI-57-01 AWRS) Qty P/N Description 4 U1079 Water Rudder Stop 4 U1085 Water Rudder Stop 2 U1083 Water Rudder Stop Doubler 8 AN960-10 Washer 8 MS21042-3 Nut 8 AN525-10R12 Screw WEIGHT & BALANCE: There is a negligible change in weight and balance due to the VG and Water Rudder Stop installation. For the wingtip installation, the standard wingtip weight should be removed and the new wingtip weight should be amended with appropriate arms. For the ventral fin removal, the ventral fin weight should be removed. See table below. Part Description Weight (lbs) Arm (in.) Moment/1000 (in-lbs) Swept Wingtips (a set of two) 8.0 25.9 0.21 Ventral fin and hardware 3.0 190.0 0.57 Standard Wingtips (set of two) 3.6 14.3 0.05 The wing tip weights do not include the weight of the lights. DRAWINGS/MANUALS: FAC2-M200 Maintenance Manual (ICA) M400-S14 Flight Manual Supplement (FMS) www.foundair.com Page 3 of 27
IMPLEMENTATION INSTRUCTIONS: Part I: Vortex Generators (VG) Installation Instructions: 1. Clean the leading edge area where the VGs will be applied with alcohol. 2. Determine the reference line to install the VG templates. a. Using Figure 2, mark a 2.5" location near the rib #3 (string mark 1). b. Using Figure 3, mark a 2.5" location near the rib #9 (string mark 2). c. Using Figure 4, mark a 2.0" location near the rib #16 (string mark 3). d. Tape a string along the three marks. Ensure that the string is tight. This will ensure straight line. 3. Apply the VG templates (TF1709, TF1699 and TF1833) along the string line. See Figure 5 and Figure 6. Align the back edge of the VG templates with the string line. See Figure 1 for template placement. Start near rib #9 and move inboard or outboard. Note the starting point for VG template is 0.5 inboard of the rib #9 rivet line. This is shown in Figure 3. 4. Use special care near the landing light region. Use TF1699 (Port) or TF1833 (Starboard) to avoid the landing light cover. The landing light is only present on the starboard side but the equivalent VG set is shifted aft on both sides of the wing for symmetry. 5. Some templates need to be trimmed in length. For example, on the last outboard template, only one VG set out of three sets on the VG template is used. Another example is the most inboard VG template. Only two sets of VGs out of three sets are installed. See Figure 1 for details. There should be 72 VGs for the whole wing (36 per side). 6. Once the templates are in place, trace out the VG locations using a pencil or a thin marker. 7. Remove the templates once the VG locations are marked. Ensure all VG locations are clearly marked. 8. A VG set (2 VGs) may be shifted spanwise by maximum of one VG width to avoid rivet heads. Move the set as a whole, not just one VG, keeping the same spacing between the two VGs in a set. 9. Tolerance for the spanwise VG location and set spacing is +/- 0.25. 10. If the aircraft is already equipped with three sets of VGs per side (just outboard of rib#9), those VGs do not need to be replaced. 11. Installing the VGs. a. Be sure you have 72 VGs (RAP-VG-10C12), the kit contains spare VGs. b. The VGs are glued on with a two-part glue consisting of an adhesive and activator. c. Put approximately 2 drops of the adhesive on the bottom of one VG and use the bottom of another to spread it around to complete coverage. Avoid excess glue which will squeeze out from under the VG and be very hard to clean up. Here, less is better! www.foundair.com Page 4 of 27
d. Lightly spray the activator in the marked VG locations with the second part of the adhesive, the activator. Do not over spray. Again, less is better! e. Place the glue covered VGs on the activated surface and press in place. Round edges should face forward. f. Set up time of the glue varies depending on air temperature and plane temperature. Allow 5 to 6 minutes for the glue to begin to set g. Clean up excess glue and overspray with alcohol. 12. Install placard, X969, on the instrument panel in plain view of the pilot as shown in Figure 7. If this location is occupied, select the nearest suitable location in view of the pilot. www.foundair.com Page 5 of 27
C B Figure 1: VG Installation Overview www.foundair.com Page 6 of 27
Figure 2: String Mark 1 (Rib 3) Detail A Figure 3: String Mark 2 (Rib 9) Detail B www.foundair.com Page 7 of 27
Figure 4: String Mark 3 (Rib 16) Detail C Figure 5: VG Template (TF1699, TF1833) www.foundair.com Page 8 of 27
MASTER ON OFF OVER VOLTAGE STALL WARNING ALT. ENABLE OFF UNDER Normal Category: No acrobatic maneuvers including spins, approved. Flight into known icing conditions prohibited. This airplane is certified for the following flight operations: DAY-NIGHT-VFR-IFR (With required equipment) MANEUVER SPEED = 114 KIAS This aircraft is airworthy with up to 4 VGs missing per wing. The upper wing surface must be inspected prior to each flight to verify that no more than 4 VGs per wing are missing or damaged. The markings and placards installed in this airplane contain operating limitations which must be complied with when operating this airplane in the Normal Category. Other operating limitations which must be complied with when operating this airplane in this category are contained in the Airplane Flight Manual. To apply parking brake depress brake pedals and pull parking brake handle To release parking brake depress brake pedals and push parking brake handle Parking Brake Handle AUX. FUEL OFF AVIONICS MASTER OFF NAV. LTS OFF TAXI LIGHT OFF LAND. LTS OFF 10 20 0 30 FOR FLOAT EQUIPPED AIRCRAFT WATER RUDDER ALWAYS UP EXCEPT FOR TAXIING STROBE LIGHT OFF FLAPS UP DOWN PITOT HEAT OFF BACKUP POWER OFF INTERIOR LIGHT OFF DIMMER CONTROLS ZONE1 ZONE2 ZONE3 AUX. STALL GEAR GEAR GEAR ALT VOLT. IGN FUEL WARN MOTOR CNTRL ADV. FLD REG. SW PITOT FLAP FLAP INSTR. TURN MAN TACH FUEL HEAT MOTOR IND CLUSTER CO-OR PRESS FLOW NAV. STROBE TAXI LAND INTER PULSE PULSE PANEL LTS LTS LTS LTS LTS CNTRL LT LTS COMM1 NAV 1 COMM2 NAV 2 GPS 1 GPS 2 XPNDR ADF NO SMOKING FASTEN SEATBELTS DO NOT RELY ON FUEL FLOW INSTRUMENT TO DETERMINE FUEL LEVEL IN TANKS 13.75 V.D.C. 4 AMP CONT. 5 AMP MAX. DME AUTO PILOT HOBBS METER A P HSI ALERT 12Vdc ENG AUDIO AUX. MONITOR INT AVN BLIND FAN ENC. FIRE EXTINGUISHER LOCATED UNDER PILOT SEAT Figure 6: VG Template (TF1709) This aircraft is airworthy with up to 4 VGs missing per wing. The upper wing surface must be inspected prior to each flight to verify that no more than 4 VGs per wing are missing or damaged. www.foundair.com Page 9 of 27
Figure 7: Recommended VG Placard (X969) Location Part II: Swept Wingtip Installation Instructions: 1. Remove the current standard of type wingtips and position lights. Retain all hardware. 2. Prepare the wingtip for position light installation as shown in Figure 8. Install MS21061L06 nut plates on the inside web of the wingtip end rib as shown. Use CCR264SS-3 Cherry Nut-plate rivets supplied. 3. Locate the wingtips using the following procedures: a. Install the TF1802 on the end tip of the wingtip. Use Clekos to hold TF1802 onto the wingtip end using three position light mounting holes. See Figure 9. b. Mount the laser level along the outboard wing aft spar rivet line on the bottom side of the wing as shown in Figure 10. The outboard aft spar is where the aileron hinges are mounted. Laser beam should point outboard along the rivet line. Ensure the laser is set to output a laser line instead of a point. Secure the laser level using double sided tape and a strip of duct tape. Stick the bottom side of the torpedo laser onto the wing bottom skin. The laser level should not shift during the wingtip positioning process. c. Prepare three 4 inch long strips of duct tape and temporarily stick onto the top surface of the wingtip. d. Slide the wingtip underneath the wing skin. Push the wingtips in tight to the rib #16 web and to the wing skin. Apply the three duct tape across the top surface of the wingtip and the wing skin. This will hold the wingtip temporarily. See Figure 11. e. Position the wingtip using the laser line and TF1802. Locate the wingtip until the laser line falls within the two wingtip locating slots on TF1802: bottom two or longest slots. Laser line must fall within the width of the two bottom slots as shown in Figure 12. This will ensure the vertical position of the wingtip. Ensure that the wingtips are pushed in tight to the rib #16 web and to the wing skin during this process. This will ensure that the wingtip is correctly located in spanwise and longitudinal direction. 4. Mark and match drill the holes from wing skin onto wingtip. These holes will locate the floating nutplates later. Follow the procedure below. a. Once the wingtip has been positioned per Step 3, mark the first two holes to be drilled out on the wingtip top surface. Mark the second from the LE and the last hole on the top surface. Use drill #20 for both holes. Install Clekos after drilling. See Figure 13. b. Recheck the position of the wingtip using the laser guideline and TF1802 plate. While ensuring that the wingtip is in correct position, trace a witness mark onto the bottom wingtip surface, at bottom wing skin edge (just outboard of Rib#16) as a reference line. Drill off one bottom hole using drill #20. Drill the middle hole of the seven bottom holes. See Figure 14. Install Cleko in the drilled hole. This should hold the wingtip in correct position. www.foundair.com Page 10 of 27
c. At this point, check that the laser level line still falls within the two wingtip locating lines on TF1802. Leave the Clekos installed on the three holes. Draw a witness mark on the wingtip bottom surface along the bottom wing skin edge. This mark will help to quickly locate the wingtip in correct position in future. d. Drill the remaining holes with drill #20 (top and bottom). Install a Cleko in all the holes after drilling. e. Once the wingtip position is satisfactory, trace a line (witness mark) to mark the location of the wingtip spar location on the rib #16 web face as shown in Figure 15. This is used later to determine the shear clip location. f. Remove the wingtips from the wing. 5. Locate and install the shear clip angle, W1113, on rib #16 web. Follow the steps below. a. Measure the thickness of the wingtip spar thickness at inboard end. This should be approximately 0.050 thick. b. Offset the line marked in step 9 forward (towards the leading edge) by the wing tip spar thickness measured in the previous step. c. Locate the W1113 shear clip centered vertically on the rib #16 web as shown in Figure 16. d. Match drill the four holes to rib #16 web. Drill #30. Do not install W1113 at this point. e. Temporarily hold the W1113 onto rib#16 with two Clekos (top and bottom). f. Now, install the wingtip back on with several Clekos along the top and bottom surface. g. Drill two matching #20 holes through wingtip spar and the shear clip, W1113. Use the pre-drilled holes on wingtip spar as guidelines. Use a long drill bit, approx. 12. h. Remove the wingtip. i. Remove the W1113 shear clip from rib #16. j. Install two floating nutplates, MS21059L08, centered about the two holes drilled at step g above. Use flush rivets to install the nutplates to W1113. Install the nutplates on the inside flange surface of the W1113 angle. See Figure 17. k. Install the shear clip, W1113, on to rib #16 web using four Cherry Max rivets provided (CR3213-4-2). 6. Locate the two blank floating nutplate strips, W1115, on the inside surface of the wingtip inboard flanges (top and bottom) as shown in Figure 18. Locate them flush with the edge of the fiberglass wingtip flange (inboard end). Use the drilled out holes as templates to locate the nutplate strips. Ensure minimum edge distance. Mark and drill the matching holes on the nutplate strips. Drill #20. 7. Hold the nut plate strips (W1115) and floating nutplates (MS21059L08K) using the Clekos. See the original wingtips (standard wingtips) as a guide for steps 5 to 7. 8. Install the floating nutplates, MS21059L08K, onto W1115 using flush solid rivets (AD3). www.foundair.com Page 11 of 27
9. As an option, the installer may reuse the nutplate strips that were already installed on the original standard wingtips instead of W1115. Drill off the flush rivets and install the nutplate strips onto the new wingtips. 10. Connect the wingtip position light extension cords (L949, L951 and L45) supplied to the position light module on the wingtip side. See Figure 20. For bonding wire attachment see Figure 21. 11. Install the wingtip position lights. See Maintenance Manual (FAC2-M200) 33-40-01 for instructions. 12. Install the wingtips using new AN525-832R6 screws supplied. 13. Check wingtip for security after the installation. 14. Check operation of position lights. 15. Complete a W&B revision for installation of the new wingtips. 16. Update M400 Section 9 Supplement, Log of Approved Supplements to include M400-S14. 17. Complete a Technical Log Book entry indicating the SI-57-01, Rev 2, VG / Wing Tip modification Parts I and II have been accomplished. www.foundair.com Page 12 of 27
Figure 8: Nut plate installation for position light mount www.foundair.com Page 13 of 27
LH = Height of laser beam from the base (bottom) of the torpedo laser. Figure 9: TF1802 installed on wingtip end www.foundair.com Page 14 of 27
Double sided tape. Figure 10: Laser mounted on outboard aft spar along the bottom rivet line near Rib #14. www.foundair.com Page 15 of 27
Push wingtip forward and inboard to keep this area flushed to the wing skin. Shim between aileron balance weight and wingtip spar temporarily. Figure 11: Picture showing the wingtip mounted flush to the LE skin www.foundair.com Page 16 of 27
TF1802 Laser line Figure 12: Position the wingtip using the laser line. Laser line must fall within the width of the two bottom slots as shown above. www.foundair.com Page 17 of 27
Figure 13: First two holes marking and drilling top side. Figure 14: Bottom hole marking and drilling third hole www.foundair.com Page 18 of 27
Shear clip reference line Figure 15: Marking the Shear Clip Reference Line (Wingtip Spar Web Location) W1113 locating lines. Wingtip spar aft surface and forward surface. Four prepiloted holes. Match drill on rib #16. Offset W1113 by the spar web thickness. Figure 16: Locating the shear clip, W1113, on rib#16 (Wingtip spar web location) www.foundair.com Page 19 of 27
Two pre-piloted #20 holes on the wingtip spar web W1113 Shear Clip Angle MS21059L08 Figure 17: Preparing W1113, Shear Clip, for Wingtip spar and rib #16 attachment www.foundair.com Page 20 of 27
Matching holes drilled through W1115 and the wingtip. Typically 7 holes. Locate these holes and install MS21059L08K floating nutplates on W1115 before riveting W1115 onto the wingtip flange. Same on top and bottom side. Pitch in an AD3 flush head rivets in between two nutplates, to install W1115 onto the wingtip flange. Install W1115 after the nutplates are installed on the W1115 first. W1115 Figure 18: Install the Floating Nutplates (MS21059L08K) on W1115 www.foundair.com Page 21 of 27
Figure 19: W1115, Nutplate strip installed on the wingtip flange (MS21059L08K installed on W1115). L45 Bonding wire L951 2 wires L949 3 wires Figure 20: Connect the wingtip position lights (Extension cords shown) www.foundair.com Page 22 of 27
Use one of the two front mounting holes to secure the bonding wire. Figure 21: Bonding wire installation Figure 22: Wipline floatplane water rudder stop installation www.foundair.com Page 23 of 27
Part III: Wipline Floatplane Water Rudder Stop Installation Instructions: NOTE: Part III of this Service Instruction is applicable to all float equipped aircraft and cannot be embodied without accomplishment of parts I and II of this Service Instruction. 1. Check to see if a set of water rudder stops are installed. 2. If installed, compare the length of the new U1081 with the ones that are currently installed. If they are the same, no change is necessary. Go to step 5. 3. If not installed, follow the following procedures: a. Position the water rudder to UP position. b. Find the existing water rudder stop holes. c. Locate U1081 as shown in Figure 22. d. Match drill the holes through U1081. Repeat steps b to d for all four water rudder stops. e. Install the water rudder stops using the original screws. 4. The ventral fin may be removed if the Full VG and Swept Wingtip option is installed. See Figure 25 for ventral fin removal. 5. Perform a function check of the water rudder control system to ensure full and unrestricted travel of both water rudders. 6. Complete a W&B revision for removal of the ventral fin. 7. It is acceptable to use the water rudders as an additional means of rudder trim. This can be accomplished by installing a longer U1087 stop on one side of the water rudder post and trimming the opposite stop. The U1087 stop may be trimmed to reduce the amount of water rudder offset as required by flight test. The adjustment must be done on both, port and starboard floats. 8. Complete a Technical Log Book entry indicating the SI-57-01, Rev 2, VG / Wing Tip modification Parts III has been accomplished. Part IV: Aerocet Floatplane Water Rudder Stop Installation Instructions: NOTE: Part IV of this Service Instruction is applicable to all float equipped aircraft and cannot be embodied without accomplishment of parts I and II of this Service Instruction. 1. Check to see if a set of water rudder stops and doublers are installed. 2. If installed, no change is necessary. Go to step 5. 3. If not installed, follow the following procedures: a. Undo the water rudder cables temporarily. b. Remove the four attachment bolts indicated in Figure 23. www.foundair.com Page 24 of 27
c. Install the doubler, U1083, between the brackets just removed and the aft bulkhead of the floats. Match drill holes. Reinstall the attachment bolts. Use sealant (RTV, etc) around the bolt to ensure a water tight seal. d. Once the doublers are installed, locate the water rudder in UP position. e. Locate U1079 as shown in Figure 24. f. Drill holes and install U1079 on the water rudder arms as shown in the figure. g. Repeat steps e and f for all four water rudder stops. 4. The ventral fin can be removed if the Full VG and Swept Wingtip option is installed. See Figure 25 for ventral fin removal. 5. Perform a function check of the water rudder control system to ensure full and unrestricted travel of both water rudders. 6. Complete a W&B revision for removal of the ventral fin. 7. It is acceptable to use the water rudders as an additional means of rudder trim. This can be accomplished by installing a longer U1087 stop on one side of the water rudder post and trimming the opposite stop. The U1087 stop may be trimmed to reduce the amount of water rudder offset as required by flight test. The adjustment must be done on both, port and starboard floats. 8. Complete a Technical Log Book entry indicating the SI-57-01, Rev 2, VG / Wing Tip modification Parts IV has been accomplished. LOG BOOK CERTIFICATION: The VG/Wingtip Mod was accomplished per Service Instruction SI-57-01 Rev 2 Part I & II. For Wipline float equipped aircraft in addition to Part I and II, The VG/Wingtip Mod was accomplished per Service Instruction SI-57-01 Rev 2 Part III. For Aerocet float equipped aircraft in addition to Part I and II, The VG/Wingtip Mod was accomplished per Service Instruction SI-57-01 Rev 2 Part IV. www.foundair.com Page 25 of 27
Remove these four bolts to install the doubler U1083. Retain bolts for reinstallation. Figure 23: Aerocet floatplane water rudder stop doubler installation preparation. Figure 24: Aerocet floatplane water rudder stop installation www.foundair.com Page 26 of 27
Figure 25: Ventral Fin Removal www.foundair.com Page 27 of 27