Silverwing AEROPRAKT A22 FOXBAT manual

The Silverwing AEROPRAKT A22 FOXBAT is a high-performance, comfortable, and easy-to-fly ultralight aircraft. Designed for both experienced and novice pilots, it's capable of operating from short airstrips, making it perfect for exploring diverse destinations. With its roomy cockpit, excellent visibility, and generous luggage space, it offers a comfortable flight experience.

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Page 2 - © SilverWing Aviation, 2005

Introduction to the Aeroprakt A22 Foxbat

The prototype A22 was conceived during 1996 on the drawing board of

Antonov Design Bureau engineer Yuri Yakovlev - purely as an easy-to-fly

450-525 kg aircraft with excellent pilot and passenger comfort and competitive all-round performance. It was intended that pilots of average ability would be able to operate the A22 in safety from the typically short ultralight airstrips found around the world.

The design is aimed squarely at the growing ultralight market in Western

Europe and the USA although examples are also operating in UAE, Malaysia and Eastern Europe. In Germany the A22 has achieved certification to the stringent BFU-95 requirements. Approval in UK to BCAR'S' via PFA engineering was achieved in late 2001. Standard engine is the 100 bhp

Rotax 912ULS, with the 80 bhp 912UL available as an option.

Known in Australia South Africa and the UK as the ‘Foxbat’, the A22 is a quality-engineered aircraft with no aerodynamic vices. The airframe is in riveted aluminium with part Ceconite type fabric-covered wings and control surfaces. It retains adequate control response in all axes at speeds down to

30 kts and provides the unthreatening STOL capability of a genuine ultralight. Yet it can cruise at 85-90kts on 14ltrs/hr and has a range of more than 500 miles. The cockpit is very roomy with excellent visibility and plenty of luggage space in a container behind the seats.

This aircraft is an excellent choice for pilots of either ultralights or GA light aircraft. Equally at home on short ultralight airstrips or GA bitumen the

Foxbat is a plane that can introduce light aircraft pilots to a much wider choice of destinations, and give ultralight pilots a level of speed and, in particular comfort, previously unavailable within the weight limit.

Building the Foxbat

Although the Foxbat is a modern aircraft in concept it uses a very conventional method of construction in riveted Alclad aluminium. The kit is supplied with some of the fuselage, much of the wings, tailplane, fin and control surfaces pre-riveted. The builder’s riveting (using ‘pop’ rivets) consists of fitting the cabin floor-pan (which is partly pre-drilled), finishing and riveting the wing and fin tips, securing the fin itself and various mounting brackets and webs to the bare fuselage monocoque. Final riveting includes all the glazing, including the windscreen.

The A22 Build Manual is illustrated with around 100 exploded-view drawings that cover each step of the assembly process together with easy-to follow

Page 3 - © SilverWing Aviation, 2005

text. As an option, a full set of engineering reference drawings is available on CD at extra cost.

The bulk of the airframe construction work is centred on the fuselage and consists of fitting the control mechanisms (torque tubes, push rods, bell-cranks, cables, etc) the main components of which are factory finished, anodised and/or plated. The factory requires the wings, tailplane and control surfaces to be pre-riveted in jigs leaving the builder to add the fuel tanks, as well as covering and painting. At every point where a rotating action takes place, an aerospace-quality rose-joint or bearing is pre-pressed into the bracket.

The airframe can be assembled and finished to a rolling but bare stage before buying the engine, instruments and covering system. This means purchases of major items can be staggered to suit the budget or build schedule – for example, if six months or more is planned to build the plane, there is little point in having an expensive engine bolted to the airframe (or in a box) using up its warranty time. After installing the engine the final finishing involves installing and connecting the fuel tanks, covering and painting, and fitting instruments, windscreen, and other glazing.

One person, working at a steady and meticulous pace can build a finished aircraft from a Foxbat kit in around 500 hours (or fewer with an assistant) some jobs need extra hands for completion. With good planning, a largish double garage will be a big enough workshop space to complete all the sub-assemblies (including covering and painting them) providing the wings and tailplane are stored elsewhere while work progresses on the fuselage.

Obviously a larger space is required for the final assembly of the aircraft although this can be done outdoors prior to Final Inspection and trailer transportation to the airfield for Test Flying. With a little practice, two people can detach the standard wings quite easily in about 30 minutes. Reassembly takes about the same.

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INTRODUCTION TO BUILDING

Before you begin….

Thoroughly read through the complete construction manual several times so you are completely familiar with each stage of the process.

Make sure you understand all the diagrams/drawings.

Check your parts against the parts list to ensure you have all the items you need.

Prepare your workshop and collect together all the tools you need.

Construction of the Foxbat requires no really specialised tools – a set of metric spanners, a hand pop-rivet gun, flat and cross-head screwdrivers, long-nose and standard pliers some files and cutters are the main requirements. Later, you will need lifting tackle for the engine – but this can be hired for the day or so you will need it.

If you are buying the kit in stages, plan when you will need the engine, covering/paint and instruments, so that they can be ordered in plenty of time.

If you are in doubt about anything – call SilverWing Aviation for clarification. Once a hole is drilled, it can’t be un-drilled! So take your time.

Constructing your Foxbat should be an enjoyable experience – much of it is an assembly process, with actual making of parts kept to the minimum - many of the rivet holes are measured and, in some cases, drilled. Final covering and painting the aircraft is a straightforward if time consuming job which done well will give you an aircraft which will not only fly well but will last you many years.

Should you require assistance at any time, just contact SilverWing

Aviation for help and guidance.

10.

Happy constructing!

SilverWing Aviation, PO Box 9050, Gold Coast MC, Qld 9726

(07) 5597 0391 & 0413 900 892 [email protected]

Page 5 - © SilverWing Aviation, 2005

AEROPRAKT A22 FOXBAT

PARTS LIST

REGIME - ITEM NUMBER - PART DESCRIPTION - (DRAWING NUMBER) - AEROPRAKT

NUMBER

FUSELAGE/WINGS/ETC

1. MONOCOQUE (1.050+) 2.0100

2. WING R/L (6.500) 3.2000

3. STRUT R/L (4.510) 3,2900

4. FLAPERON R/L (6.500) 0.3700

5. FIN (2.030+) 1.3400

6. RUDDER ((3.500) 0.3300

7. TAILPLANE (8.500) 1.3100.00

8. ELEVATOR (8.500) 3.3200

9. TRIM TAB (9.500) 1.4000

10. BEAM R/L (1.010) 0.0116

11. LG BEAM R/L (1.020) 0.4350

12. GUSSET R/L (1.030) 0.0148

13. ANGLE R/L (1.030) 0.0149

14. ANGLE R/L (1.030) 0.0150

15. HINGE X 4 (1.040) 0.1391

16. SUPPORT (1.130) 0.0156

17. BASEPLATE (1.140) 0.0164

18. BRACKET R/L (1.140) 0.0108

19. LG BRACKET R/L (1.150) 1.4130

20. LG BRACE R/L (1.150) 0.4150

21. LG BRACKET R/L (1.160) 0.4140

22. FITTING (1.160) 0.4150

23. BRACE R/L (1.050) 1.1371

24. BRACE R/L (1.050) 1.1372

25. BRACE R/L (1.060+) 1.1373

26. FITTING X 9 (1.070 +) 1.1377

27. BRACKET (18.010) 0.7625

28. BRACE X 3 (1.090/110) 1.1374

29. BRACE X 3 (1.090 +) 1.1375

30. BRACE X 3 (1.100 +) 1.1376

31. FLOORING (1.170) 0.0119

32. ANGLES R/L (1.180) 0.0171

33. DOUBLER (1.190) 0.0172

34. DOUBLER X 2 (1.190) 0.0173

35. SUPPORT (1.200) 3.4307

36. GUSSET X 2 (1.200) 3.4307

37. FLOORING (1.210) 0.0120

38. GUSSET R/L (1.220) 2.0147

39. BEAM (1.310) 1.0121

40. ANGLE (1.310) 0.0194

41. BELT (18.020) 0.7626

UNDERCARRIAGE

1.MAIN LEG R/L (1.270) 5.4110

2.AXLE X 2 (1.300) 3.4133.BLOCK X

2 (1.300) 8.4121

4.PLATE X 2 (1.300) 3.4123

5.MATCO 5.00-5 (+ BRAKE) X 2

6.SUPPORT (1.280) 3.4308

7.FLANGE (1.280) 3.4324

8.STRUT (1.280) 3.4300

9.NOSELEG (1.290) 3.4300

10.MATCO 6.00-6

11.AXLE (1.290) 1.4301

12.SPACER X 2 (1.290) 1.4316

MOULDINGS, ETC

1.PROP: SPINNER

2.SPINNER BACKPLATE

3.ENGINE COWLING UPPER

4.ENGINE COWLING LOWER

5.WING FILLETS R/L 0.1500

6.WHEELSPAT FRONT

7.WHEELSPAT RIGHT

8.WHEELSPAT LEFT

9.FIN CAP 0.3409

10.FLAPERON COWL 1.5400.04

11.CENTRAL CONSOLE 0.7152

12.INST: HOUSING 1.7151

13.INST: PANEL DURAL: 0.7001

14.INST: PANEL CARBON

15.WINDSCREEN 0.1301.00

16.SIDEWINDOW R/L 0.1301.01

17.TOPWINDOW 0.1303

18.PITOT HEAD/TUBES

FUEL SYSTEM

1. TANK R/L (17.100) 3.6120.00

2. FAIRING (18.100) 0.7627.01

3. GASCULATOR (SKYCRAFT,ETC)

4. J/TUBE (17.010) 3.6100.01

5. F/COCK X 2 (17.100)

6. T/PIECE X 2 (17.020)

7. DRAIN VALVE (17.020)

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ENGINE AND ANCILLARIES

1. E/MOUNT (10.010+) 0.6401.01

2. E/MOUNT (10.010+) 0.6402.00

3. BRACKET (10.020+) 0.6402

4. ROD (10.020) 0.6403

5. LUG (10.020) 0.6401

6. BEARINGS (10.020) 0.6404

CONTROLS (THROTTLE/CHOKE)

1. BRACKET L (16.010) 3.6018

2. BRACKET R (16.010) 3.6019

3. T/LEVER L (16.010+) 3.6025

4. T/LEVER R (16.010+) 3.6026

5. C/TUBE (16.010) 3.6021

6. F/CLAMP (16.010) 3.6029

7. SPACER (16.010) 3.6016

8. C/STOP (16.020) 3.6017

9. SHACKLE (16.020) 3.6023

10. HANDLE (16.020) 1.6028

11. I/CABLE (16.020+) 2.6040

12. O/CABLE (16.020+) 2.6041

13. C/LEVER (16.030) 1.6051

14. C/CABLE (16.030+) 1.6055

15. BRACKET (16.040) K20.2.42.02

16. J/BLOCK (16.040) K20.0.42.03

17. COVER (16.040) K20.2.42.05

18. CABLE X 2 (16.040) 1.6056

19. B/CABLE X 2 (16.050) 3.6040.00

CONTROLS (PEDALS)

1. PEDALS (11.050) 4.5210.01C6

2. PEDALS (11.050) 4.5210.02C6

3. BRACKET R (11.050) 3.5270.01

4. BRACKET L (11.050) 3.5270.02

5. CABLE R (11.050+) 5.5230.01C6

6. CABLE L (11.050+) 5.5230.02C6

7. ROD (11.050) 0.5240.01

8. ROD (11.050) 0.5240.02

CONTROLS (STICK)

1. S/HINGE (13.040+) I.5124.02

2. S/HINGE (13.040+) 1.5167.00

3. C/SHAFT (13.040+) 0.5123

4. BRACKET (13.030) 1.5502

5. ANGLE (13.030) 1.5124.04

6. SHAPE (13.030) 1.5124.05

7. HINGE (13.030) 1.5124.01

8. PLATE (13.030) 1.5124.03

9. BRACKET (13.010) 1.5168

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10. BRACKET (12.020+) 2.5181

11. STOP (13.020) 1.5168

12. PAD (13.020) 1.5169

13. C/STICK (1.260+) 0.5122.00

14. BELLCRANK (12.030+) 1.5182

15. SLEEVE (12.030) 0.5186

16. ROD (12.040) 2.5132.00

17. ROD (12.040) 1.5183.00

18. COVER (1.330) 1.0196

19. FRAME 4 (15.010) 0.0940

20. C/GUIDE X 2 (15.010) 1.5500.04

21. PAD X 2 (11.020) 5.5293.00

22. CABLE R/L (11.020) 5.5230.01CB

23. BRACKET L (11.030) 5.5251.00

24. BRACKET R (11.030) 5.5252.00

25. CABLE R/L (11.030+) 5.5230.02

26. GUARD (11.030) 5.5253.00

27. SHACKLE (11.010) 0.5269.00

28. BELLCRANK (12.010) 1.5185

29. ROD (12.050) 1.5183.00

30. ROD (12.050) 1.5186.00

DOORS/FITTINGS

1. DOOR R/L (1.530) 0.1350.00

2. HINGE X 4 (1.500) 0.1380.00

3. HANDLE R/L (1.510) 0.1375.00

4. SPRING R/L (1.510) 0.1379.00

5. HANDLE R/L (1.510) 0.1376.00

6. PIN X 4 (1.600) 0.1350

7. G/STRUT (1.610) 0.1350.00

8. VENT (1.520) 1.1385.00

9. “K” D/EXCLUDER STRIP

CONTROLS (FLAP MECHANISM)

1. BRACKET R/L (14.010) 1.5405

2. BRACKETS (14.010+) 1.5400.01

3. C/STOP (14.010+) 1.5400.03

4. PAD R/L (14.010) 1.5400

5. ROCKER (14.020) 1.5403

6. LEVER (14.020+) 1.5402

7. BRACKETS (14.020) 1.5400.02

8. C/PLATE (14.020) 1.5404

9. BEARING (14.020) 1.5400.06

10. BEARING (14.020) 1.5400.07

11. HANDLE (14.030) 1.5401

12. SPRING (14.030) 1.5400.05

13. CABLE (14.030) 1.5407

14. C/STOP (14.030) 1.5404.03

15. C/SHAFT (13.050+) 1.5410

16. C/RING (13.050+) 1.5410.01

17. C/SHAFT (13.060+) 0.5123.00

18. ROD (13.060) 1.5408.00

19. TRIMCABLE (7.500) 1.5503.00

LUGGAGE AND SEATS

1. L/BAG (1.320) 1.8101

2. F/E TUBE (1.320) 0.8102

3. U/TUBE (1.320) 0.8103

4. L/TUBE (1.320) 0.8104

5. GUSSET (1.320) 0.8105

6. GUSSET (1.320) 0.8106

7. BELT (1.340) 0.7550.02

8. BELT (1.340) 0.7550.03

9. BELT (1.340) 0.7550.01

10. LUG (1.340+) 0.7550.10

11. SPACER (1.340) 0.7550.12

12. SEAT X 2 (1.350) 1.7560

13. SQUAB X 2 (1.350) 1.7561

CONTROLS (BRAKES, MATCO)

1. M/CYLINDER (19.010+)

2. C/TUBE (19.010+)

3. B/LEVER 19.010+)

4. T/PIECE X 2 (19.010)

5. S/CYLINDER (19.010)

ELECTRICAL

1. FUEL PROBE X 2 (18.100)

2. P/WIRE (18.100+) 0.7609.01.00

3. WIRE (18.040+) 0.7605

4. WIRE (18.050) 0.7612

5. F/GAUGES X 2

FOR REMAINING ELECTRICAL PARTS

SEE ROTAX AND OTHER COMPONENT SUPPLIER’S OWN PARTS LISTS, WHICH ARE

PROVIDED WITH YOUR KIT.

NUTS/BOLTS/FASTENERS/ETC

SUFFICIENT QUANTITY OF THE VARIOUS SIZES AND TYPES ARE PROVIDED TO

COMPLETE YOUR KIT. ALL THREADS ARE METRIC. SEE THE ASSEMBLY

DRAWINGS FOR EXACT DETAILS.

ORDER REPLACEMENTS FROM SILVERWING AVIATION OR SPECIALIST FIRMS

SUCH AS AIRCRAFT SPRUCE.

COVERING AND PAINT

A FOXBAT-SPECIFIC KIT OF “POLYFIBER” MATERIALS CAN BE SUPPLIED BY

SILVERWING AVIATION. CONTACT US DIRECTLY FOR INFORMATION. THE 2-

PACK STRUCTURAL ADHESIVE FOR FABRIC-TO-DURAL ATTACHMENT IS

AVAILABLE IN ONE-JOB QUANTITIES FROM SILVERWING AVIATION.

TYRES AND TUBES

AIRCRAFT QUALITY 6” WITH CHOICE OF PROFILES. ORDER

REPLACEMENTS FROM SILVERWING AVIATION OR SPECIALIST FIRMS

ADVERTISING IN THE AVIATION PRESS.

Page 8 - © SilverWing Aviation, 2005

PAGE ONE

DRAWING NUMBER 1.010

Installing the Central Console Beams

SEE DRAWING FOR PARTS REQUIRED

Recommended job for two persons with fuselage monocoque supported as required

Locate and inspect the left and right central console beams as illustrated in the drawing.

Offer up both parts ensuring that their orientation is exactly as shown in the drawing. Clico in place then check the fit and alignment.

Re-check steps 1 and 2.

Working from side to side alternately replace the clicos with rivets.

Thoroughly examine the finished work and compare it with the drawing.

Notes:

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PAGE TWO

DRAWING NUMBER 1.020

Installing the Landing Gear Support Beams

SEE DRAWING FOR PARTS REQUIRED

Recommended job for two persons with the fuselage monocoque supported as required.

Locate and inspect the left and right landing gear (LG) beams illustrated in the drawing.

Offer up both parts to the fuselage ensuring that their orientation is exactly as shown in the drawing. Clico in place.

Re-check steps 1 and 2.

Working from side to side alternately replace the clicos with rivets.

Thoroughly examine the finished work and compare it with the drawing.

Notes:

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PAGE THREE

DRAWING NUMBER 1.030

Installing the Door Gussets

SEE DRAWING FOR PARTS REQUIRED

Recommended job for two persons with fuselage monocoque supported as required

Locate and inspect the angle pieces and gussets as illustrated in the drawing (left and right sets).

Offer up the three parts to the fuselage left side ensuring that their orientation is exactly as shown in the drawing. Clico in place then check the fit and alignment.

Re-check steps 1 and 2.

Working from end to end alternately replace the clicos with rivets.

Thoroughly examine the finished work.

Repeat on right-hand side.

Notes

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PAGE FOUR

DRAWING NUMBER 1.040

Installing the Door Hinges

SEE DRAWING FOR PARTS REQUIRED

Recommended job for one person with the fuselage monocoque supported as required

Locate and inspect door hinges as illustrated in the drawing. Select the correct size bolts with stiff nuts and washers.

Loosely assemble both hinges in turn on the left side exactly as shown on the drawing.

Re-check steps 1 and 2.

Tighten stiff-nuts until the hinges are snug and firm. Don’t over-tighten.

Thoroughly examine the finished work.

Repeat on right-hand side.

Notes:

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PAGE FIVE

DRAWING NUMBER 1.130

Installing the Upper Central Support

SEE DRAWING FOR PARTS REQUIRED

Recommended two persons job with the fuselage monocoque supported as required

Locate and inspect the support bracket as illustrated in the drawing.

Offer up parts and pre-assemble with clicos exactly as shown in the drawing.

Re-check steps 1 and 2. When you are completely satisfied that the assembly is correct replace clicos with rivets working outwards from the top centre.

Very carefully centre-punch, drill and pop-rivet the bottom of the bracket to the cross-spar as shown in the drawing. Make certain to use the correct drill and rivet size. Double-check before drilling.

Thoroughly examine the finished work.

Notes

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PAGE SIX

DRAWING NUMBER 1.140

Installing the Wing Rear Hinge Bracket

SEE DRAWING FOR PARTS REQUIRED

Recommended one person job with the fuselage monocoque supported as required

Locate and inspect base plate and rear hinge bracket as illustrated in the drawing. Select correct sized bolts with stiff-nuts and washers.

Offer up and loosely assemble parts exactly as shown in the drawing.

Re-check steps 1 and 2.

Tighten stiff-nuts until the assembly is snug and firm. Don’t overtighten.

Thoroughly examine finished work.

Repeat on left-hand side.

Notes:

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PAGE SEVEN

DRAWING NUMBER 1.150

Installing the LG Spring Upper Brackets and Braces

SEE DRAWING FOR PARTS REQUIRED

Recommended one person job with fuselage supported as required

Locate and inspect LG spring bracket and brace as illustrated on the drawing. Select the correct size bolts with stiff-nuts and washers.

Offer up and loosely assemble parts exactly as shown on the drawing.

Re-check steps 1 and 2.

Tighten stiff-nuts until the assembly is snug and firm. Don’t overtighten.

Thoroughly inspect finished work.

Repeat on right-hand side.

Notes

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PAGE EIGHT

DRAWING NUMBER 1.160

Installing the LG Spring Lower Brackets and Fittings

SEE DRAWING FOR PARTS REQUIRED

Recommended one person job with the fuselage monocoque supported as required

Locate and inspect the LG spring bracket and fitting as illustrated on the

Drawing. Select correct size bolts with stiff nuts and washers.

Offer up and loosely assemble the parts exactly as shown on the drawing.

Note that the rivets (item 8 in drawing) will not be fitted until after the floor pan is fitted. The lower face of the fitting (item 3) should align flush with the lower edge of the fuselage (item 1). Study this drawing very carefully and remember that although the floor pan is illustrated on the drawing it is not yet in place on the actual work.

Re-check steps 1 and 2.

Tighten the stiff-nuts until the assembly is snug and firm. Don’t overtighten.

Thoroughly examine the finished work.

Repeat on right-hand side.

Notes:

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PAGE NINE

DRAWING NUMBERS 1.050/060/070/080/18.010

Installing the Fuselage Side Braces and Battery Tray

SEE DRAWING FOR PARTS REQUIRED

Recommended job for two persons with the fuselage monocoque supported as required

After carefully studying the four drawings locate and inspect the braces, fittings and battery tray.

Offer up parts and pre-assemble with clicos exactly as shown in the drawings.

Re-check steps 1 and 2. Ensure good fit and alignment.

Replace clicos with rivets.

Thoroughly examine the finished work.

Repeat on right-hand side.

Notes

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PAGE TEN

DRAWING NUMBERS 1.090/100/110/120

Installing the Fuselage Top Braces

SEE DRAWING FOR PARTS REQUIRED

Recommended job for two persons with the fuselage monocoque supported as required

After carefully studying the four drawings locate and inspect braces and fittings.

Offer up parts and pre-assemble with clicos exactly as shown in the drawings.

Re-check steps 1 and 2. Ensure good fit and alignment.

Working from end to end alternately replace clicos with rivets.

Thoroughly examine the finished work.

Notes:

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PAGE ELEVEN

DRAWING NUMBER 1.170

Installing the Fuselage Forward Flooring

SEE DRAWING FOR PARTS REQUIRED

Recommended job for two persons with the fuselage supported as required

Locate and inspect the forward floor panel as illustrated on the drawing.

Offer up to the fuselage and clico in place exactly as shown on the drawing.

Re-check steps 1 and 2. Be especially careful to ensure correct positioning and alignment with the pre-drilled holes in the fuselage.

Replace clicos with rivets working in an alternating “spread” pattern.

Thoroughly examine the finished work.

Notes:

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PAGE TWELVE

DRAWING NUMBER 1.180

Installing the Central Console Angles

SEE DRAWING FOR PARTS REQUIRED

Recommended job for two persons with the fuselage supported as required

Locate and inspect central console angles as illustrated on the drawing.

Offer up parts and clico in place exactly as shown on the drawing.

Re-check 1 and 2.

Working alternately and from side to side replace clicos with rivets but

do not rivet the holes circumscribed on the drawing (4

, 5 th

and 6 th

from the front on each side).

Thoroughly examine the finished work.

Notes:

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PAGE THIRTEEN

DRAWING NUMBER 1.190

Installing the Nose Leg Doublers

SEE DRAWING FOR PARTS REQUIRED

Recommended two persons job with fuselage supported as required

Locate and inspect one medium doubler and two small doublers as illustrated on the drawing.

Offer up parts and clico in place exactly as shown on the drawing.

Note that the outer 3 holes in the small doublers mate with the holes previously left un-riveted (see page twelve).

Re-check steps 1 and 2.

Replace clicos with rivets in the holes in the indicated holes only.

Note. Pre-view page fourteen for clarification of nose leg support assembly.

Thoroughly examine the finished work.

Notes:

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PAGE FOURTEEN

DRAWING NUMBER 1.200

Installing the Noseleg Supports

SEE DRAWING FOR PARTS REQUIRED

Recommended job for two people with fuselage monocoque supported as required

1. Locate and inspect the support and gussets as illustrated in the drawing.

Select the correct size bolts with stiff-nuts and washers, and the stud .

Note. After airframe 016 the gussets were replaced with straight link plates connecting the stud (4) to the bolts (6).

2. Offer up the parts exactly as shown on the drawing. Clico support (2) in place and assemble the other parts loosely.

Note. Pre-view page twenty for further clarification of this assembly.

3. Re-check 1 and 2.

4. Replace Clicos with rivets then progressively tighten the stiff-nuts working from side to side until the assembly is snug and firm. Don’t over-tighten.

5. Thoroughly examine the finished work.

Notes:

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Page 43 - © SilverWing Aviation, 2005

PAGE FIFTEEN

DRAWING NUMBERS 1.210/220

Installing the Fuselage Aft Flooring

SEE DRAWINGS FOR PARTS REQUIRED

Recommended job for two people with fuselage monocoque supported as required

Locate and inspect aft flooring panel and floor gussets as illustrated on the drawing.

Offer up the floor panel and floor gussets making sure the pre-drilled holes in each are aligned with the fuselage holes exactly as shown in the drawing. Clico in place.

Re-check 1 and 2.

Replace clicos with rivets working from end to end and diagonally in a

“spread” pattern.

Thoroughly examine the finished work.

Notes:

Page 44 - © SilverWing Aviation, 2005

Page 45 - © SilverWing Aviation, 2005

Page 46 - © SilverWing Aviation, 2005

PAGE SIXTEEN

DRAWING NUMBERS 1.230/240

Sealing the Corrugation Gaps

NON-SILICONE SEALANT REQUIRED

Recommended one person job. This work can be left until a later time but is shown now for continuity with the previous drawings.

Using a small spatula or other suitable tool neatly fill the triangular endgaps in the floor and ceiling panels with a proprietary non-silicone sealant.

Note. Many paint types will either not cover, or react with, silicone sealants. Consult your paint supplier for more specific guidance.

Thoroughly examine and make good.

Notes:

Page 47 - © SilverWing Aviation, 2005

Page 48 - © SilverWing Aviation, 2005

Page 49 - © SilverWing Aviation, 2005

PAGE SEVENTEEN

DRAWING NUMBER 1.250

Installing the Wing Fillets

SEE DRAWING FOR PARTS REQUIRED

Recommended two persons job with the fuselage monocoque supported as required

Locate and inspect the wing fillets as illustrated on the drawing.

Clico in place exactly as shown on the drawing.

Note. It’s advisable to check that the fillets are symetrical prior to riveting. That is equal distance from the fuselage centreline. Any out-of-alignment will create a slightly asymetric gap between the left and right fillet/wing junctions when the aircraft is assembled.

Re-check 1 and 2.

Replace clicos with rivets where shown.

Leave the circumscribed holes just clico’d for now.

Thoroughly examine the finished work.

Notes:

Page 50 - © SilverWing Aviation, 2005

Page 51 - © SilverWing Aviation, 2005

PAGE EIGHTEEN

DRAWING NUMBERS 1.270/300

Installing the Main LG Legs, Wheels and Disc-Brakes

SEE DRAWING FOR PARTS REQUIRED

Recommended two persons job with fuselage monocoque supported as required. If you are limited for workshop width this job can be left until later.

Locate and inspect main LG legs, Matco wheels and brake components as illustrated on the drawing. Select correct size bolts with castle nuts, washers and cotter pins.

Offer up the left LG leg first and fit loosely exactly as shown on drawing number 1.270.

Re-check 1 and 2.

Tighten castle nut but don’t over-tighten and insert cotter pin.

Offer up the Matco brake components, plate, block and axle. Assemble them exactly as shown on drawing number 1.300. Tighten nuts securely.

Lightly grease the axle before fitting the wheel.

Thoroughly examine the finished work.

Repeat on right hand side.

Notes:

Page 52 - © SilverWing Aviation, 2005

Page 53 - © SilverWing Aviation, 2005

Page 54 - © SilverWing Aviation, 2005

PAGE NINETEEN

DRAWING NUMBERS 1.280/90

Installing the LG Nose Strut and Wheel

SEE DRAWING FOR PARTS REQUIRED

Recommended job for two people with the fuselage monocoque positioned in the cradle.

Note. The nose-leg assembly may be manufactured “tight” and require reaming before it will rotate freely. This is not a big job but needs professional equipment and skill, if you are not able to get the work done locally contact Foxbat Aircraft. Remember that the nosewheel assembly is linked into the rudder control circuit so it must rotate freely.

Locate and inspect the LG nose strut as illustrated on the drawing.

Select the correct size bolts with stiff-nuts, castle nut, washers and safety pin.

Offer up the parts and assemble exactly as shown on the drawing.

Re-check 1 and 2, in particular check for free rotation.

Tighten assembly until firm and snug. Don’t over-tighten.

Thoroughly examine the finished work and check again for free rotation.

Notes:

Page 55 - © SilverWing Aviation, 2005

Page 56 - © SilverWing Aviation, 2005

Page 57 - © SilverWing Aviation, 2005

PAGE TWENTY

DRAWING NUMBER 1.310

Installing the Centre Bulkhead Crossbeam

SEE DRAWING FOR PARTS REQUIRED

Recommended two persons job with fuselage monocoque supported as required

Locate and inspect the centre bulkhead crossbeam as illustrated on the drawing. Select the correct size bolts with stiff-nuts and washers.

Note.

The crossbeam is not fully shown on the drawing but is the transverse component that also forms the seat-back and luggage container mount.

Offer up the part and clico in place exactly as shown in the drawing with the nuts finger-tight.

Re-check 1 and 2.

Replace clicos with rivets alternately and then tighten the nuts. Don’t over-tighten.

Thoroughly examine the finished work.

Notes:

Page 58 - © SilverWing Aviation, 2005

Page 59 - © SilverWing Aviation, 2005

PAGE TWENTY-ONE

DRAWING 13.040 (1 of 9)

Installing the Central Pitch/Roll Mixer Mechanisms

SEE DRAWINGS FOR PARTS REQUIRED

Recommended job for two persons with fuselage supported as required

Locate and inspect all the parts as illustrated on the nine drawings.

Separate the ones that will be riveted to the fuselage.

Study the next nine drawings until you have a good grasp of how the mixer system works. The heart of it is the central control shaft illustrated in the drawing 13.040. Note how it locates in the bearings pressed into the brackets (2) forward and (3) aft.

Note. Do not commence any assembly or riveting until you are sure you know how the system works!

The brackets and lever forward of (2), are for the manual trim system.

Option : some Foxbats have a MAC electric trim activator mounted in the aft fuselage and operated by a rocker switch on the control stick. See separate fitting instructions with the electric trim, if you ordered this option.

Re-check 1, 2 and 3.

Notes :

Page 60 - © SilverWing Aviation, 2005

Page 61 - © SilverWing Aviation, 2005

PAGE TWENTY-TWO

DRAWING NUMBER 13.030 (2 OF 9)

Installing the Central Pitch/Roll Mixer Mechanisms

SEE DRAWING FOR PARTS REQUIRED

Recommended two persons job with fuselage monocoque supported as required

Locate and inspect all parts aft of (3) as illustrated on the drawing. If you are using the electric trim option ignore the manual trim parts that are illustrated forward of (4). For the electric option there is a righthand bracket (5) that is not illustrated on the drawing. The right-hand bracket (5) gives the strength previously provided by trim bracket (4) but is fitted aft of the hinge bracket (3).

Offer up the parts and clico in place exactly as shown on the drawing.

Re-check 1 and 2.

Replace clicos with rivets.

Note. You can rivet the hinge bearing plate

(6) and plate (7) to the bracket (3) before offering up to the fuselage.

Thoroughly examine the finished work.

Notes:

Page 62 - © SilverWing Aviation, 2005

Page 63 - © SilverWing Aviation, 2005

PAGE TWENTY-THREE

DRAWING NUMBER 13.010 (3 OF 9)

Installing the Central Pitch/Roll Mechanisms

SEE DRAWING FOR PARTS REQUIRED

Recommended job for two persons with fuselage monocoque supported as required

Locate and inspect the bracket as illustrated on the drawing.

Offer up the part and clico in place exactly as shown on the drawing.

Re-check 1 and 2.

Replace clicos with rivets.

Thoroughly examine the finished work.

Notes:

Page 64 - © SilverWing Aviation, 2005

Page 65 - © SilverWing Aviation, 2005

PAGE TWENTY-FOUR

DRAWING NUMBER 12.020 (4 OF 9)

Installing the Central Pitch/Roll Mixer Mechanisms

SEE DRAWING FOR PARTS REQUIRED

Recommended two persons job with fuselage monocoque supported as required

Locate and inspect the elevator bell crank bracket as illustrated on the drawing. Select the correct bolt, stiff-nut and washers.

Clico in place exactly as shown on the drawing with the nut finger-tight.

Re-check 1 and 2.

Replace clicos with rivets and tighten the bolt. Don’t over-tighten.

Thoroughly examine the finished work.

Notes:

Page 66 - © SilverWing Aviation, 2005

Page 67 - © SilverWing Aviation, 2005

PAGE TWENTY-FIVE

DRAWING NUMBER 13.020 (5 OF 9)

Installing the Central Pitch/Roll Mixer Mechanisms

SEE DRAWING FOR PARTS REQUIRED

Recommended job for two people with fuselage monocoque supported as required

Locate and inspect the stops and pads as illustrated on the drawing.

These are the “bump” stops for the aileron bell crank which is fixed to the aft end of the central control shaft.

Offer up the parts and clico in place exactly as shown on the drawing.

Re-check 1 and 2.

Replace clicos with rivets.

Thoroughly examine the finished work.

Notes:

Page 68 - © SilverWing Aviation, 2005

Page 69 - © SilverWing Aviation, 2005

PAGE TWENTY-SIX

DRAWING NUMBERS 13.040 AND 1.260 (6 OF 9)

Installing the Central Pitch/Roll Mixer Mechanisms

SEE DRAWING FOR PARTS REQUIRED

Recommended one person job with fuselage monocoque supported as required

Review drawing 13.040 on page twenty one (21). Locate and inspect the central control shaft as illustrated on that drawing. Select the correct castle nut, washer and cotter pin. Lightly grease the shaft locating pins.

Offer up the central control shaft exactly as shown on drawing 13.040 on page twenty one, recheck assembly, then tighten the castle nut (don’t

over-tighten) and fit cotter pin.

Locate and inspect the control stick (with pre-assembled side plates).

Select the correct bolt with castle-nut, washer and cotter pin. Offer up to the central control shaft exactly as shown on the drawing on the right

(1.260). Re-check the entire assembly. Tighten castle nut and fit cotter pin.

Thoroughly examine the finished work and check for free rotation of the central control shaft.

Notes:

Page 70 - © SilverWing Aviation, 2005

Page 71 - © SilverWing Aviation, 2005

Page 72 - © SilverWing Aviation, 2005

PAGE TWENTY-SEVEN

DRAWING NUMBER 12. 030 (7 OF 9)

Installing the Central Pitch/Roll Mixer Mechanisms

SEE DRAWING FOR PARTS REQUIRED

Recommended one person job with the fuselage monocoque supported as required.

Locate and inspect the elevator bellcrank and sleeve as illustrated on the drawing. Select the correct bolt with stiff-nut and washer. Lightly grease the sleeve inside and out.

Offer up the part and assemble exactly as shown in the drawing with the nut finger-tight.

Re-check 1 and 2.

Tighten the bolt (don’t over-tighten).

Thoroughly examine the finished work and check for free rotation of the bellcrank.

Notes:

Page 73 - © SilverWing Aviation, 2005

Page 74 - © SilverWing Aviation, 2005

PAGE TWENTY-EIGHT

DRAWING NUMBER 12.040 (8 OF 9)

Installing the Central Pitch/Roll Mixer Mechanisms

SEE DRAWING FOR PARTS REQUIRED

Recommended job for one person with the fuselage monocoque supported as required

Locate and inspect the rod (3) as illustrated on the drawing. Don’t include the rod (4) at this stage, it will be installed later. Select the

correct size bolts with castle nuts, washers and cotter pins.

Offer up using the rod to connect the control stick to the elevator bellcrank. Assemble finger-tight.

Re-check 1 and 2.

Tighten castle-nuts (don’t over-tighten) and insert cotter pins.

Thoroughly examine the finished work.

Notes:

Page 75 - © SilverWing Aviation, 2005

Page 76 - © SilverWing Aviation, 2005

PAGE TWENTY-NINE

DRAWING NUMBER 1.330 (9 OF 9)

Installing the Central Pitch/Roll Mixer Mechanisms

SEE DRAWING FOR PARTS REQUIRED

Recommended job for one person.

Note. This job can be left until later, the cover is supplied in bare aluminium but many people prefer to paint or upholster it before final fitting.

Locate and inspect the cover as illustrated on the drawing. Select the correct size screws.

Offer up the part and start screws in the captive stiff-nuts.

Re-check 1 and 2.

Tighten screws.

Thoroughly examine the finished work.

Notes:

Page 77 - © SilverWing Aviation, 2005

Page 78 - © SilverWing Aviation, 2005

PAGE THIRTY

DRAWING NUMBER 15.010

Installing the Trim Cable Guide

SEE DRAWING FOR PARTS REQUIRED

Recommended one person job with the fuselage monocoque supported as required

Locate and inspect the trim cable guides as illustrated on the drawing.

Offer up the parts and hold loosely in place with pop rivets exactly as shown on the drawing.

Re-check 1 and 2.

Compress the pop rivets.

Thoroughly examine the finished work.

Notes:

Page 79 - © SilverWing Aviation, 2005

Page 80 - © SilverWing Aviation, 2005

PAGE THIRTY-ONE

DRAWING NUMBER 15.020

Installing the Manual trim lever

SEE DRAWING FOR PARTS REQUIRED

Recommended job for two persons with fuselage monocoque supported as required

Page 81 - © SilverWing Aviation, 2005

Page 82 - © SilverWing Aviation, 2005

PAGE THIRTY-TWO

DRAWING NUMBER 11.020

Installing the Rudder-Cable Forward Guides and Pads

SEE DRAWING FOR PARTS REQUIRED

Recommended job for two persons with fuselage monocoque supported as required

Locate and inspect the pad and cable guide as illustrated on the drawing.

Note. Item (3) is the cable guide.

Offer up the parts exactly as shown on the drawing and clico in place.

Note. Providing the rudder cables are still “open” at their forward ends the cable guides can be threaded through later. In this instance “open” means just a cut cable-end with nothing swaged on to it. Normally the ferrules securing the forward thimbles and turnbuckles are swaged “in situ” later but at the time of writing that method is under review.

Examine the forward ends of the supplied rudder cables to confirm.

Re-check 1 and 2.

Replace clicos with rivets.

Repeat on the left-hand side.

Thoroughly examine the finished work.

Notes:

Page 83 - © SilverWing Aviation, 2005

Page 84 - © SilverWing Aviation, 2005

PAGE THIRTY-THREE

DRAWING NUMBER 11.030

Installing the Forward Rudder-Cable Pulleys

SEE DRAWING FOR PARTS REQUIRED

Recommended job for one person with the fuselage monocoque supported as required

Locate and inspect the rudder-cable, the outer and inner brackets, the pulley and the guard as illustrated on the drawing. Select the correct size bolts, stiff-nuts, castle nut, washers and cotter pin.

Offer up and loosely assemble exactly as in the drawing.

Re-check 1 and 2.

Tighten the nuts until the assembly is snug and firm (don’t over-

tighten). Ensure that the pulley can rotate freely.

Repeat on the right-hand side.

Thoroughly examine the finished work.

Notes:

Page 85 - © SilverWing Aviation, 2005

Page 86 - © SilverWing Aviation, 2005

PAGE THIRTY-FOUR

DRAWING NUMBER 11.010

Installing the Aft Rudder-Cable Pulleys

SEE DRAWING FOR PARTS REQUIRED

Recommended job for one person with the fuselage supported as required

Locate and inspect the rudder-cables, the shackles and the pulleys as illustrated on the drawing. Select the correct size bolts, stiff-nuts, castle-nuts, washers and cotter pins.

Offer up the parts and assemble loosely exactly as shown on the drawing.

Re-check 1 and 2.

Tighten the nuts until the assembly is snug and firm (don’t over-

tighten). Ensure that the pulleys rotate freely.

Thoroughly examine the finished work.

Notes:

Page 87 - © SilverWing Aviation, 2005

Page 88 - © SilverWing Aviation, 2005

PAGE THIRTY-FIVE

DRAWING NUMBER 12.010

Installing the Aft Elevator Bellcrank

SEE DRAWING FOR PARTS REQUIRED

Recommended job for two persons with the fuselage monocoque supported as required

Locate and inspect the elevator bellcrank. This should be pre-assembled to the pivot-brackets with bolts, stiff-nuts and washers as illustrated on the drawing.

Offer up the part and clico in place.

Re-check 1 and 2.

Replace clicos with rivets.

Thoroughly examine the finished work.

Notes:

Page 89 - © SilverWing Aviation, 2005

Page 90 - © SilverWing Aviation, 2005

PAGE THIRTY-SIX

DRAWING NUMBER 12.O50

Installing the Elevator Rods

SEE DRAWING FOR PARTS REQUIRED

Recommended job for one person with fuselage monocoque supported as required

Locate and inspect the elevator rods as illustrated on the drawing.

Select the correct size bolts, castle-nuts, washers and cotter pins.

Note.

The rod (2) on this drawing is the same part as the rod (4) on drawing number 12.040 (see page twenty eight). Refer to that drawing for view of forward rod connection.

Offer up the parts and assemble them loosely exactly as illustrated on the drawings.

Re-check 1 and 2.

Tighten the nuts and install the cotter pins (don’t over-tighten). Ensure free rotation at each rod-to-bellcrank connection and at both bellcrank pivots.

Thoroughly examine the finished work.

Notes:

Page 91 - © SilverWing Aviation, 2005

Page 92 - © SilverWing Aviation, 2005

PAGE THIRTY-SEVEN

DRAWING NUMBER 14.010 (1 of 6)

Installing the Flaperon Mechanism

SEE DRAWINGS FOR PARTS REQUIRED

Recommended job for two persons with fuselage monocoque supported as required

Locate and inspect all the parts as illustrated on the four drawings

14.010/20/30/40 and 13.060/50. Separate the parts that will be riveted to the fuselage.

Study the next six drawings until you have a good grasp of how the flaperon mechanism works. The key to understanding is the rocker arm

(3) (drawing number 14.020) and the way the rocking action links to the flaperon control shafts (1) (drawing number 13.060). The drawings are

“busy” in comparison with previous ones but the mechanism itself is basic and robust.

Note. Do not commence any assembly or riveting until you are sure how the mechanism works.

Select the main brackets, rocker brackets, cable stop and pad as illustrated on the drawing to the right. Select the correct size bolts, stiff-nuts and washers. Offer up the parts and clico in place exactly as shown on the drawing. Insert bolts and finger-tighten the nuts.

Re-check 1, 2 and 3.

Replace clicos alternately with rivets then tighten the nuts.

Thoroughly examine the finished work.

Notes:

Page 93 - © SilverWing Aviation, 2005

Page 94 - © SilverWing Aviation, 2005

PAGE THIRTY-EIGHT

DRAWING NUMBER 14.020 (2 OF 6)

Installing the Flaperon Mechanism

SEE DRAWING FOR PARTS REQUIRED

Recommended job for two persons with the fuselage monocoque supported as required

Select the rocker, the lever, the bracket, the cogged plate, the bearing and the bracket bearing as illustrated on the drawing. Lightly grease the sleeve-bearing surfaces. Select the correct size bolts with castle-nuts, washers and cotter pins.

Offer up the parts and loosely assemble them exactly as shown in the drawing with the nuts finger-tight.

Re-check 1 and 2.

Tighten the nuts (don’t over-tighten) and insert the cotter pins.

Thoroughly examine the finished work and check for free action of the partly-assembled mechanism.

Notes:

Page 95 - © SilverWing Aviation, 2005

Page 96 - © SilverWing Aviation, 2005

PAGE THIRTY-NINE

DRAWING NUMBER 14.030 (3 of 6)

Installing the Flaperon Mechanism

SEE DRAWING FOR PARTS REQUIRED

Recommended job for one person with the fuselage monocoque supported as required

Select the handle, the spring, the cable and the conduit stop as illustrated on the drawing. Select the correct size bolts with castle-nuts, stiff-nuts, washers and cotter pins. Lightly grease the moving surfaces where appropriate.

Offer up the parts and loosely assemble them exactly as shown in the drawing with the nuts finger-tight.

Re-check 1 and 2.

Tighten the nuts (don’t over-tighten) and install the cotter pins.

Thoroughly examine the finished work and re-check for free action of the assembled mechanism.

Notes:

Page 97 - © SilverWing Aviation, 2005

Page 98 - © SilverWing Aviation, 2005

PAGE FORTY

DRAWING NUMBER 14.040 (4 OF 6)

Installing the Flaperon Mechanism

SEE DRAWING FOR PARTS REQUIRED

Recommended job for two persons. Note. This job can be left until later.

See “Interior Mouldings” section.

Locate and inspect the housing as illustrated on the drawing. Select the correct size screws to match the captive stiff-nuts in the main brackets.

Offer up the part and attach with the screws finger-tight.

Note. You will need to hold the housing laterally to the centre-line for the initial fit over the lever and then manoeuvre it horizontally and backwards through 90 degrees to its final position.

Re-check 1 and 2.

Tighten screws.

Thoroughly examine the finished work.

Notes:

Page 99 - © SilverWing Aviation, 2005

Page 100 - © SilverWing Aviation, 2005

PAGE FORTY-ONE

DRAWING NUMBER 13.050 (5 OF 6)

Installing the Flaperon Mechanism

SEE DRAWING FOR PARTS REQUIRED

Recommended job for one person.

Note. The control shaft is dealt with here for clarity of function. You will not need to install it until you attach the wings. See “Wings and Flaperons” section.

Select the flaperon control shafts and the cardan rings as illustrated on the drawing. Select the correct size bolts with castle-nuts washers and cotter pins.

Fit the cardan ring to the shaft exactly as shown in the drawing. Offer up the shaft to the rocker.

Re-check 1 and 2.

Tighten the castle-nut (don’t over-tighten) and fit the cotter pin.

Repeat on the right-hand side.

Thoroughly examine the finished work.

Notes:

Page 101 - © SilverWing Aviation, 2005

Page 102 - © SilverWing Aviation, 2005

PAGE FORTY-TWO

DRAWING NUMBER 13.060 (6 OF 6)

Installing the Flaperon Mechanism

SEE DRAWING FOR PARTS REQUIRED

Recommended job for two persons

Select the aileron rods as illustrated in the drawing. Select the correct size bolts with castle-nuts, washers and cotter pins. Lightly grease the bolts.

Offer up the parts and loosely assemble them exactly as shown in the drawing.

Re-check 1 and 2.

Tighten the nuts (don’t over-tighten) and fit the cotter pins.

Repeat on the right-hand side.

Thoroughly examine the finished work.

Notes:

Page 103 - © SilverWing Aviation, 2005

Page 104 - © SilverWing Aviation, 2005

PAGE FORTY-THREE

DRAWING NUMBER 2.030

Fitting the Fin Tip

SEE DRAWING FOR PARTS REQUIRED

Recommended one person job

Locate and inspect the fin tip as illustrated on the drawing.

Offer it up to the fin and attach loosely in place with pop rivets but don’t compress the rivets yet. Ensure that the fin tip is correctly aligned with the fin.

Re-check 1 and 2.

Compress the pop rivets.

Thoroughly examine the finished work.

Notes:

Page 105 - © SilverWing Aviation, 2005

Page 106 - © SilverWing Aviation, 2005

PAGE FORTY-FOUR

DRAWING NUMBER [ ]

Fitting the Wing Tips

SEE DRAWING FOR PARTS REQUIRED

Recommended one person job

Locate and inspect the port wing tip as illustrated on the drawing.

Ensure the upward curve of the tip is on the underside of the wing.

Offer it up to the wing and attach loosely in place with pop rivets but don’t compress the rivets yet. Ensure that the wing tip is correctly aligned with the wing.

Re-check 1 and 2.

Compress the pop rivets.

Repeat for starboard wing and tip.

Thoroughly examine the finished work.

Notes:

Page 107 - © SilverWing Aviation, 2005

Page 108 - © SilverWing Aviation, 2005

PAGE FORTY-FIVE

DRAWING NUMBERS 2.010 and 2.020

Fitting the Fin to the Fuselage

SEE DRAWING FOR PARTS REQUIRED

Recommended 3 persons job with fuselage monocoque supported as required.

Carefully study both drawings. Locate and inspect the fin and select the correct size bolts washers and 14 pop rivets as illustrated on the drawings. Brief your two assistants to ensure that they both understand their supporting roles.

With the help of your two assistants offer up the fin to the fuselage exactly as shown on the drawings. Wind in the rear bolts until fingertight in the captive nuts and insert the pop rivets but don’t compress them at this stage.

Re-check 1 and 2. Ensure that the fin is vertical to the fuselage and in alignment with the “spine” of the aft monocoque, and that the forward and aft pop rivet “tabs” are flush with the fuselage skin.

Tighten the bolts until the fin is snug with the rear fuselage and recheck the “tabs” for fit. Starting at the front and working from side to side begin compressing the pop rivets. Ensure that the rivet is fully inserted and that the gun is properly aligned before squeezing the trigger.

Thoroughly examine the finished work.

Notes:

Page 109 - © SilverWing Aviation, 2005

Page 110 - © SilverWing Aviation, 2005

Page 111 - © SilverWing Aviation, 2005

PAGE FORTY-SIX

DRAWING NUMBER 16.010

Installing the Throttle Torque-tube/levers

SEE DRAWING FOR PARTS REQUIRED

Recommended two person job.

Note.This is the standard twin throttle-lever installation as supplied with your kit. If you wish to install an alternative system please consult with

Foxbat Aircraft.

Carefully study the drawing. Locate and inspect the left and right brackets, the left and right throttle levers, the connecting tube, the friction clamps and the spacers all as illustrated on the drawing. Select the correct size bolts, screws, stiff-nuts and castle-nuts with their respective washers and cotter pins. Lightly grease the spigot ends of the throttle levers (4).

Offer up the parts and loosely assemble them in situ exactly as shown on the drawing.

Re-check 1 and 2.

Tighten the nuts as normal but don’t over-tighten and insert the cotter pins where shown.

Note. The friction clamp (6) will be adjusted later to resist throttle-spring pressure.

Thoroughly examine the finished work.

Notes:

Page 112 - © SilverWing Aviation, 2005

Page 113 - © SilverWing Aviation, 2005

PAGE FORTY-SEVEN

DRAWING NUMBER 16.020

Fitting the Throttle Handles and Cable-Stops

SEE DRAWING FOR PARTS REQUIRED

Recommended one person job

Study the drawing carefully. The system looks unworkable at first until you realise that it’s intended for the Rotax 912S engine’s “default to open” option.

(The throttles are spring-loaded to the fully open position and the lever’s friction nut holds them closed. In the event of throttle cable failure you will still have engine power).

Locate and inspect the conduit stops, the shackles, the handles and the cables/conduits (Bowden cables) as illustrated on the drawing. Select the correct size bolts with stiff-nuts, castle nuts, washers and cotter pins.

Clico the conduit stop (3) in place and fit the throttle handle (5) and shackle (4) exactly as shown on the drawing.

Re-check 1 and 2.

Replace the clicos with rivets, tighten the nuts and insert the cotter pin.

Repeat 2 to 4 on right-hand side. Install the cables as shown on the drawing.

Thoroughly examine the finished work.

Note. The throttle cables should be coiled on the fuselage floor until engine installation.

Notes:

Page 114 - © SilverWing Aviation, 2005

Page 115 - © SilverWing Aviation, 2005

PAGE FORTY-EIGHT

DRAWING NUMBER 10.010

Installing the Engine Mounting

SEE DRAWING FOR PARTS REQUIRED

Recommended two person job

Locate and inspect the engine mounts part 1 and 2. Pay particular attention to the butt-welding. Your Inspector will also want to inspect the engine mounts prior to installation. Select the correct size bolts with stiff-nuts, castle-nuts washers and spring pins.

Offer up the engine mount part 1 to the fuselage and loosely assemble exactly as shown on the drawing. Re-check your work and then tighten the nuts (don’t over-tighten). Offer up the engine mounts part 2 and loosely assemble exactly as shown on the drawing.

Re-check 1 and 2.

Tighten the castle nuts as normal and insert the spring pins.

Thoroughly examine the finished work.

Notes:

Page 116 - © SilverWing Aviation, 2005

Page 117 - © SilverWing Aviation, 2005

PAGE FORTY-NINE

DRAWING NUMBER 10.020

Installing the Engine Unit

SEE DRAWING FOR PARTS REQUIRED

Recommended 3 persons job. You could leave this job until later but if so you will need to secure some ballast to the engine mount to keep the nosewheel on the ground. Please use professionally built engine lifting equipment (a small gantry with castors) that is placarded safe for the engine weight (58kg). Many DIY car enthusiasts have such lifts in their workshops or you can rent one from your local tool-hire shop. Note. Do not trust unsupported garage roof beams to take the weight of an engine!

Unpack the Rotax 912/912S and read the manufacturer’s instructions regarding handling and lifting. Locate and inspect the brackets, the rod, the lug and the bearings as illustrated on the drawing. Select the correct size bolts with nuts, washers, cotter pins and spring pins. Brief your two assistants on their parts in the job so that each person is clear about their area of responsibility. Ensure that you are familiar with the operation and control of the lifting tackle. Practice before you start the job.

Lift the engine and offer it up very carefully to the engine mountings.

Bolt it in place exactly as shown on the drawing but with the nuts fingertight and the weight still supported by the lifting equipment.

Re-check 1 and 2.

Tighten the nuts as normal and insert the cotter pins and the spring pins. Give the mountings one more check then gradually transfer the weight to the fuselage.

Remove the lifting tackle and thoroughly examine the finished work.

Note that the bolts 8 and 9 are secured with locking wire.

Page 118 - © SilverWing Aviation, 2005

Page 119 - © SilverWing Aviation, 2005

PAGE FIFTY

DRAWING Nos:

7.500/8.510/8.500/9.500/3.500/3.510/15.030

Pre-assembling the Stabiliser and Aft Flying Surfaces

SEE DRAWINGS FOR PARTS REQUIRED

Recommended two or three person job. Note. The next seven drawings illustrate the various mounting points of the stabiliser, elevator, rudder and trim tab. Prior to covering and painting these parts must be preassembled and checked for alignment.

Carefully study the drawings in the following sequence before offering up any parts: 3.500/3.510/8.500/8.510/7.500/9.500/15.030. Select and inspect the components and all necessary fittings as illustrated on the drawings. Lightly grease all bearing surfaces.

Offer up the parts exactly as shown on the drawings and assemble finger-tight. Connect the operating rod and cables.

Note. The rudder cables will be fitted at the forward connections whilst the rudder is pre-assembled but see separate instructions for that job. You can install the electric trim motor and cable at a later stage.

Re-check 1 and 2.

Tighten the nuts until the assembly is snug but don’t over-tighten.

Thoroughly examine the assembly checking for good alignment and free movement of the flying surfaces. Consult your PFA Inspector then dismantle all except rudder.

Notes:

Page 120 - © SilverWing Aviation, 2005

Page 121 - © SilverWing Aviation, 2005

Page 122 - © SilverWing Aviation, 2005

Page 123 - © SilverWing Aviation, 2005

Page 124 - © SilverWing Aviation, 2005

Page 125 - © SilverWing Aviation, 2005

Page 126 - © SilverWing Aviation, 2005

Page 127 - © SilverWing Aviation, 2005

PAGE FIFTY-ONE

DRAWING NUMBERS 11.050 AND 11.040

Installing the Rudder Pedals and Cables

SEE DRAWINGS FOR PARTS REQUIRED

Recommended job for two persons.

Note. Instruction number 8 on drawing 11.050 refers to the standard method of wire-locking turnbuckles.

Carefully study drawing number 11.050 before proceeding. Make sure you have fully grasped how the system operates, including the nosewheel linkages. Select and inspect the components as listed in the drawings.

Follow the installation sequence on drawing 11.050 to step 5 but don’t connect the cables until you have carefully studied and fully grasped the installation method described on drawing 11.040.

Re-check 1 and 2.

Proceed with the cable connection sequence.

Thoroughly examine the finished assembly and check operation with the nosewheel clear of the ground.

Notes:

PAGE FIFTY-TWO

DRAWING NUMBERS 16.030/40/50

Installing the Throttle and Choke Bowden Cables

SEE DRAWINGS FOR PARTS REQUIRED

Recommended job for one person.

Carefully study the drawings then select and inspect the components, fittings and fasteners as listed in the drawings. Lubricate the inner cables at this stage.

Starting with the choke cable you can now offer up and install the components exactly as illustrated on the drawings.

Recheck 1 and 2.

Thoroughly examine the finished work and check for smooth cable action. Choke and throttle arms should close fully at the carburettors.

Adjust the lever frictions so that they stay set in position but don’t over-

tighten. Final adjustment and balancing will be carried out later in accordance with the Rotax engine manual.

Notes:

PAGE FIFTY-THREE

DRAWING NUMBERS 19.010/20

Installing the Brake Lines and Fittings

SEE DRAWINGS FOR PARTS REQUIRED

Recommended one person job.

Note. Some people prefer to use plastic or braided metal brake lines due to the flexing of the LG. Aeroprakt report no problems using copper tube providing it is installed as shown.

Carefully study the drawings then select and inspect the copper tube and compression fittings. Make sure the tubes are clear and not crushed at any point. Route the tubes exactly as shown on the drawings. Observe the coil near the master cylinder exit and the slightly raised “slack” at the fuselage exit, these are to accommodate movement. Also note the nylon protection tubes at the cable-tie attachments to the LG legs.

Loosely fit the compression fittings and cable ties as shown on the drawings.

Note. Don’t fit more cable-ties than shown on the drawing!

Recheck 1 and 2.

Tighten the cable-ties, recheck the routing and then tighten the compression joints but don’t over-tighten.

Thoroughly inspect the finished work. The brake fluid can be added and bled later according to the instructions provided elsewhere.

Note. The

Matco brake system is fitted with seals designed for use with “Aviation

Hydraulic Fluid”. DO NOT USE AUTOMOTIVE BRAKE FLUID!

Notes:

PAGE FIFTY-FOUR

DRAWING NUMBERS 17.100/010/025/020/030

Installing the Fuel Tanks, Lines, Taps and Fittings

SEE DRAWINGS FOR PARTS REQUIRED

Recommended two persons job.

After carefully studying the five drawings select and inspect the wingtanks, taps and fittings as illustrated. You will need about six metres of fuel line. Cut the fuel line to the lengths specified allowing about 10% extra on each length for fitting.

Install the wing-tanks first and then loosely connect the lines, hose-clips and fittings following the exact sequence illustrated in the drawings.

Temporarily fix the fuel lines in position with duct-tape and trim the lengths as required but when inserting the spigots inside the lines be careful not to shave off a sliver of material that might eventually find its way to the carburettors.

Note 1. Drawing 17.100 shows an under-wing fuel vent line but there is also a “vented-cap” option not illustrated here. Note 2. There is no water trap (gascolator) illustrated in the drawing but a small one should be fitted in the lowest part of the fuel line after the “T” fitting (9) to allow external access for contamination checks. This will require a small hole to be cut in the floor panel.

Recheck 1 and 2.

Tighten the hose clips and secure the lines with cable-ties as shown.

Thoroughly inspect the finished work.

Notes:

PAGE FIFTY-FIVE

DRAWING NUMBERS 18.030/060/100/040/050/020

Electrical Installations

SEE DRAWINGS AND SEPARATE DIAGRAMS FOR PARTS REQUIRED

Recommended one person job. Special skills required.

Note 1. These drawings are to be used only as a basic guide in conjunction with the Installation Manual supplied by Rotax and the wiring diagrams supplied by various other component manufacturers. For example you may have a preference for digital rather than the traditional analog engine instruments, or may opt for the advantages of a modern fully digital “glass cockpit” such as the Brauniger Alpha. Instructions for installing the optional

MAC electric pitch-trim option are also supplied separately. If in doubt contact Foxbat Aircraft or an aircraft or auto electrician for specific advice.

Note 2. Incorrect wiring can damage electrical components beyond repair or can lay the foundations for serious problems in the future! So, unless you are certain of your skills, consult a professional!

Notes:

PAGE FIFTY-SIX

DRAWING NUMBERS 1.360/70/80/20/40/50

Installing the Interior Mouldings, Seats and Luggage Bag

SEE DRAWINGS FOR PARTS REQUIRED

Recommended job for one or two persons. The mouldings should be prefitted to check alignment prior to painting or fabric covering.

Select and inspect the interior mouldings, the luggage bag and fittings, the seat belts, and the seats.

Offer up and fix the instrument binnacle and console mouldings according to the drawing sequence. Installation of the flaperon lever cowl is described on page forty (40). The instrument panel itself may be offered up at this stage for an alignment check but final fitting will take place after the instrument type and layout has been decided and holes cut to suit.

Offer up and fit the luggage bag followed by the seat belts and seats exactly as shown in the drawings.

Thoroughly inspect the finished work.

Notes:

PAGE FIFTY-SEVEN

DRAWING NUMBERS 6.500/10/4.500/10/20

Fitting the Flaperons to Wings and Wings to Fuselage

SEE DRAWINGS FOR PARTS REQUIRED

Recommended job for three persons. Note. An initial check fitting should take place prior to covering and painting, and prior to fitting the doors or windscreen.

Carefully study the drawings. Select and inspect the components as illustrated on the drawings. Position the right wing on a suitably padded flat surface. Connect the flaperon to the wing exactly as shown on drawing number 6.500 and check for free movement. Carefully move the wing into position at approximately 90 degrees to the fuselage and rest the wing tip on a padded trestle.

Connect the wing root to the fuselage exactly as shown in drawing number 4.500. It’s best to have two assistants at this stage. Don’t use force. It will be necessary for an assistant to carefully lift the wing tip and adjust the wing’s position whilst following your instructions. The safety pins can be inserted later. Connect the lower end of the wing strut to the fuselage. Raise the wing tip as required and connect the upper end of the strut to the wing as shown in drawing 4.510. Providing the engine (or suitable substitute ballast is installed) the fuselage will now support the wing without tipping sideways. Connect the cardan ring to the flaperon exactly as shown in drawing 4.520.

Repeat the process on the left-hand side then thoroughly inspect the finished work. Make sure the gaps are equal each side between the wing root mouldings and leading edges. Check the flaperon function using the control stick and flap lever, then carefully remove the wings by the reverse sequence to that described above.

Notes:

PAGE FIFTY-EIGHT

DRAWING NUMBER 1.400

Fitting the Aft Glazing Panels

SEE DRAWING FOR PARTS REQUIRED

Recommended job for two persons. Note. You may wish to paint the fuselage before installing the glazing. Don’t remove the protective film at this stage. Apart from a slight peel-back at the edges it can stay on until after the fuselage has been painted and the glazing has been fitted.

Select the pre-cut Lexan panels as illustrated on the drawing and inspect the edges. Remove any burring with course sandpaper wrapped around a straight-edged block. Peel back the edges of the protective film about

50mm inside and out.

Offer up the top panel first by butting the front edge against the corrugated Dural roof panel and duct-taping it in place at the sides and rear. Make sure the panel is accurately positioned. The fuselage is predrilled so using those holes as a guide carefully drill through the Lexan at strategic positions and fix the panel in place with clicos. Remove the duct-tape. Working from the front and from side to side drill out the remaining holes using clicos as required. Replace the clicos with pop rivets working very carefully and in a sequence so as to avoid “piecrusting” or “mattressing” of the edges.

Repeat this method for fixing the side panels. Note. For access to the aft interior it’s recommended that you cut the right-hand panel into three triangles and fix the central (inverted) triangle with button-head

M4 bolts and stiff-nuts instead of pop rivets.

To ensure a neat join attach the panel temporarily with clicos and using a long straight-edge carefully mark it with a sharp chinagraph pencil. Cut the panel carefully with a pair of shears or get it professionally cut.

Notes:

PAGE FIFTY-NINE

DRAWING NUMBER 1.390

Fitting the Windscreen

Recommended job for three persons; one at each side and one to position the lower edge. Note. This is a tricky process to complete accurately so each person should be familiar with the method and their own part in it.

You will need something secure to stand on at each side of the fuselage.

One person to be Leader. Don’t rush it!

Locate the pre-cut Lexan windscreen and de-burr the edges using the same method as for the aft glazing. Peel back the protective film about 50mm inside and out. Using a straightedge very accurately mark a chinagraph line vertically down the exact centre of the windscreen on the outside. Locate and inspect the pre-drilled side angled Dural strips and the curved pre-drilled Dural trimstrip (not illustrated) for the lower side-to-side attachment. Offer up the windscreen by butting the top edge into its slot snug against the corrugated roof panel and underneath the wing fillets. The upper transverse support lip is also pre-drilled so, first making sure the screen is exactly central, one of the side assistants must drill and clico the top edge. Next, with the lower assistant supporting the windscreen and keeping it exactly central the side assistants should press the Lexan into a curve snugly following the inside contour of the wing fillets, then drill and clico the Lexan to the curve.

Warning. Don’t lean on the wing fillets at this point or they will be “set” inwards possibly resulting in an unequal and unsightly gap at the wing leading edge/fillet junction.

Now go to the lower windscreen centre and, working outwards equally towards either side, clico and drill to form a Lexan “sandwich” between the Dural trimstrips and the fuselage.

If during this process the windscreen “overlaps” its lip in the bulkhead then

very

carefully

“un-clico” and shave it to fit with a Multi-file. Now take the Dural strips and fit them tight against the fuselage side tubes thereby sandwiching the Lexan again. Using the Multi-file if necessary make sure the Dural is snug against the tube’s side and rear 90 degree points and are also flush with the sides of the fuselage, then drill and clico in place.

Thoroughly examine the work so far for a good fit. “Straight-edge” the wing fillets or offer up the wings if you feel that the fillets may have taken a “set”.

Finally, replace the clicos with pop rivets by working carefully outwards or in an appropriate sequence to avoid “pie-crusting” the edges of the Lexan.

PAGE SIXTY

DRAWING NUMBERS 1.500/10/600/10/520/30

Fitting the Doors

SEE DRAWINGS FOR PARTS REQUIRED

Recommended job for two persons. Note. This job can be left until after the fuselage is painted and the instruments, etc are installed. Don’t remove the protective film until all interior work is completed and the doors are fitted. These doors have been blow-moulded so if the film peels of its own accord stick it back with masking tape. Lexan is vulnerable in a workshop!

Study the six drawings. Locate and inspect the doorframes, gas struts and fittings as illustrated. Select the required nuts and bolts.

Working first on the left door, offer up the components and assemble the door exactly as shown in the drawings. Leave a small amount of play in the hinges shown in drawing 1.500 to allow final alignment of the “R” pins shown in drawing 1.600. Loosely attach the lower end of the gas strut (3) shown in drawing 1.610 and allow it to hang there for now.

Slightly loosen the fuselage-side hinges.

Recheck 1 and 2.

Lightly grease two of the “R” pins and with the help of an assistant offer the door up to the left-hand fuselage hinges. Insert the “R” pins on the external side exactly as shown in drawing 1.600. Carefully lift the door up and down a few times. Tighten the nuts on the door- and hinges

(don’t over-tighten) and then recheck for smooth “gull-wing” action.

Connect the gas strut as shown in drawing 1.610 and tighten the nuts.

Fit the air vent and draught strip. Thoroughly examine the finished work and then repeat on the right-hand side.

Notes:

PAGE SIXTY-ONE

DRAWING NUMBERS 4.400abc/6.400/8.400/3.400

Guidance for Fabric Covering Lay-Out

Recommended job for two or three persons (to complete the covering process).

Description.

We recommend you use the Ceconite system for covering your Foxbat.

Other systems may be suitable if you have a preference. However, in our experience the Ceconite team provide a very high quality product and are extremely helpful. They are also familiar with the Foxbat’s covering requirements and provide a kit of materials (with Foxbat specific instructions) that is likely to incur the minimum of waste.

There is nothing particularly unusual about covering a Foxbat, it’s basically a standard “fabric over aluminium ribs” technique, and almost everything relevant to covering a Foxbat can be found in Ceconite’s excellent

Instruction Manual. No respiratory apparatus is required when applying the adhesive although skin contact should be avoided. Full instructions for use are provided with our covering kit.

Fabric Covering Process

As a general guide, here are some basic instructions for covering the

Foxbat – however, refer to the Ceconite Manual for full details.

Scour and degrease aluminium-cement-fabric contact points. Use scratch pads and fresh cloths or paper wipes from paint shop to avoid contamination with silicone.

Brush neat cement onto contact points (two coats).

Lay pre-cut Ceconite fabric on job so that it lies naturally without wrinkling or excessive sagging. There is no need to stretch the fabric tight at this stage. Ample fabric is supplied with your kit but take note of the cut pattern illustrated in the build manual.

Brush a 9:1 MEK/cement mixture through fabric at contact points around the perimeter of job (but not the inner ribs at this time). This MEK mix will soften the previously applied cement (see #2 above). Use a light rubbing action with a finger to help draw the cement up through the fabric weave. Allow the cement to dry.

Carry out first-stage fabric shrink with a large heat iron set to medium.

NEVER use a heat blowgun!

Brush the 9:1 MEK/cement mixture through fabric at inner contact points as in #4 above and allow the cement to dry.

Tidy up job with small heat iron set to medium, the iron can be used to soften and smooth set cement. Use 600-grade wet-and-dry paper to finish fabric overlaps and a very sharp blade to neatly trim the edges of the job.

Carry out final stage fabric shrink (and tidy up) with your heat irons on the higher setting.

Brush on one weave-sealing coat using a 9:1 non-tautening nitrate dope/cement mix (NOT the previous 9:1 MEK/cement mix). Add dope thinners as required for easy smooth brushing (less in warm conditions).

10.

Tip: - Try to avoid excessive "drip-through" of liquid, it can sometimes remain discernible in the paint texture of the finished aircraft when viewed from certain angles. You can suck still-liquid drips back through the fabric with a vac cleaner (place a patch of scrap fabric over the vac nozzle before applying to the job).

11.

Brush on four coats of dope thinned as required for quick brushing (ratio will depend on ambient temperature). Rub with 600-grade paper between each coat.

12.

Position pinked-edge tape strips as required and secure the strips using the 9:1 weave-sealing mixture. Allow to dry for 24 hours then finish with

600-grade paper to remove any ‘nibs’ of dope or spikey fabric threads.

The following six drawings show the general fabric lay-out of an A22. The three drawings 4.400 (a, b and c) show the wings, 6.400 the flaperons,

8.400 the elevator, and 3.400 the rudder. There’s no fabric on the fuselage.

Aeroprakt A22 ‘Foxbat' Final Checklist

Before flight, all items on this list must be checked and signed off.

1.1.

Do not fly the aircraft until every item on this list has a tick next to it.

1.2.

Keep this original Checklist for inspection.

Confirm that all items detailed in the Build Manual have been completed.

2.1.

Confirm that the aircraft incorporates no unauthorised modifications.

2.2.

Registration letters correct, right size and affixed to aircraft.

2.3.

Registration document checked.

2.4.

Fireproof/stainless steel identity plate checked.

2.5.

Cockpit placards checked.

2.6.

Confirm weight and balance is within the limits specified in the

Pilot Manual.

Air frame

3.1.

Confirm all project assembly work checked.

(See relevant Build Manual page and drawing for each assembly).

3.2.

Fuselage monocoque checked.

(Skin, rivets, joints, doublers, etc)

3.3.

Wings checked.

(‘D’ boxes, spars, brackets, ribs, rivets, I/edges, tip-cowls, drains, etc)

3.4.

Tailplane and fin checked.

(Skins, rivets, fin-cap, brackets, fittings, fin/monocoque attachment etc)

3.5.

Flaperons, elevator and rudder checked.

(‘D’ boxes, spars, ribs, rivets, brackets, dowels, fixings, t/edges, etc)

3.6.

Wing-struts checked.

(Doublers, rivets, brackets, pitot/static, left/right and top/bottom alignment, etc)

3.7.

Attachment of flaperons to wings and wings to fuselage checked.

(Bolts, nuts and fasteners, root and spar ends, dowels, flaperon cardan rings, etc)

3.8.

Attachment of rudder to fin checked.

(Bolts, nuts and fasteners, dowels, bearings, etc)

3.9.

Attachment of elevator to tailplane checked.

(Bolts, nuts and fasteners, dowels, bearings, etc)

3.10.

Trim tab checked.

(Hinge, torque spring, Bowden cable, attachment to elevator, etc)

3.11.

Flying control mechanisms checked.

(Cables, pulleys, turnbuckles, guides, pushrods, cranks, torque tubes, etc)

3.12.

Flaperon droop mechanism checked.

(Bolts, nuts/washers/fasteners, springs, lock-stops, rocker, connections, etc)

3.13.

Rudder pedals and nose wheel checked.

(Pushrod rose-joint linkages, brackets, spring, leg, steering rotation, axles, tyres, etc)

3.14.

Electric pitch-trim operating system and tab torque-spring.

(Servo-cable security, down tab deflection shows panel LED indicator ‘up’, etc)

Fabric covering and paint:

4.1.

Checked for satisfactory fabric covering and security.

4.2.

Special glue attachment at front top/bottom wing surface checked.

4.3.

All drain holes and paintwork checked.

Main landing gear legs, mainwheels and brakes:

5.1.

Steel LG leg attachments checked.

(Fuselage brackets, axle blocks, calliper mounts, disc/wheel security, axles, tyres, etc)

5.2.

Hydraulic brake system operation and effectiveness checked.

(Fluid level, fittings, lever pressure, brake-line security, symmetric operation, park brake etc)

5.3.

Wheels checked for free rotation.

(Clear of ground, brakes ‘off/on’ technique, nose wheel and ‘tail wheel’ checked, etc)

5.4.

Tyres checked, pressure should be 12-14 psi in 15x6.00 tyres

Doors, harnesses, seats, windows, cockpit sealing:

6.1.

Doors inspected, hinge clips, handles and gas-struts checked.

(Fitting, draught exclusion, operation and security, air-vent scoops, etc)

6.2.

Harnesses inspected, and adjustment and release method checked

(Stitching, mount-point security, operation of clips and buckles, no belt twists, etc)

6.3.

Seats inspected and energy-absorbing under-seat foam checked.

(Stitching, padding, Velcro positioning, mount security, foam sculpting, etc)

6.4.

Windscreen and rear side and top glazing checked.

(Security and neatness of fitting, rivets, rear supports, rear access panelscrews, etc)

6.5.

Cockpit weather sealing inspected and passed.

(Sealant filler in the rib-fluted panel-end gaps in top and bottom monocoque)

Interior cockpit cowlings, instruments, switches, fuses, levers and taps:

7.1.

All interior mouldings secure and correctly mounted.

(Good fit without ‘fretting’ of cables/wires/tubes/mechanisms, all screws tight etc)

7.2.

Instrument panel and instruments secure and correctly positioned.

(Altimeter in reach when ‘strapped in’, all instruments functioning correctly, etc)

7.3.

Adequate VFR/engine instrument array for legal and safe flight.

(Consider relevant advice available as well as legal requirements, etc)

7.4.

Master, mag and ignition ‘on/off’ switches functional and safely positioned.

(Typically a master plus a 5-way key switch, both must be in reach when

‘strapped in’)

7.5.

Circuit breaker fuses fitted and checked as required.

(Consider relevant circuits in the aircraft and other appropriate advice)

7.6.

Throttle levers, choke lever and fuel taps.

(Positions identified, placarded, functionally checked and in reach when

‘strapped in’)

Fuel tanks, clips and fittings, senders, drain tap and gascolator:

8.1.

Check wing-tank fixings, vent tubes clear and hose routings as

Build Manual.

(Tank-holding screws, wiring from senders to gauges, hose security, etc)

8.2.

Throughout the fuel system check hose material and bore, clips and fittings.

(Matched bore/fittings, right material, kink free, clips and fittings secure)

8.3.

Check gascolator valve.

(Operate gascolator spring valve several times)

8.4.

Check connections to carburettors.

(Hose clips, kink-free routing, fuel-flow sender connections if fitted etc)

8.5.

Venting checked at gravity flow rate with filler caps tight.

(Unscrew drain-tap and measure fuel into calibrated Jug for one minute)

8.6.

Vapour return line checked clear

Coolant and oil circulation systems:

9.1.

Hoses and connections secure and installed as per Rotax manual.

(Routing okay, no kinks, doublers/heat shields fitted as required, fittings)

9.2.

Coolant radiator, oil cooler, pressure cap and expansion tank

(Cush-mounts, cap seal, connections, coolant level, etc)

10.

Engine and monitoring instruments:

10.1.

Rotax engine installation Checklist completed.

(This Checklist is supplied with the engine, file it with your Project records)

10.2.

Engine monitoring system checked as appropriate for type.

(Choice of several digital or analogue systems)

11.

Propeller, backplate and spinner:

11.1.

Standard prop is the 3-blade KievProp 283 series (71” diameter).

(For alternative propellers consult SilverWing Aviation)

11.2.

Check security of prop-bolts, lock-wire, back-plate and spinner.

(Check this prior to engine test run, DO NOT run engine without prop)

12.

Control deflections in degrees from the neutral position:

12.1.

Tolerance allowed is plus or minus one degree in all cases.

12.2.

Elevator: up 22, down 22.

12.3.

Trim tab: up 20 (nose down), down 30 (nose up).

12.4.

Rudder: 21 left, 21 right.

12.5.

Ailerons: up 20, down 13.

12.6.

Flaperon droop: First position 10, second position 20.

12.7.

Re-confirm that items 12.2 to 12.6 are satisfactory.

13.

C of G information, all units are metric:

13.1.

Datum point is the front face of the Propeller Flange.

13.2.

C of G range loaded is 1.5 to 1.7 aft of datum.

13.3.

Nose wheel arm 0.48

13.4.

Main wheel arm 1.80

13.5.

Pilot/Passenger 1.6

13.6.

Fuel 1.90

13.7.

Baggage 2.20

13.8.

Maximum empty weight 275 kgs

13.9.

Maximum take off weight 525 kgs

13.10.

Re-confirm that items 13.3 to 13.9 are satisfactory..

14.

Airframe symmetry

14.1.

Wingtips to prop flange are equal to within 5 mm.

14.2.

Wingtips to elevator horn are equal to within 5 mm.

14.3.

Wingtips to fuselage lift-strut mount are equal to within 3 mm.

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Key Features

Riveted Aluminum Construction
Fabric Covered Wings
Rotax 912ULS Engine
STOL Capability
Roomy Cockpit
Large Luggage Space
500 Mile Range
Build-Your-Own Kit
Comprehensive Manual

Frequently asked questions

What is the engine size and type of the Foxbat?

The standard engine is the 100 bhp Rotax 912ULS, with the 80 bhp 912UL available as an option.

How much time does it take to build the Foxbat?

One person can build a finished aircraft from a Foxbat kit in around 500 hours.

How much space do I need to build the Foxbat?

A largish double garage will be a big enough workshop space to complete all the sub-assemblies.

Do I need specialized tools to build the Foxbat?

No, you don't need any specialized tools. A basic set of metric spanners, a hand pop-rivet gun, screwdrivers, pliers, files, and cutters are the main requirements.

What kind of covering material is used on the Foxbat?

A Foxbat-specific kit of “POLYFIBER” materials can be supplied by SilverWing Aviation.

Where can I get replacement parts for the Foxbat?

You can order replacements from SilverWing Aviation or specialist firms such as Aircraft Spruce.