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FLIGHTLINE SERIES BD-5 CONSTRUCTION SEQUENCE

The following is a brief outline of the assembly construction/sequence instructions provided with the FLS-5B kit. These same instructions are also provided with the various A&D services. The original construction drawings are used as a reference and general overview only. If there is a conflict between the construction drawings and FLS instructions, the FLS instructions are to be followed. Items are listed in the build sequence that has proven the most efficient in our shop. First, subassemblies are built, then components, and final stage is fuselage assembly. The outline gives a general overview only and does not go into a lot of construction or procedural detail as provided in the actual FLS Instructions. For builders who have chosen not to have their components jig drilled, this information or FLS kit instructions will not help them to build the various components or subassemblies. However, it will assist them in developing their own construction sequence.

SUBASSEMBLIES

COMPONENTS

FLS-5B FUSELAGE ASSEMBLY

GENERAL NOTES

  1. Do not use instructions in the construction drawings unless specifically told to do so.
  2. Use notes in the construction drawings ONLY if they do not conflict with these instructions.
  3. The following instructions are given in a specific sequence. Any deviation may result in increased building time and possible construction error.
  4. Check bend angles on parts during construction and again just before final assemble. Bend angle call outs in construction drawnings are nominal and angles should be adjusted to ensure proper nesting of parts against each other.
  5. Use a #40 size drill for drilling all pilot holes.
    NOTE: To make it easier to install clecos into sheetmetal, a #39 size drill may be used instead.
  6. Use a .38" to .25" minimum edge distance when locating pilot holes, unless otherwise noted.
    NOTE: Maintaining a .38" edge distance is preferred.
  7. Use a fine point plastic tipped marker only for marking on aluminum.
    NOTE: DO NOT use a scribe or lead pencil.
  8. When cutting aluminum, make sure all sharp edges are removed and cleaned of all burrs and roughness.
  9. When drilling holes, make sure all burrs and roughness are removed from the edge of the holes before dimpling, bolting or riveting in place.
  10. Before Prosealing and riveting, degrease, metal etch and alodine all parts for better bonding of Proseal and corrosion protection.
NOTE: If Proseal is "balling" up during application, it may be necessary to roughen surface with a ScotchBrite pad.

SUBASSEMBLIES

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  1. FU35 Spreader Bar assembly
  2. FU137/138 Wing Fillet and FU139 Filler, FU141/142 Rib assembly.
  3. LG97 M.L.G. Wheel Well Access Plate (2) assembly.
  4. LG34 Nose Gear and Retract Mechanism assembly.
  5. LG72 Nose Gear assembly.
  6. LG73 Nose Gear Door assembly.
    NOTE: Instruction details are for the FLS Nose Door. The aft mounted nose gear door system in the blue lines drawings is considered a potentially unsafe installation.
  7. LG80 M.L.G. Pulley assembly
  8. LG132 M.L.G. Cable Pulley, R.H., assembly
  9. LG133 M.L.G. Cable Pulley, L.H., assembly
  10. CR33/34 Rudder Pedal/Brake assembly
  11. CR31 Rudder Stop assembly
  12. CR35 Rudder Evener System
  13. LG183 Landing Gear Handle assembly
    NOTE: CF36 Flap Handle system is eliminated. This is considered a potentially unsafe mechanism.
  14. CA7 Stick and Stick Box assembly
  15. CA9 Aileron Torque Tube assembly
  16. CA23/24 Aileron Torque Tube Bracket assembly
  17. CA15 Aileron Crossover Torque Tube assembly
  18. CA13 Control Rod assembly (2)
  19. BD-0083 H.S. Pulley Mount assembly
  20. CHS11/12 Aft H.S. Pulley Mount assembly
  21. 7E05 Electric Trim System assembly
    NOTE: Manual trim system is eliminated because of the potential of trim surfaces moving during maneuvers.
  22. CR4 Rudder Pulley Mount assembly
  23. CC16 Forward Pivot Arm assembly (2)
  24. CC25/FU7 Aft Pivot Arm assembly
  25. CC42 Instrument Panel Cove assembly

COMPONENTS

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The following components are assembled and made ready for installation to the fuselage according to the FLS instructions provided in the FLS-5B kit or appropriate A&D service.

  1. VERTICAL STABILIZER
    CR4 Rudder Pulley Mount assembly is installed during V.S. construction.
  2. RUDDER
    Rudder should already be hung on V.S. with rudder tip installed.
    V.S. and Rudder as a unit is now ready for locating and drilling to fuselage at the appropriate stage of construction.
  3. HORIZONTAL STABILIZER CENTER SPAR
    Do not drill locating holes or install the 12 nutplates for attaching H.S.’s.
  4. HORIZONTAL STABILIZER
    Trim tab should have been fitted and installed on H.S.’s.
    Center Spar should have been used to install trim tab, but H.S.’s should not be drilled in place to Center Spar until later.
  5. NOSE GEAR BOX
    If Nose Gear Box sheetmetal structure was not delivered assembled do so at this time.
    Do not rivet FU77 Bulkhead to Nose Gear Box. This is done after Pitot Tube has been drilled into place.
    Do not drill or rivet FU78, 103, 104 Angles to Nose Gear Box. This is done during locating and drilling of N.G. Box to fuselage.
    After fitting of N.G. strut/retract system, rudder/brake pedal assemblies, and landing gear handle assembly, remove so N.G. Box is ready for locating and drilling to fuselage.
    To save construction time, these systems can be fitted and permanently installed after N.G. Box has been drilled to fuselage.
  6. FLAP and AILERON
    F & A should be closed and ends trimmed.
    The F & A and attachment brackets are located on wing rear spar and drilled in position.
  7. WING
    After wing bracket nutplates and fuel system details have been installed wing is closed.
  8. FU99 CENTER SPAR and MAIN LANDING GEAR RETRACT MECHANISM
    If FU99 Center Spar was not delivered already installed into fuselage, prepare for installation as follows:
    Locate and drill LG132/133 M.L.G. Cable Pulley assemblies to LG14 Pulley Axles.
    Remove LG132/133 M.L.G. Cable Pulley assemblies, LG147 Trunions with M.L.G. strut assemblies along with LG117/118 Link, Side Braces.

FLS-5B FUSELAGE ASSEMBLY

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Components and subassemblies are located and drilled to fuselage in a modular style. Fuselage skins are removed and reinstalled as needed during location and drilling procedures. After the various parts, subassemblies, and components have been located and drilled to the fuselage, they are countersunk and/or dimpled, holes sized accordingly, and deburred as they are removed. Parts are then degreased, metal etched, and alodined in preparation for permanent installation.

AFT FUSELAGE SECTION

Locate and drill:

Cleco together:

Locate and drill:

Remove upper pulley.

COCKPIT SECTION

Locate and drill:

Cleco together:

Locate and drill:

CC107/108 Heel Skid Plates should already have been located and predrilled to N.G. Box.
Locate and drill FU78, 103, and 104 Angles at this time.
Location as shown in construction drawings is wrong for fuselages with NACA air intake scoops.
Drill to FU1 only at this time.

FUSELAGE CENTER SECTION

Cleco together:

Locate and drill:

EM11 Crossmember, Front and EM12 Stiffeners (8) are located and drilled into place after final positioning of engine.

Cleco together:

Locate and drill:

Cleco together:

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    FU95 Mid, Upper skin, L.H. to aft FU1, FU6, and FU10

    Locate and drill:

    Remove FU96, FU24, FU51/53, and DS10.

    Locate and drill:

    Dismantle aft fuselage section and fuselage center section in preparation for final assembly as noted previously.

    FINAL ASSEMBLY

    1. Cut out FU3/4 Engine Compartment Doors.
    2. Rivet together aft fuselage section and fuselage center section EXCEPT for the following parts:
      EM11 Crossmember, Rear
      EM32 Rear Crossmember Floor
      FU23 Longeron, W.L. 41.50
      FU24 Longeron, W.L. 41.50
      FU39 Aft, Upper Skin, L.H.
      FU41 Aft, Lower Skin, L.H.
      FU51,52,53,and 54 Door Frames
      FU95 Mid, Upper Skin, L.H.
      FU96 Mid. Upper Skin, R.H.
      V.S. Attach Series
      DS18 Drive Housing Tube

      CA9 Aileron Torque Tube assembly is also installed at this time.

    3. Cleco cockpit section to fuselage center section.
    4. Level fuselage and secure to prevent movement for the following:
      Cleco FU39 and FU41 in place for the following procedures.
      Locate and drill in:
      FU99 Center Spar and FU75/76 Spar Attach Plates.
      V.S. and Rudder.
      H.S. Center Spar.
      Pitot Tube to FU77.
      Install FU99 and FU75/76 using Devcon.
      Reassemble M.L.G. retract mechanism to FU99.
      Drill wings to FU99 Center Spar.
      Rivet H.S. Center Spar attachment weldment into place on right hand side.
      Locate and drill Horizontal Stabilizers to H.S. Center Spar.
    5. Dismantle cockpit section and prepare for riveting to fuselage center section.
    6. Rivet together cockpit section to fuselage center section.
    7. Install Pitot Tube and FU77 as an assembly to nose gear box.
    8. Rivet nose gear box to fuselage.
    9. Locate and drill in CR27 Pedal Brackets (2), net trim, and rivet to fuselage.
    10. Rivet all parts to cockpit section as noted in the cockpit section.
    11. Install and secure brake lines with clamps from master cylinders to brakes.
    12. Install and rig N.G. cables.
    13. Install and rig FLS Nose Gear Door to N.G. strut.
    14. Install and rig M.L.G. cables.
    15. Secure wings to the center spar for the following procedures:
    Locate and install rack and pinion gear wing removal system.
    Locate and drill in CA23/24 Aileron Torque Tube Bracket assemblies.
    Install aileron control system, stick box assembly, and rig aileron travel.
    Locate and drill in electric flap control mechanism and flap torque tubes.
    Install flap control system and rig flap travel.
    1. Remove FU39.
    2. install nutplates and rivet V.S. Attach Series in place.
    3. Install H.S. control cables.
    4. Install electric trim tab system.
    5. Rivet FU41 in place.
    6. Rig H.S. control cables and electric trim system.
    7. Rivet FU39 in place.
    8. Install V.S. and rudder.
    9. Install and rig rudder control cables.
    10. Locate and drill in V.S. fairing.
    11. Install DS18, propeller drive shaft, lower drive pulley, and upper drive pulley.
    12. Adjust tension and tracking on propeller drive belt.
    13. Locate and drill in wing fillets.
    14. As one piece, locate and trim canopy to fuselage.
    15. Drill then cleco windshield area to Windshield Attachment Series parts.
    16. Cut canopy at windshield/canopy juncture.
    17. Fit and install canopy frame.
    18. Locate and drill into place canopy pivot arms.
    19. Install windshield and canopy systems.

    The following parts/assemblies are installed after the powerplant, electrical, fuel, and flight instruments have been installed as detailed in the Powerplant Installation Instructions. (Powerplant Installation Instructions are to be used concurrently with the FLS-5B Fuselage Assembly Instructions. Powerplant components are installed during Final Assembly procedures.)

    Congratulations, the airframe and powerplant installation are now complete and ready for airworthiness inspection. Prior to inspection the aircraft must be weighed to determine empty weight and for center of gravity calculations. If aircraft has not been painted, a new empty weight and CG calculations must be performed after painting. Finally, before taxi tests begin, castor and camber adjustments should be made to Main Landing Gear with aircraft at gross weight.

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