Section 11, Rudder Assembly, LSA

Progressive Aerodyne, Inc.

3801 State Rd 19
Tavares, FL 32778

Document Number
Revision Description Remarks Date
01 Initial Creation TBD 10/26/2009
Corrected error on page 4, steps 3.13 & 3.15 specified rivet 264CR33, should
1.01 03/10/2010
have been 264CR35. Removed references to Item #’s (not being used).
02 Update 01242012 01/24/2012
03 Update Page 5, orientation of leading edge 03/02/2012
04 Update Re-arrange order of assembly 03/13/2013
05 Update Page 5, corrected photo 11/05/2013

Page 1 of 8
 Section 11, Rudder Assembly, LS
1.0 Scope
This document will detail the steps necessary to assemble a SeaRey LSX Rudder frame assembly up to, but not including covering. This assembly is the
same part for either left or right assemblies.

2.0 Applicable Documents

N/A

3.0 Requirements

3.1 Equipment
3.1.1 The following tools will be necessary to perform this procedure:
 3/32 Drill Bit
 Awl
 Drill
 Rivet Gun
 Socket, 3/8”
 Socket, 7/16”
 Wrench, 3/8” Open End
 Wrench, 7/16” Open End

3.2 Materials
The following general supplies will be necessary to perform this procedure:

 N/A

3.3 Procedure (see following pages)

Page 2 of 8
Section 11, Rudder Assembly, LS

7” from
Top

3 1/2”
from
bottom

Page 3 of 8
 Section 11, Rudder Assembly, LS

Rudder
Horn
Temporary
install

Bolt, AN4-15A
Rudder
Trailing
Edge

Rivet, CCR-
Nutplate, 1/4-28 264-SS-3-5

Figure 1. Attaching Nutplate to Rudder Trailing Edge

1.1 Locate the (2) 1/4” holes drilled completely through the Rudder Trailing Edge (#5540-040) at the bottom end where there is a
slight bend in the tube, and temporarily insert Bolt, AN4-15A (#N415A) from the outside edge.
1.2 Thread Nutplate, NP1/4-28 lightly onto Bolt, AN4-15A.
1.3 Align Nutplate, 1/4-28 (#NP1/4-28) along the inside of the Rudder Trailing Edge (#5540-040) through one of the 1/4” holes.
1.4 Using a 3/32” drill bit, drill through one of the mounting lug holes through ONE side of Rudder Trailing Edge.
1.5 In the hole just drilled, rivet Nutplate to Rudder Trailing Edge using Rivet, CCR-264-SS-3-5 (#264CR35).
1.6 Drill through the remaining mounting lug in Nutplate,1/4-28 (#NP1/4-28) using 3/32” drill bit.
1.7 Rivet using Rivet, CCR-264-SS-3-5 (#264CR35).
1.8 With Nutplate, NP1/4-28 riveted firmly in place against Rudder Trailing Edge (#5540-040), remove Bolt, AN4-15A.
1.9 Repeat Steps 1.2 – 1.8 for second Nutplate installation.

Note: The Rudder Horn is shown installed only as a test fit – Do Not leave installed

Page 4 of 8
 Section 11, Rudder Assembly, LS

Nutplate 1/4-28
Rivet
CCR-264-SS-3-5

Figure 2. Installation of the Rudder Hinge Nutplates into Rudder Leading Edge

2.1 Locate the 1/4” holes drilled completely through on both the ends of the Rudder Leading Edge (#5540-030). Temporarily insert
Bolt, AN4-14A (#N414A) from the outside edge.
2.2 Thread Nutplate 1/4-28 (#NP1/4-28) lightly onto Bolt, AN4-14A.
2.3 Align Nutplate 1/4-28 (#NP1/4-28) along the inside of the Rudder Leading Edge (#5540-030).
2.4 Using a 3/32” drill bit, drill through ONE side of the mounting lug holes.
2.5 In the hole just drilled, rivet using Rivet, CCR-264-SS-3-5 (#264CR35).
2.6 Drill through the remaining mounting lug in Nutplate, NP1/4-28, using the 3/32” drill bit.
2.7 Rivet using Rivet, CCR-264-SS-3-5 (#264CR35).
2.8 With Nutplate, NP1/4-28 riveted firmly in place against Rudder Leading Edge, remove Bolt, AN4-14A.

Note: Torque Value on the AN4 bolts in this section should be between 60 inch lbs and 70 inch lbs of torque.

Page 5 of 8
 Section 11, Rudder Assembly, LS

Threaded Insert AN3-13A Top, Rudder

Trailing Edge Bolt AN3-13A
AN4-15A

Top, Rudder
Leading Edge

Drill open
to 1/4”

Tube Bolt, AN4-15A

Connector, 1” (Temporary)
Tube Connector, 1” Bolt, AN4-15A

Figure 3. Inserting Tube Connector into Rudder Trailing Edge

3.1 Press Threaded Insert, 7/16” Steel (#5520-008) into Tube Connector 1” (#5520-009) aligning as shown in photo on left. Note: Do this twice – the
first setup will keep the 3/16” hole, and the second setup will be drilled open to 1/4” hole in next step.

Note: Install a temporary Bolt AN4-15A through the top of Tube Connector and Threaded Insert to help align while pressing.

3.2 Place one Threaded Insert/Tube Connector assembly in vise and drill the 3/16” hole open to 1/4” diameter.
3.3 Insert Tube Connector into the upper outboard end of the Rudder Trailing Edge (#5540-040), aligning the Threaded Insert with the 3/16” hole.
3.4 Place Washer, AN3 (#N3W) over Bolt, AN3-13A (#N313A) and insert through the Rudder Trailing Edge (#5540-040) at the top
connection, locking the Threaded Insert, 7/16” Steel (#5520-008) into position. Install a Washer AN3 (#N3W) and Nut, Lock AN3
(#N3LN) and tighten.

Caution: In the next step orient the Rudder Leading Edge up and down. From the top of the tube measuring down will be 7” to
the ¼” hole. From the bottom of the tube measuring up will be 3 1/2” to the ¼” hole.

3.5 Join the top end of the of Rudder Leading Edge (#5540-030) together with the upper end of the Rudder Trailing Edge (#5540-
040), Install the Bolt, AN4-15A with Washer AN4 through the 1/4” hole on the end of the Rudder Leading Edge (#5540-030) and
tighten into the Threaded Insert, 7/16” Steel (#5520-008).

Note: Torque Value on the AN3 bolts in this section should be between 15 inch lbs and 25 inch lbs of torque.
Note: Torque Value on the AN4 bolts in this section should be between 60 inch lbs and 70 inch lbs of torque.

Page 6 of 8
 Section 11, Rudder Assembly, LS

Rudder Horn
Temporary Nutplate 1/4-28
HERE

Bolt, AN4-15A

Bottom, Rudder Bolt, AN4-15A

Trailing Edge
Bottom, Rudder
Leading Edge

Saddle, 1”

Nutplate 1/4-28 Saddle, 1”

HERE

Bolt, AN4-15A Rudder Horn

Nutplate

Figure 4. Assembly of the Rudder Trailing Edge to the Leading Edge

4.1 Before inserting the Tube Connector assembled in the previous page into the Rudder Trailing Edge tube, cut a slot in the side of the tube
connector where it lines up with the rivet bodies from the nutplate. Push the Tube Connector into the tube and make sure it clears and seats
properly.
4.2 Insert Threaded Insert/Tube Connector Assembly with 1/4” hole (from Step 3.2) into bottom end of Rudder Trailing Edge.
4.3 In the Nutplate closest to the end on the bottom of the Trailing Edge tube insert a Bolt AN4-15A temporarily to hold the alignment
of the Tube Connector/Threaded Insert assembly.
4.4 Join the bottom end of the of Rudder Leading Edge (#5540-030) together with the bottom end of the Rudder Trailing Edge (#5540-
040) by inserting a Bolt, AN4-15A (#N415A) through a Washer, AN4 (#N4W), through the 1/4” hole on the end of Tube Connector
1” (#5520-009) and catching the Threaded Insert, 7/16” Steel (#5520-008).

Note: Torque Value on the bolts in this section should be between 60 inch lbs and 70 inch lbs of torque.

Page 7 of 8
 Section 11, Rudder Assembly, LS

Rudder Leading
Edge
Rivet AB6-8A

Rib Insert

Rudder Rib

Rudder Trailing
Edge
Rudder Rib

Figure 5. Installation of the Rudder Rib

5.1 Locate the 3/16” drilled hole on the inside edge in the center of the Rudder Leading Edge (#5540-030). Place Rivet, AB6-8A (#P-
68) through Rib Insert (#5520-007) and rivet at the 3/16” hole.
5.2 Locate the 3/16” drilled hole on the inside edge in the center of the Rudder Trailing Edge (#5540-040). Place Rivet, AB6-8A (#P-
68) through Rib Insert (#5520-007) and rivet at the 3/16” hole.
5.3 Slide the Rudder Rib (#5540-001) onto the Rib Insert (#5520-007) on the Rudder Leading Edge (#5540-030). Pull outward on the
Rudder Trailing Edge (#5540-040) and slip the Rudder Rib (#5540-001) over the Rib Insert (#5520-007). Release the Rudder
Trailing Edge (#5540-040) so the Rib insert is secure inside the Rudder Rib.

Note: Prior to covering install Rubber Filler, 3/4” x 3/8” (#5510-011) to both sides of the ribs before covering.

Page 8 of 8