Section 7, Aft Cockpit, SeaRey, LSA

Progressive Aerodyne, Inc.

3801 State Rd 19
Tavares, FL 32778

Document Number
Revision Description Remarks Date
09292011 Update 09/29/2011
12012011 Update 12/01/2011
12222011 Update Added page 8, Figure 6, Securing Push-Pull Guide 12/22/2011
05012012 Updated Removed page on Securing Push-Pull Guide 05/01/2012
09052012 Updated Added pg 13 from section 5 document 09/05/2012
05172013 Major Review Builder check verifying build, parts and quantities 05/17/2013
09272013 Update Pg 4, pulley part # was incorrect and changed 09/27/2013

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 Section 7, Aft Cockpit, SeaRey, LSA

1.0 Scope
This document will detail the steps necessary to assemble the components of the aft cockpit.

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:
 Awl
 Center Punch
 Deburring Tool
 Drill Bits, Jobber Length, 3/32”
 Drill Bits, Jobber Length, 1/4”
 Drill Bits, Jobber Length, 1/8”
 Drill Bits, Jobber Length, 3/16”
 Drill, Electric, or Cordless
 Hammer, Plastic Tip
 Marker
 Open End Wrench, 3/8”
 Open End Wrench, 7/16”
 Open End Wrench, 1/2”
 Pop Rivet Gun, Manual or Pneumatic
 Ruler
 Socket Set, SAE, 3/8”, 7/16”, 1/2” sockets
3.2 Materials
The following general supplies will be necessary to perform this procedure:

 Lacquer thinner (Cleaning labels off of parts)

3.3 Procedure (Following pages)

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 Section 7, Aft Cockpit, SeaRey, LSA

Trim Slave Boom Support

Arm Tube, Lower LS

Bolt AN4-20A

Bolt AN4-26A

Electric Trim
Pulley Support
Actuator Aft
Mid

Figure 1. Assembly of the Electric Trim Actuator

Note: In the following step, note the orientation of the Electric Trim/Flap Actuator in relation to the Trim Slave Arm.
1.1 Insert Bolt AN4-20A (#N420A) through a Washer, AN4 (#N4W), Trim Slave Arm LS (#2740-016), (1) Spacer(s) 1/4 x 1/4 Metal (#2710-
013), Electric Trim/Flap Actuator (#2750-011), (1) Spacer(s) 1/4 x 1/4 Metal (#2710-013), Trim Slave Arm LS (#2740-016), followed by
Washer, AN4 (#N4W), Nut, AN4 (#N4LN). Tighten snug, allowing the Trim Slave Arm LS to rotate Bolt AN4-20A.

Note: In the following step, Electric Trim/Flap Actuator is attached to the Boom Support Tube, Lower on the co-pilot side of the
airframe, aft of the bulkhead.
1.2 Insert Bolt AN4-26A (#N426A) through a Washer, AN4 (#N4W), Pulley Support Mid (#3230-089), Boom Support Tube, Lower LS (#5310-
030), two (2) Spacer(s) 1/4 x 1/4 Metal (#2710-013), Electric Trim/Flap Actuator (#2750-011), followed by Washer, AN4 (#N4W), Nut
(#N4LN) and tighten.
Note: Torque Value on the AN4 bolts in this section should be between 60 inch lbs and 70 inch lbs of torque.

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 Section 7, Aft Cockpit, SeaRey, LSA

Aft

Bolt AN4-11A

Bolt AN4-11A

Pulley Support
Mid
Boom Support
Tube, Lower LS
Pulley Guard

Figure 2. Assembly of the Pulley onto the Electric Trim Actuator

2.1 Insert Bolt AN4-11A (#N411A) through a Washer, AN4 (N#4W), Pulley Guard (#3230-086), Pulley, 1-3/4” (#175P), Pulley Guard (#3230-
086), Pulley Support Mid (#3230-089), followed by Washer, AN4 (#N4W), Nut, AN4 (#N4LN). Tighten snug, allowing the Pulley to spin
freely.

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 Section 7, Aft Cockpit, SeaRey, LSA

Trim Slave Arm

Trim Slave Arm

Bolt AN4-20A

three (3) Washers

Bolt AN4-30A

three (3) Washers

Figure 3. Assembly of the Electric Trim Actuator to Boom Support Tube, Lower

3.1 Insert Bolt AN4-30A (#N430A) through a Washer, AN4 (#N4W), Boom Support Tube, Lower LS (#5310-030), Plastic Washer, 1/4” I.D.
(#14PW), Trim Slave Arm LS (#2740-016), three (3) Washer(s) AN4 (#N4W), Tee Bar Bushing (#3230-070), three (3) Washer(s) AN4
(#N4W), Trim Slave Arm LS (#2740-016), followed by Washer, AN4 (#N4W), Nut (#N4LN). Tighten snug, allowing the Trim Slave Arm LS
to rotate on the Bolt, AN4-30a and on Bolt, AN4-20A previously installed in Step 1.1.

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 Section 7, Aft Cockpit, SeaRey, LSA

Forward

Springs, one (1)

face forward,
one (1) face aft
Three (3) Washers

Bolt AN4-20A Tee Bar Bushing

Three (3) Washers

Figure 4. Assembly of the Electric Trim Actuator

4.1 Insert Bolt AN4-20A (#N420A) through a Washer, AN4 (#N4W), Trim Slave Arm LS (#2740-016), three (3) Washer(s), AN4 (#N4W), and
Tee Bar Bushing (#3230-070).
4.2 Next, install the ‘loop’ end of each of two (2) Spring(s), 9/16 x 6” (#5750-031) over the Tee Bar Bushing (#3230-070). One (1) Spring faces forward
and one (1) Spring faces aft.
4.3 Install three (3) Washer(s), AN4 (#N4W), Trim Slave Arm LS (#2740-016), Washer, AN4 (#N4W), Nut (#N4LN), and tighten.

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

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 Section 7, Aft Cockpit, SeaRey, LSA

Forward
This connection
will be made in
Section 10 Bolt AN4-20A Bolt AN4-20A

Saddle, 1”
Control Elevator
Column Push-Pull Push-Pull
Torque Tube Tube Strap Tube

Figure 5. Installation of Elevator Push-Pull Tube, Forward Cockpit

5.1 Insert Bolt, AN4-20A (#N420A) through Washer, AN4 (#N4W) then insert into Push-Pull Tube Strap (#3230-009), Saddle, 1”
(#5310-024) over the bolt. Repeat for the second bolt.

5.2 Insert the two (2) 1/4” holes in the Elevator Push-Pull Tube LS (#2730-017) over the two (2) Bolt(s), AN4-20A from above, then
place a Saddle, 1” (#5310-024), and the remaining Push-Pull Tube Strap (#3230-009). Follow with Washer AN4 (#N4W) and
Locknut AN4 (#N4LN). Do not Tighten!

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 Section 7, Aft Cockpit, SeaRey, LSA
Aft side of Lower
Bulkhead Cross Tube

Elevator
Push-Pull
Rivet AB6-6A
Oversleeve Drill 3/16” hole

Elevator Push-Pull Elevator Push-Pull

Bend Tube Tube

Figure 6. Securing the Push-Pull Oversleeve

6.1 Confirm the Elevator Push-Pull Oversleeve (#2730-003) is positioned so that the aft edge of the oversleeve ends at approximately
the start of the second bend of Elevator Push-Pull Tube, and is inside the Elevator Push-Pull Guide LSX (#2730-019). Drill a 3/16”
hole through the Oversleeve and secure with Rivet AB6-6A (#P-66).

Note: Check Elevator Push-Pull Tube travel to make sure the Elevator Push-Pull Oversleeve is adjusted fore or aft so the sleeve
does not go past the hole in the Elevator Push-Pull Guide.

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 Section 7, Aft Cockpit, SeaRey, LSA
7.1 Co-pilot side, aft 7.2 Co-pilot side, aft
of bulkhead of bulkhead
Fender Washer
Aft
Aft

(1) Spring,
Elevator
9/16 x 6”
Bolt, AN3-22A Push-Pull
Tube

Elevator
Push-Pull
(1) Spring,
Tube
9/16 x 6”

Bolt, AN3-22A Fender Washer

Figure 7. Installation of Elevator Push-Pull Tube Springs

7.1 On the Elevator Push-Pull Tube, locate the 3/16” bolt hole just aft of the second bend where the oversleeve ends. Insert Bolt from the outboard
side to the inside. Insert Bolt, AN3-22A (#N322A) through Washer, ¼ x 1” SS Fender (#FW100-14), Tee Bar Bushing (#3230-070). Slide
on open end of one (1) Springs, 9/16” x 6” (#5750-031) previously attached to the Electric Trim / Flap Actuator (#2750-011) facing forward
over the Aluminum Spacer into the Elevator Push-Pull Tube LS (#2730-017) followed by a Washer AN3 (#N3W) and Locknut AN3
(#N3LN), and tighten nut.

7.2 Locate the 3/16” hole 19” aft of the hole in step 7.1. Insert Bolt from the outboard side to the inside. Insert Bolt, AN3-22A (#N322A) through
Washer, ¼ x 1” SS Fender (#FW100-14), Tee Bar Bushing (#3230-070). Slide on open end of two (1) Springs, 9/16” x 6” (#5750-031)
previously attached to the Electric Trim / Flap Actuator (#2750-011) facing aft over the Aluminum Spacer, Elevator Push-Pull Tube LS
(#2730-017) followed by a Washer AN3 (#N3W) and Locknut AN3 (#N3LN) and tighten nut.

Note: Torque Value on the AN3 bolts in this section should be between 15 inch lbs and 25 inch lbs of torque.
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 Section 7, Aft Cockpit, SeaRey, LSA

Aft

Measure 6” from
aft end and drill
3/16” hole
Bone Tang
Boom Tube,
Bolt AN3-13A Lower LS

Figure 8. Installation of a Bone Tang on Boom Support Tube, Lower

8.1 On the co-pilot side Boom Support Tube, Lower LS (#5310-030), measure 6” from the aft end of the tube and drill a 3/16” hole as shown in
the photo above.
8.2 Insert Bolt AN3-13A (#N313A) through a Tang, Bone (#5720-013), Boom Support Tube, Lower LS (#5310-030), Washer, AN3 (#N3W),
Nut (#N3LN), and tighten. Position the Tang, Bone, aft and bend out slightly to face aft.

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

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 Section 7, Aft Cockpit, SeaRey, LSA

Bolt AN4-15A Bolt AN4-11A

Boom Support
Pulley Support Mid Tube, Lower LS
Pulley Guard

Figure 9. Installing Rudder Cable Pulley to the Lower Bulkhead (Pilot side)

9.1 Insert Bolt AN4-15A (#N415A) through a Washer, AN4 (#N4W), Pulley Support Mid (#3230-089), Boom Support Tube, Lower
(#5310-030), followed by Washer, AN4 (#N4W), Nut, AN4 (#N4LN) and tighten.
9.2 Insert Bolt AN4-11A (#N411A) through a Washer, AN4 (#N4W), Pulley Guard (#3230-086), Pulley, 1-3/4” (#175P), Pulley Guard
(#3230-086), Pulley Support Mid (#3230-089), followed by Washer, AN4 (#N4W), Nut, AN4 (#N4LN). Tighten snug, allowing the
Pulley to spin freely.
Note: Torque Value on the AN4 bolts in this section should be between 60 inch lbs and 70 inch lbs of torque.

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 Section 7, Aft Cockpit, SeaRey, LSA

Boom Support Boom Support

Tube, Upper Tube, Upper

Pilot Side
Co-Pilot Side Bolt AN4-11A
Bolt AN4-11A

Pulley Mount
Bracket Aft
Pulley Guard Pulley, 1-3/4”

Figure 10. Installing Rudder Cable Pulleys to the Boom Tube Mid-Section

Note: The Pulley Mount Bracket Aft (#3230-084) has been installed in previous assembly directions.

10.1 (Co-pilot side) Insert Bolt AN4-11A (#N411A) through a Washer, AN4 (#N4W), Pulley Guard (#3230-086), Pulley, 1-3/4” (#175P),
Pulley Guard (#3230-086), Pulley Mount Bracket Aft (#3230-084), followed by Washer, AN4 (#N4W), Nut, AN4 (#N4LN). Tighten
snug, allowing the Pulley to spin freely.
10.2 Repeat this procedure for the pilot side.

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 Section 7, Aft Cockpit, SeaRey, LSA

Elevator
Reversing Horn

Bolt, AN4-24A

Spacer and Saddle Saddle and Spacer

Elevator Push-Pull Rubber Seal,
Tube Transom
Tie Wrap

Figure 11. Installation of Elevator Push-Pull Tube Aft End

Note: Use grease in this assembly process

11.1 Insert Bolt, AN4-24A (#N424A) through an AN4 Washer (#N4W), then insert the bolt through one side of Elevator Reversing Horn (#2730-012).

11.2 Place a dab of grease on Plastic Spacer, 1/8” (#5530-005) and slide on the bolt. Place a dab of grease on the backside of Saddle 1”
(#5310-024) and place on the bolt. Now insert the bolt through the Elevator Push-Pull Tube LS (#2730-017).

11.3 Follow up the remaining side by installing the Saddle, 1”, then Plastic Spacer, 1/8” (#5530-005), and the Elevator Reversing Horn, an AN4
Washer (#N4W) and AN4 Locknut (#N4LN). Don’t forget the grease!

11.4 Place Tie Wrap, Plastic (#7310-020) around the end of the Rubber Seal, Transom (#5330-011) where in contact with the Elevator Push-Pull Tube.

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