Section 23, Rudder Final Finishes, SeaRey, LSA

Progressive Aerodyne, Inc.

3801 State Rd 19
Tavares, FL 32778

Revision Description Remarks Date

01 Initial Creation 04/10/2012

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 Section 23, Rudder Final Finishes, SeaRey, LSA
1.0 Scope
This document will detail the steps necessary for final assembly of the Rudder.

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
 Crescent Wrench
 Needle Nose Pliers
 Screwdriver, Straight Blade
 Deburring Tool
 Allen Wrench Set
 Drill Bits, Jobber Length, 1/8”
 Drill Bits, Jobber Length, 3/16”
 Drill, Electric, or Cordless
 Files
 Hammer, Plastic Tip
 Marker
 Open End Wrench, 3/8”
 Open End Wrench, 7/16”
 Screwdriver, Phillips Head
 Socket Set, SAE, 3/8” and 7/16” sockets
 Tape Measure

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 Section 23, Rudder Final Finishes, SeaRey, LSA
3.2 Materials
The following general supplies will be necessary to perform this procedure:

 Sandpaper, Coarse
 Lacquer thinner (Cleaning labels off of parts)
 Protective gloves

3.3 Procedure (See the following pages)

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 Section 23, Rudder Final Finishes, SeaRey, LSA

Hinge Hinge

Hinge

Bolt AN4-14A

Top

Figure 1. Installing Hinges on the Rudder

1.1 Install the hinges on the Rudder Leading Edge (#5540-030). Locate two the mounting holes on the leading edge tube, one at 4” up from
the bottom and one at 6-1/2” down from the top. Use a hot knife to open up the holes and remove the fabric covering.
1.2 Install Hinge (#5520-010) at the top and bottom of the Rudder: Install Bolt AN4-14A (#N414A) through Hinge (#5520-010) and tighten into
the Nutplate, 1/4-28 installed on the Rudder Leading Edge (#5540-030).

Note: Torque Value on the AN4 bolts in this section should be between 50 inch lbs and 70 inch lbs of torque

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 Section 23, Rudder Final Finishes, SeaRey, LSA

Drain
Hole
Rudder Horn
Bolt Holes

Bottom
Edge

Figure 2. Preparing Rudder for Rudder Horn

2.1 At the bottom of the Rudder Leading Edge (#5540-030) tube open up a hole with a hot knife to allow for moisture buildup in the Rudder to
drain out.
2.2 Locate the (2) holes in the Rudder Trailing Edge (#5540-040) bottom edge. Coming from the edge of the Rudder Leading Edge (#5540-
030) measure 1-3/4” to the first hole and 3-1/2” to the second hole. Using a hot knife open up the two holes and clean out fabric covering
material.

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 Section 23, Rudder Final Finishes, SeaRey, LSA

Saddle, 1”

Saddle, 1”

Rudder Horn Bolt AN4-15A

Rudder Horn

Figure 3. Installing the Rudder Horn onto the Rudder

3.1 Install the Rudder Horn LS (#2720-018) onto the bottom of Rudder Trailing Edge (#5540-040). Locate the mounting holes on the trailing
edge tube located in the Rudder Trailing Edge’s bottom edge. Coming from the edge of the Rudder Leading Edge (#5540-030) measure
1-3/4” to the first hole and 3-1/2” to the second hole.
3.2 In both holes, install Bolt AN4-15A (#N415A) through Washer AN4 (#N4W) Rudder Horn (#2720-018), Saddle, 1” (#5310-024), Rudder
Trailing Edge (#5540-040) and tighten into the pre-installed nutplate.

Note: Torque Value on the AN4 bolts in this section should be between 50 inch lbs and 70 inch lbs of torque

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 Section 23, Rudder Final Finishes, SeaRey, LSA
Hinge
Vertical Fin
Rudder

Bolt AN3-14A

Hinge
Hinge

Hinge

Figure 4. Installing the Rudder onto the Vertical Fin

4.1 Test fit the Rudder to the Vertical Fin to see if the Hinge(s) (#5520-010) on the Rudder should sit on top of the Hinge(s) (#5520-010) on
the Vertical Fin or the bottom based on transition from the Rudder to the Vertical Fin.
4.2 Install Bolt AN3-14A (#N314A) through each Hinge (#5520-010) with the bolt head up and a Washer AN3 (#N3W) on the bottom. Tighten
the Nut AN3 (#N3LN) allowing hinges to rotate freely.

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 Section 23, Rudder Final Finishes, SeaRey, LSA

Vertical Fin

Rudder

Upper Tail Post

Support

Rudder Horn
Stop

Rivet SBL44 Rudder Horn

Figure 5. Installing the Rudder Horn Stops

5.1 Slide both of the Rudder Horn Stop(s) (#2720-046) onto the forward side of the Rudder Horn LS (#2720-018) with the wider side facing
inboard.
5.2 Using an angle finder up against the Vertical Fin and the Rudder, set at 32 degrees in each direction and push the Rudder Horn Stops up
against the Upper Tail Post Support (#3220-017).
5.3 Using the pre-drilled holes in the Rudder Horn Stops, drill through the holes into the Rudder Horn LS with a 1/8” drill bit. Install (2) Rivet
SBL44 (#SL-44) per Stop.

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 Section 23, Rudder Final Finishes, SeaRey, LSA

Rudder
Rudder

Rudder
Trim Tab

Rudder
Rivet SBL44 Trim Tab

Figure 6. Installing the Rudder Trim Tab onto the Rudder

6.1 Install the Rudder Trim Tab (#2720-007) onto the pilot side of the Rudder. Locate the center point of the Rudder Trailing Edge (#5540-
040) and the center point of the Rudder Trim Tab. Match up the two center points. Now align the pre-drilled holes in the Rudder Trim Tab
on the centerline of the Rudder Trailing Edge. Clamp the Rudder Trim Tab into position on the Rudder.
6.2 Using a 1/8” drill bit, drill (5) 1/8” holes through the pre-drilled holes in the Rudder Trim Tab (#2720-007) into the Rudder Trailing Edge
(#5540-040) tube through one side only. Do not drill all the way through the Rudder Trailing Edge (#5540-040).
6.3 Install (5) Rivet SBL44 (#SL-44).

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 Section 23, Rudder Final Finishes, SeaRey, LSA

Rudder Vertical Fin

Rudder Gap
Seal Upper

Rudder Gap
Seal Upper

Rivet AB4-3A
Rudder Gap
Rudder Gap Seal Lower
Seal Lower

Rudder

Figure 7. Installing the Rudder Gap Seals

7.1 Install the Rudder Gap Seal Upper (#5540-032) to the Rudder. Clamp the Rudder Gap Seal Upper into position with a 1/8” spacing from
the end of the Gap Seal to the trailing edge of the Vertical Fin. Position vertically below the upper bend and above the top Hinge.
7.2 Locate the centerline of the Rudder Leading Edge tube. Transfer that line onto the surface of the Rudder Gap Seal Upper. Drill (3) 3/16”
holes into the Rudder Gap Seal Upper (#5540-032) and into the Rudder Leading Edge (#5540-030). Do not drill all the way through the
tube.
7.3 Install (3) Rivet AB4-3A (#AB4-3A).
7.4 Repeat steps 7.2 and 7.3 on the other side.
7.5 Install the Rudder Gap Seal Lower (#5540-033) to the Rudder. Clamp the Rudder Gap Seal Lower into position with a 1/8” spacing from
the end of the Gap Seal to the trailing edge of the Vertical Fin. Position vertically evenly spaced between the Hinges.
7.6 Locate the centerline of the Rudder Leading Edge tube. Transfer that line onto the surface of the Rudder Gap Seal Lower. Mark and drill
1/8” holes, spaced about 2-1/2” apart, into the Rudder Gap Seal Lower (#5540-033) and into the Rudder Leading Edge (#5540-030). Do
not drill all the way through the tube.
7.7 Install Rivet(s) AB4-3A (#AB4-3A) into the holes you just drilled.
7.8 Repeat steps 7.6 and 7.7 on the other side.

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 Section 23, Rudder Final Finishes, SeaRey, LSA

Rudder
Cable
Assembly,
Rudder LS
Cable
Assembly,
Rudder LS

Lubricate
with Lithium
Grease
Bolt, AN3-06A
Bolt,
Rudder Horn LS AN3-06A

Figure 8. Installing the Rudder Cables

8.1 Install the Cable Assembly, Rudder LS (#2720-029) to the Rudder Horn LS (#2720-018). The remaining, shorter end of the split on the
Rudder Cable will be attached. Install Bolt AN3-06A (#N306A) through a Washer AN3 (#N3W), Cable Assembly, Rudder LS (#2720-029),
(2) Washer AN3 (#N3W), Rudder Horn LS (#2720-018), Washer AN3 (#N3W), Nut AN3 (#N3LN) and tighten so that the Cable can swing
freely.
8.2 Repeat to the other side.
8.3 Spray lithium grease inside of the plastic tubing to lubricate the cables.

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 Section 23, Rudder Final Finishes, SeaRey, LSA

Screw #10-32 x 3/4 Boom Tube

Cover Angle
Cable
Assembly,
Rudder LS Cable Clamp
Plastic Tube

Cable Assembly,
Rudder LS Screw #10-32 x 3/4
Boom Tube
Cover Angle

Figure 9. Securing the Rudder Cables that Lead to Steering Extension

9.1 Secure the Cable Assembly, Rudder LS (#2720-029) that leads to the Tail Wheel Steering Extensions. Slide a Cable Clamp, 1/4” (#2460-
001) over the plastic tubing around the Cable Assembly, Rudder LS. Center the plastic tubing at the point where it passes by the Boom
Tube Cover Angle (#5340-005). Center the Cable Clamp, 1/4” and position the bolt hole over the Boom Tube Cover Angle.
9.2 Drill a 3/16” hole through the hole in the Cable Clamp, 1/4” and into the Boom Tube Cover Angle.
9.3 Install Screw #10-32 x 3/4” Dome Head (#S75-1032) through a Washer AN3 (#N3W), the Cable Clamp, 1/4” (#2460-001), Boom Tube
Cover Angle (#5340-005), Washer AN3 (#N3W) and Nut AN3 (#N3LN) and tighten.
9.4 Repeat to the other side. Spray lithium grease inside of the plastic tubing to lubricate the cables.

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 Section 23, Rudder Final Finishes, SeaRey, LSA

Boom Tube Cover

Screw #10-32 x 3/4

Plastic Tube
Cable
Assembly,
Rudder LS Cable
Assembly,
Cable Clamp Boom Tube Cover
Rudder LS

Figure 10. Securing the Rudder Cables that Lead to Rudder Horn

10.1 Secure the Cable Assembly, Rudder LS (#2720-029) that leads to the Rudder Horn (#2720-018). Slide a Cable Clamp, 1/4” (#2460-001)
over the plastic tubing around the Cable Assembly, Rudder LS. Center the plastic tubing at the point where it passes through the Boom
Tube Cover, Left (#5430-001) and Right (#5430-002) cable opening. Center the Cable Clamp, 1/4” on the plastic tube and position the
Cable Clamp bolt hole so that it holds the cable centered through the slot in the Boom Tube Cover.
10.2 Drill a 3/16” hole through the hole in the Cable Clamp, 1/4” (#2460-001) and into the Boom Tube Cover, Left (#5430-001) and Right
(#5430-002).
10.3 Install Screw #10-32 x 3/4” Dome Head (#S75-1032) through a Washer AN3 (#N3W), Boom Tube Cover, Left (#5430-001) (or Right
(#5430-002), Cable Clamp, 1/4” (#2460-001), Washer AN3 (#N3W) and Nut AN3 (#N3LN) and tighten.
10.4 Repeat to the other side. Spray lithium grease inside of the plastic tubing to lubricate the cables.

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