Section 28, Wing Final Finishes, SeaRey, LSA

Progressive Aerodyne, Inc.

3801 State Rd 19
Tavares, FL 32778

Revision Description Remarks Date

01 Initial Creation 05/22/2012
02 Update Pg 16, added view for Wing/Flap Gap Seal 09/20/2013
03 Update Moved VG Kit installation from this section and moved to section 34 02/07/2014

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 Section 28, Wing Final Finishes, SeaRey, LSA
1.0 Scope
This document will detail the steps necessary for final assembly of the Wing.

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 28, Wing 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 28, Wing Final Finishes, SeaRey, LSA

Aileron
Torque Tube Aileron
Horn Slot

Inspection
Holes

Inboard end

Figure 1. Trimming Inspection Holes and Slots in Wing

1.1 Trim out all of the (6) Inspection Holes with a razor knife.
1.2 Trim out (1) Flap Horn access slot and (2) Strut Plate slots with a knife.
1.3 Trim fabric around the inboard aileron torque tube.

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 Section 28, Wing Final Finishes, SeaRey, LSA

Wing –
Bottom Side

Aileron Torque
Tube Horn
Inside Wing

Aileron Torque
Tube Horn
Bolt AN4-16A
Inspection Hole

Figure 2. Installing the Aileron Torque Tube Horn

2.1 Install Aileron Torque Tube Horn (2710-001) onto the outboard end of the Aileron Torque Tube inside the wing. Slide the welded cylinder
on the end of the Torque Tube Horn into the end of the Aileron Torque Tube with the arm of the Tube Horn extending through the slot in
the wing. Line up the ¼” holes in the Tube Horn and the Torque Tube. Use AN4-16A Bolt, Washer AN4, Torque Tube, Washer AN4, Nut
AN4 and Tighten.

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 Section 28, Wing Final Finishes, SeaRey, LSA

Strut Wing Bottom Trailing Edge Wing Bottom

Plate Inboard end

Strut
Bolt AN5-30A Plate

Rivet SBL44
Leading Edge
Inboard end
Hinge Standoff Bolt AN4-41A Hinge

Figure 3. Installing the Leading Edge Wing Strut Plate

3.1 Install leading edge Wing/Strut Plate, Forward LSA (5720-027). Cut slot in fabric to allow the plate to come through. Install (2) Bolt AN5-
30A, Washer AN5, leading edge spar, Wing Strut Plate, Forward LSA, Washer AN5, Nut AN5, Lock (N5LN) and tighten.
3.2 Install trailing edge Wing/Strut Plate (5720-011). Cut slot in fabric to allow the plate to come through. Install (2) Bolt AN4-41A, Hinge
(5520-010), Hinge Standoff (5750-018), Trailing Edge Wing Spar, Wing Strut Plate (5720-011), Washer AN4, Nut AN4, Lock (N4LN) and
Tighten. Install a Rivet SBL44 on each side of the Hinge Standoff.

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 Section 28, Wing Final Finishes, SeaRey, LSA

Wing bottom

Aileron Torque
Tube Horn

Aileron Torque
Tube Horn
Bolt AN4-16A
Bolt AN4-16A

Figure 4. Installing the Outboard Aileron Torque Tube Horn

4.1 Install Aileron Torque Tube Horn (2710-001) onto the inboard end of the Aileron Torque Tube. The Horn will face down to the bottom side
of the wing. Use Bolt AN4-16A, Washer, Torque Tube, Tube Horn, Torque Tube, Washer, AN4 Nut.

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 Section 28, Wing Final Finishes, SeaRey, LSA

1/8” Spacers Inspection

and Saddle Hole Eyebolt AN43B-23A
Inside Wing
bottom

Compression Fender Washer

Strut

Trailing Edge Shown Here

Eyebolt AN43B-23A

Figure 5. Installing the Jury Strut Eyebolts into the Wing

5.1 Install Eyebolt AN43B-32A for Wing Jury Strut in the leading edge: Burn hole at 51-3/8” from inboard root rib into the wing fabric. Check
that the hole in the compression strut lines up with the dimension by installing temporary bolt through the compression strut pre-drilled
hole to locate where to burn the hole exactly.
5.2 Eyebolt AN43B-32A, Fender Washer, ¼” x 1” (FW100-14) , fabric, (10) 1/8” Plastic Spacers (5530-005), Saddle 1” (5310-024),
Compression Strut, Washer AN4, Nut AN4 and tighten.
5.3 Install Eyebolt AN43B-23A for Wing Jury Strut in the trailing edge: Burn hold at 51” from inboard root rib into the wing fabric. Check that
the hole in the compression strut lines up with the dimension by installing temporary bolt through the compression strut pre-drilled hole to
locate where to burn the hole exactly.
5.4 Eyebolt AN43B-23A, Fender Washer, ¼” x 1” (FW100-14), fabric, (5) 1/8” Plastic Spacers (5530-005), Saddle 1” (5310-024), Comp Strut,
Nut, Thin AN4.

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 Section 28, Wing Final Finishes, SeaRey, LSA

Trailing Edge Wing Spar

Wire & Plug

Screw #08 x 2” Navigation

Sheet Metal, Light
¼” Hole Tapered Head

Figure 6. Installing the Navigation Light and wiring in the Wing

6.1 Drill a 1/4” hole in the inboard end of the trailing Wing Spar at the plastic plug.
6.2 Install Navigation Light (Aveo Flash LP) – Lay the gasket over the wing tip raised area for the light. Mark the location for the screw, hole
for wire and set pin. (Set pin 5/32”) (Screw 1/16”) (Wire Hole 3/8”). Insert a wire snare from wing tip wire hole out to the spar – Pull Wire
Harness through.
6.3 Attach the Navigation Light wires to the wire harness. Push the wires back into the wing and install the Screw, #08 x 2” Sheet Metal,
tapered head to hold the Navigation Light in place.

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 Section 28, Wing Final Finishes, SeaRey, LSA

Inspection
Hole Cover
Cable Clamp

Figure 7. Installing the Navigation Light and wiring in the Wing

7.1 Install the Inspection Cover Plates (6): Slide one retaining finger in all the way to the Inspection Hole Retaining Ring then slide back to
center to install opposite finger.
7.2 Install (3) Cable Clamps, ½” Plastic with Screw, #10 x ¾” Sheet Metal (S75-10) on the wood rib to hold the Nav light Harness Connector.

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 Section 28, Wing Final Finishes, SeaRey, LSA

Gap Seal Attach

Angle 8”
Gap Seal Attach Screw #10
Angle 12”
Screw #10

Figure 8. Installing the Gap Seal Attach Angles to the Wing

8.1 Add Gap Seal Attach Angle 12” on the top side of the wing. Measure from apex leading edge back 14”.
8.2. Cut notches in the angle so the angle will follow the curve of the wing.
8.3 Drill a 1/8” hole in the angle 1/2” in each end and center hole.
8.4 Install Screw #10 x 3/4” Sheet Metal (S75-10) into the (3) holes.
8.5 Add Gap Seal Attach Angle 8” on the bottom side of the wing. Measure from the apex of the leading edge back
7 ½”.
8.6 Drill a 1/8” hole in the angle 1/2” in each end and center hole.
8.7 Install Screw #10 x 3/4” Sheet Metal (S75-10) into the (2) holes to match the bottom line of wing.

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 Section 28, Wing Final Finishes, SeaRey, LSA

Hinge
Standoff

Hinges
Qty (6)
Inboard End

Rivet SBL44 Hinge

Bolt AN4

Figure 9. Attaching Hinges to the Wing

9.1 Burn holes or cut out bolt heads for hinges on Flap at 3”, 53”, and 105” from inboard end of Trailing Edge Wing Spar.
9.2 Burn holes or cut out bolt heads for hinges on Aileron at 109”, 140-3/8”, and 170” from inboard end of Trailing Edge Wing Spar.
9.3 Remove Bolt AN4-30A from flap hinge holes at 3” and 53” locations. Install Bolt AN4-41A with Hinge (5520-010) then Hinge Standoff
(5750-018) and tighten.
9.4 At 105” location install same as above AN4-41A.
9.5 At 109” for Aileron – same as above AN4-41A.
9.6 At 140-3/8” use Bolt AN4-36A, Hinge (5520-010) and Hinge Standoff (5750-018).
9.7 At 170” use Bolt AN4-35A, Hinge (5520-010) and Hinge Standoff (5750-018).
9.8 Drill (2) 1/8” holes in each hinge standoff (5750-018) when it is perpendicular with the trailing edge wing cuff. Use Rivet SBL44 (SL-44)
and install.

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 Section 28, Wing Final Finishes, SeaRey, LSA

Hinge
Standoff
Hinge

Gap Seal Hinge

Outboard

Gap Seal
Inboard 1/8” Spacer Bolt AN3-14
Aileron if needed

Figure 10. Attaching the Aileron Gap Seals to the Aileron

10.1 Temporarily install the flap and aileron using the Bolt AN3-14. Use 1/8” Plastic Spacer behind any hinges that need spacing for alignment.
10.2 Set the Aileron Gap Seal Outboard (5760-006) and Aileron Gap Seal Inboard (5760-005) into position and space off the trailing edge wing
cuff 1/8” for Aileron Gap Seal. Check the fit and drill 1/8” holes at each end of the two Gap Seals into leading edge tube and Cleco.
Rotate wing over and set the back side and Cleco.
10.3 Space Rivet holes every 2-1/2”
10.4 Rivet in place with Rivet AB4-3A.

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 Section 28, Wing Final Finishes, SeaRey, LSA

Rivet AB4-3A

Fap
Gap Seal
Outboard
Gap Seal
Rivet AB4-3A Inboard
Flap Gap Seal
Support

Figure 11. Attaching the Flap Gap Seals to the Flap

11.1 Set the Flap Gap Seal Inboard (5750-017) and Flap Gap Seal Outboard (5750-019) into position and space off the trailing edge wing cuff
1/2” for Flap Gap Seal. Check the fit and drill 1/8” holes at each end of the two Gap Seals into leading edge tube and Cleco. Rotate wing
over and set the back side and Cleco.
11.2 Space Rivet holes every 2-1/2”
11.3 Rivet in place with Rivet AB4-3A. Install the inboard Flap Gap Seal Support (5750-029) with (3) rivets on each side.

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 Section 28, Wing Final Finishes, SeaRey, LSA

Aileron
Bolt AN3-14 Castle Nut and
Cotter Pin
Fap

Figure 12. Installing the Aileron and Flap to the Wing

12.1 Install Flap and Aileron using Bolt AN3-14 drilled thread end, Castle Nut (N314) and Cotter Pin.

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Section 28, Wing Final Finishes, SeaRey, LSA

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 Section 28, Wing Final Finishes, SeaRey, LSA

Tape

Rivet AB4-3A

Gap Seal Gap Seal

Flap

Figure 13. Installing the Wing to Flap Gap Seal to the Wing

13.1 On the back Trailing edge of the Wing to Flap Gap Seal (5750-021) install Roll, Stits 3/8” x 60 Yd Reinforcing Tape (0620-013) along the
entire length of the Gap Seal.
13.2 Start the Gap Seal flush with the Wing Inboard end. Let the Gap Seal hang over the aft edge of the wing by 1-3/4”.
13.3 Rivet the Gap Seal to the Wing Spar Trailing Edge. Drill 1/8” holes in from the trailing edge and space every 2-1/2”. Install Rivet AB4-
3A.

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 Section 28, Wing Final Finishes, SeaRey, LSA

Control Control
Horn, 5” Horn, 5”

Bolt AN3-10A Bolt AN3-05A

Bolt AN3-05A
Horn Mount
Angle, 13”

Horn Mount
Angle, 13”

Bolt AN3-20A

Figure 14. Installing the Aileron Control Horns to the Aileron

14.1 Install Horn Mount Angle 13” (2750-008) to the aileron inboard bottom side. Lay the mount on the Aileron and drill a 3/16” hole through
the leading and trailing edge tube, 1-1/4” in from end.
14.2 Install Bolt AN3-20A on the leading edge: Bolt AN3-20A, leading tube, angle, Nut AN3.
14.3 Install Bolt AN3-10A on trailing edge: Bolt AN3-10A, trailing tube, Horn Mount Angle, Washer AN3, Nut AN3.
14.4 Install Control Horn 5” (2750-003) onto the Horn Mount Angle. Use Bolt AN3-05A, Washer AN3, Horn Mount Angle, Control Horn, Washer
AN3, Nut AN3.

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 Section 28, Wing Final Finishes, SeaRey, LSA

Control
Tie Rod, 32 ½” Horn, 5”
Bolt AN4-10A

Bolt AN4-10A

Bolt AN4-10A
Aileron
Tube Horn
Tie Rod, 32 ½”

Figure 15. Installing the Aileron Tie Rod Tube

15.1 Install end of Tie Rod, 32-1/2 (2710-020) to the Aileron Tube Horn with Bolt AN4-10A, Washer AN4, Aileron Tube Horn, Tie Rod 32 ½”,
Washer AN4, Nut AN4.
15.2 Install end of Tie Rod, 32-1/2 (2710-020) to the Control Horn 5” – Bolt AN4-10A, Washer AN4, Control Horn 5”, Tie Rod Tube 32 ½”,
Washer AN4, Nut AN4.

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 Section 28, Wing Final Finishes, SeaRey, LSA

VG
VG
Rivet AB4-3A

Leading Edge Leading Edge

Cover Plate Cover Plate
Strut Plate

Figure 16. Installing the Leading Edge Cover Plate onto the Wing

16.1 Install Leading Edge Cover Plate (5740-029) onto the leading edge over the (2) Bolt AN5 holes for the Strut Plate. The larger portion of
the Cover Plate is on top side of wing.
16.2 Drill (4) 1/8” holes at each corner of the Cover Plate into the wing leading edge cuff.
16.3 Install (4) Rivet AB4-3A into each corner of the plate.

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