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Wills Wing Sport 2 155 Owner's Service Manual

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Sport 2 155
Owner / Service Manual
June 1st, 2004 - First Edition

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  • Page 1 Sport 2 155 Owner / Service Manual June 1st, 2004 - First Edition...
  • Page 3 Sport 2 155 Owner / Service Manual Copyright © 1994-2004 by Sport Kites, Inc. dba Wills Wing, Inc. All rights reserved. No part of this manual may be reproduced in any form without the express written permission of Sport Kites, Inc., dba Wills Wing, Inc.

  • Page 4: Table Of Contents

    Contents Introduction ...................... 1 Disclaimer and Warning ..................2 Technical Information and Placarded Operating Limitations ........3 Sport 2 Reassembly After Shipping and Breakdown for Shipping Procedures .... 6 Reassembling the Sport 2 after breakdown for shipping To remove the rear leading edges for shipping follow these steps Sport 2 Set-Up Procedure ..................
  • Page 5 Tip Wand Receptacles - rotational alignment Sail tension Twisting a tip Batten tension Car Top Mounting and Transport ............... 48 In Closing - A Few Final Words on Your Safety ........... 48 HGMA Sport 2 155 COMPLIANCE VERIFICATION SPECIFICATION SHEET ....50...

  • Page 7: Introduction

    We encourage you to read this manual thoroughly for information on the proper use and maintenance of your Wills Wing glider. If at any time you have questions about your glider, or about any aspect of hang gliding that your Wills Wing dealer cannot answer, please feel free to give us a call.

  • Page 8: Disclaimer And Warning

    Wills Wing hang gliding products are not covered by product liability insurance. As a hang glider pilot, you are entirely responsible for your own safety.

  • Page 9: Technical Information And Placarded Operating Limitations

    Technical Information and Placarded Operating Limitations The Sport 2 155 has been tested and found to comply with the Hang Glider Manufacturers Association (HGMA) Airworthiness Standards. At the time of publication of this manual, (May 2004) no documen- tation package nor any application for a certificate of compliance has been submitted to the HGMA, nor has a certificate of compliance been issued by the HGMA.
  • Page 10 In view of the unpredictable nature of spins and spin recovery, Wills Wing recommends that no attempt should ever be made to deliberately spin the glider. The Sport 2 provides the pilot with a high degree of pitch authority, in combination with a very low twist sail. As a...
  • Page 11 Wills Wing is well aware that pilots have in the past, and continue in the present to perform maneuvers and fly in conditions which are outside the recommended operating limitations for their gliders.

  • Page 12: Sport 2 Reassembly After Shipping And Breakdown For Shipping Procedures

    Sport 2 Reassembly After Shipping and Breakdown for Shipping Procedures The Sport 2 can often be shipped full length, without having the rear leading edges removed. If your glider has been "broken down" for shipping, follow these procedures to reinstall the rear leading edges. The front leading edge is 50mm (1.97") oversleeved with 52mm (2.05") at the nose and crossbar junction.
  • Page 13 bracket is on the inside of the leading edge, and slide the rear leading edge forward, rotating as necessary, until the slot in the rear leading edge engages securely on the pin in the front leading edge. When the rear leading edge is fully engaged, you will not be able to rotate it. 5.

  • Page 14: To Remove The Rear Leading Edges For Shipping Follow These Steps

    To remove the rear leading edges for shipping follow these steps This process will basically be the reverse of installing the rear leading edges after shipping. Before beginning, read through the section above on how to reinstall the rear leading edges. While following the instructions below, refer to the photos in the section above for reference, if necessary.

  • Page 15: Sport 2 Set-Up Procedure

    Sport 2 Set-Up Procedure A number of set up operations are made easier by the use of the Set-Up Tool - a six inch length of 3/4" tubing included with your glider. 1. Lay the glider on the ground, with the bag zipper up, with the bag at right angles to the wind. 2.
  • Page 16 7. Wills Wing convention is that black tipped battens go in the right wing and white tipped battens in the left. Top surface cambered battens are numbered from the tip inwards, and the shortest cambered batten in a Sport 2 is designated as the "#2"...
  • Page 17 into the ground when installing or removing the battens. When working with the longest inboard batten it is helpful to lift the rear end of the keel slightly, and also to insert the batten initially upside down, flipping it over after it is inserted about a quarter of the way.
  • Page 18 (Note: The purpose of aligning the wand in this way is to extend the service life of the wand - see Wills Wing Technical Bulletin TB20040424 - available at www.willswing.com - for more information.) Working from the front side of the leading edge, facing the glider, hold the end of the leading edge tube from underneath in one hand and grasp the wand lever and cup in the other hand.
  • Page 19 but to follow the procedure before tensioning the crossbar. The other is to install the wands and wand cups before installing any battens or tensioning the crossbar. To do this, install the wand into the wand receptacle as described above. Then, sitting on the ground with the wing tip in front of you, grasp the wand in one hand and the cam lever pull string in the other hand.
  • Page 20 If you do have a failure of the locking hook on the lever portion, simply pop the hinge apart and pop on a new lever part. It is also possible, though less likely, to break the forward portion of the tip.
  • Page 21 14. The next step is to deploy the sprogs and secure them in position. Before doing so, working through the sprog access zippers, preflight the following items: a. The remaining internal ribs to confirm that they are fully zipped up. b.
  • Page 22 16. With the center zipper open, look inside the sail to preflight the following items: a. The crossbar center section, including the crossbar hold down rope, the sweep wire hinge bracket attachment to the crossbar, and the hinge bracket center hinge pin, push nut and safety ring, b.

  • Page 23: Preflight Procedure

    Preflight Procedure Along the left leading edge Carefully check the entire length of the leading edge pocket to insure that the Mylar insert is lying flat in the pocket. If any section of the Mylar is folded under, de-tension the crossbar, remove the batten closest to the area of distortion, and unfold the Mylar.

  • Page 24: From The Rear Keel

    Check that all battens are properly secured. Check that the sprogs are properly secured in position supporting the transverse battens, that the transverse battens are properly located and secured in the sail, and that the sprog access zippers are properly closed. Check that the bridles are properly engaged, with the plastic retainer balls fully seated against the grommets, and that no bridle cable is hooked underneath a more inboard batten.

  • Page 25: At The Nose

    Check the sweep wire for wear and damage between the crossbar hinge brackets and where it passes by the kingpost. Check the kingpost base bracket attachment to the keel. Verify that the locknut and screw that secure the rear pulleyblock shackle to the sweepwire spreader bar are secure.

  • Page 26: Launching And Flying The Sport 2

    Launching and Flying the Sport 2 Before launching, hook in to the glider and do a careful hang check. We recom- mend that you hang as close to the basetube as possible - this will give you lighter control pressures and better control in both roll and pitch. 1.

  • Page 27: Using Wing Tufts To Find The Minimum Sink Speed Of Your Glider

    Using wing tufts to find the minimum sink speed of your glider Your Wills Wing glider has been equipped from the factory with short yarn tufts on the top surface of each wing. The shadow of these tufts will be visible through the sail. The tufts are useful for indicating the local reversal of the airflow which is associated with the onset of the stall in that portion of the wing.
  • Page 28 To find the glider’s minimum sink speed, fly the glider in smooth air, early in the morning or late in the afternoon. When you are well away from the terrain, and well clear of other aircraft, look up at the wing tufts while you very gradually reduce the speed of the glider.
  • Page 29 Also be aware that in some thermalling situations, such as when trying to maximize climb rate in a thermal with a very strong and very small core, there may be an advantage in overall effective climb performance to flying so slowly that some portion of the inside wing is partially stalled most of the time.

  • Page 30: Platform Towing

    Platform Towing Special care must be taken in any form of towing. In particular, in platform towing, it is critically important that the nose line be attached so that there is no possibility of inducing a spontaneous disengagement of the bottom front wires. In particular, there must be no way that the nose line can pull forward on the nose wires, the nose tang, or anything attached to either.

  • Page 31: Aerotowing

    Aerotowing The Sport 2 aertows fairly easily as compared with other gliders in its performance class. We recom- mend that the VG be set to 50% prior to launch. This reduces pitch pressures, slows the roll response of the glider, and provides the best qualitative flight characteristics for flying in formation with the tug at normal aerotow speeds.

  • Page 32: Trimming Your Glider In Pitch

    Trimming Your Glider in Pitch You will find that the on the Sport 2 the basetube position at trim changes with VG setting. At VG loose the glider will trim with the bar farther out, and as VG is pulled on, the basetube trim position will move back.

  • Page 33: Speeds To Fly And Using Your Airspeed Indicator

    Speeds to Fly and Using Your Airspeed Indicator The Wills Wing Hall Airspeed Indicator has been specially designed to help you fly your Sport 2 at the proper speeds for optimum safety and performance, and is a recommended option for your glider.

  • Page 34: Using The Vg System

    Using the VG System The Sport 2 VG system uses a reduction system of pulleys both inside the sail behind the crossbar center, and also inside the right downtube. Tightening the VG increases the spanwise tension which the airframe places on the sail, reducing the spanwise twist and the sail elasticity. The result is an increase in L/D performance and a reduction in roll control authority and roll control response.

  • Page 35: Landing The Sport 2

    Landing the Sport 2 The following discussion assumes that you are executing the landing without the aid of a drag device such as a drogue chute. At the end of this section, we will discuss the use of drag inducing devices. We recommend using an aircraft landing approach (45 entry leg, downwind leg, base leg, and final leg) whenever possible, and we suggest that you practice making your approaches with as much precision as possible.
  • Page 36 while at the same time suddenly increasing the glider’s sensitivity to control inputs. The result is a high probability of overshooting the intended landing point and the prospect of roll / yaw oscillations which may interfere with a proper landing. Once established on a straight final approach, with wings level and flying directly into the wind, you should fly the glider down to where the basetube is between three and six feet off the ground.
  • Page 37 put a foot down, and step onto the ground. In lighter winds, you will want to use some combination of a final nose up flare, and running out your landing, in order to finish the flight on your feet with the glider settling on your shoulders.

  • Page 38: Using Drag Devices During Landing

    Wills Wing manufactures a drogue chute that attaches to the pilot’s harness on one side, and deploys and flies off to one side behind the pilot attached to a very short bridle that keeps it inside the keel and the trailing edge of the sail.
  • Page 39 in doubt, because with the drogue chute you have limited ability to extend (flatten) your glide, but very good ability to reduce (steepen) it. For example, in the normal glider configuration, if you were ap- proaching at best L/D speed into a head wind, and were coming up short, you would speed up. With the drogue, speeding up will primarily degrade your glide and will not get you significantly more distance.

  • Page 40: Sport 2 Breakdown

    Sport 2 Breakdown Breakdown of the glider is essentially the reverse of assembly. 1. Unzip the sprog access zippers all the way to the leading edge end of the zippers. This should be your first step when you break down. If the sprog zippers are not unzipped fully when you remove the battens, the sail may catch on the end of the sprog and damage the sail or the zipper.
  • Page 41 8. Fold the wings all the way in to the keel pulling the sail over the top of the leading edges. At this time you should be able to dismount the front end of the nose batten from the top of the keel. Lift up on the batten to disengage them from the stud, and then pull the tip clear of the stud and pull the batten partly out of the pocket.
  • Page 42 11. At the wingtips, lay the sail at the tip out flat, and fold the tip of the sail forward over onto the bottom portion of the sail. Working from the trailing edge, roll the sail tightly to the leading edge, and install the tip cover bag.

  • Page 43: Sport 2 Stability Systems

    Measure the height of each thread relative to the top of the keel tube. The results should be as follows: Outer (Sprog) Thread Inner (Bridle) Thread Sport 2 155 at least 6.25" (158 mm) above keel at least 6.25" (158 mm) above keel — 37 —...

  • Page 44: Method Of Adjustment

    5. Note that this method will not disclose sprogs that are asymmetric. If, after achieving the proper measurement, you have a turn in the glider which is only present at tighter VG settings, lower the sprog on the side the glider is turning towards, and raise the other sprog by the same amount. Method of adjustment 1.

  • Page 45: Test Flight

    If you have a question about the need to repair or replace some part of your glider, feel free to contact your dealer or Wills Wing directly. It is not always obvious which items require attention and which may not. Minor dents or dings in a non critical location on an airframe tube may not require any repair or maintenance.

  • Page 46: Parts Ordering And Parts Replacement

    Wills Wing policy requires, for safety reasons, that replacement parts be ordered through an authorized Wills Wing dealer. The purpose of this policy is to insure that the parts will be delivered to someone who has the required expertise to install the parts properly. We have seen multiple examples of incidents in which a pilot's life was endangered as a result of the incorrect installation of replacement parts, or incorrect assembly of a glider.

  • Page 47: Ever Year

    The normal sprog cable length is shown below. Any cable which exceeds this measurement by more than 3/32" should be replaced. Sport 2 155: Sprog Wire 25.1" (Rear tang rivet center to center of LE mounting bolt). There are three hinge mechanisms in each sprog assembly that must be free to swivel. One is the cable attachment to the leading edge.

  • Page 48: A Note About Cables And Cable Maintenance

    stains with any commercial spot remover that is labeled for use on polyester. Such cleaning agents are available at the supermarket or drug store, or you may order a cleaning solution from Wills Wing through your dealer. A note about cables and cable maintenance The cables which support the glider’s airframe are critical components of the glider’s structure, and must be maintained in an air worthy condition.

  • Page 49: Removing The Sail From The Airframe And Re-Installing

    Removing the Sail from the Airframe and Re-Installing Many maintenance and repair procedures will require the removal of the sail from the frame. Please follow these instructions when removing and reinstalling the sail. Please read all the instructions for each operation before beginning. Sail removal You will need an unobstructed area six feet by thirty feet.

  • Page 50: Reinstalling The Sail On The Frame

    Reinstalling the sail on the frame 1. Install the Mylar in the sail. Make sure you install it right side up; the slit edge is at the front and on the bottom. The easiest way to install the Mylar is to push it into the pocket using a long lofting batten attached to the end of the Mylar insert which is first inserted in the pocket.
  • Page 51 16. Attach the bridles to the trailing edge. Finish the assembly of the glider completely according to normal assembly procedures. 17. Do a very careful and complete preflight of the glider according to the normal preflight procedure as explained earlier in this manual. —...

  • Page 52: Glider Tuning

    Glider Tuning CG adjustment This has already been covered in the section of this manual on using your wing tufts. Wills Wing recommends that tuning other than CG adjustment be performed by your Wills Wing dealer. Turn trim Turns are caused by an asymmetry in the glider. If you have a turn, first try to make the glider sym- metrical in every way.

  • Page 53: Twisting A Tip

    4" adjustments are available) or by shortening the tip wands. A one eighth of an inch difference (3mm) in the length of the tip wand can make a noticeable difference in how a glider handles. If you have a glider that is a little too stiff, you might try shortening the wands by an eighth inch. You should also check the relationship between the tension is the sail mount strap at the aft end of the leading edge, and the tension as taken by the tip wand.

  • Page 54: Car Top Mounting And Transport

    Car Top Mounting and Transport Improper or careless transport of your glider can cause significant damage. You should transport your glider on a rack which has at least three support points which span at least 13' of the length of the glider.
  • Page 55 In the end, however, making the more conservative decision will mean you’ll still be around to fly another day. Have fun. Fly safely. See you in the sky! Wills Wing, Inc. www.willswing.com — 49 —...

  • Page 56: Hgma Sport 2 155 Compliance Verification Specification Sheet

    HGMA AIRWORTHINESS STANDARDS HGMA Sport 2 155 COMPLIANCE VERIFICATION SPECIFICATION SHEET GLIDER MODEL: Sport 2 155 MANUFACTURED BY: Wills Wing, Inc. All dimensions in inches; weights in pounds. NOTE: These specifications are intended only as a guideline for determining whether a given glider is a certifIed model and whether it is in the certified configuration.
  • Page 62 Item Part No Part Name QTY. 40K-1323 KINGPOST STRM KP HANG W/BRKT 15J-1502 AT KINGPOST POLYCARB 15J-1501 AT KINGPOST TOP POLYCARB 20G-2323 KINGPOST TOP INSERT AT ALUM 10M-1361 SCREW 6/32 FLSTR MACH HEAD SS 10T-1121 SPACER AL .313 X .028 X 1.140 10T-5132 BUSH FGLASS .414 X .337 X 1.0 10C-5201...

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