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RotorWay Exec 162 Construction Manual

Standard construction procedures
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RotorWay International
Section 1
Exec 162F Construction Manual
Page A
Section 1
Standard Construction
Procedures
Procedures covered in this section:
Proper use of tools; general fitting and alignment procedures; aircraft (AN) hardware; working with 4130 steel; working
with aluminum; working with plexiglass; working with fiberglass; working with plastic filler (Bondo); painting and finishing;
plating and anodizing; Dzus fasteners and nut plates.
Cards used in this section:
None
Prints used in this section:
None
Templates used in this section:
None
Tools required for this section:
None

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Summary of Contents for RotorWay Exec 162

  • Page 1 RotorWay International Section 1 Exec 162F Construction Manual Page A Section 1 Standard Construction Procedures Procedures covered in this section: Proper use of tools; general fitting and alignment procedures; aircraft (AN) hardware; working with 4130 steel; working with aluminum; working with plexiglass; working with fiberglass; working with plastic filler (Bondo); painting and finishing;...
  • Page 2 Section 1 RotorWay International Exec 162F Construction Manual Page B...

  • Page 3: Proper Use Of Tools

    RotorWay International Section 1 Exec 162F Construction Manual Page 1 Rev. 1 3/99 1. PROPER USE OF TOOLS A. Drills and Reamers 1. When a very close tolerance fit is required, use a “D” drill (.246") for drilling 1/4" AN bolt holes. 1/4" AN bolts are normally .003"...
  • Page 4 1. The press fit. A press fit is one which requires a press to install the bearing. It may take anywhere from one hundred to several hundred pounds of pressure to press the bearing on the shaft. RotorWay does not expect the builder to work with this type of fit because it will make assembly impossible for a builder in the field.
  • Page 5 RotorWay International Section 1 Exec 162F Construction Manual Page 3 H. The bolt “grip length” is the unthreaded portion of the bolt shank and should always be correct. Normally the grip length is equal the thickness of the objects being bolted together, though bolts of slightly longer length can be used with washers.

  • Page 6: Working With Fiberglass

    Section 1 RotorWay International Exec 162F Construction Manual Page 4 Rev. 1 8/00 4. WORKING WITH 4130 STEEL A. Bracketry 1. Cut brackets to size using the templates supplied. If there is a grain direction specified on the template, paste the label on the material in that orientation.

  • Page 7: Painting And Finishing

    Airframe and landing gear: sandblast with fine grit sand, 2 part epoxy paint. 10. PLATING AND ANODIZING Contact RotorWay for recommendation of items that you want to plate or anodize. For example, a high stress item cannot be plated. Have the plating done ONLY by a company qualified to plate aircraft parts.
  • Page 8 Section 1 RotorWay International Exec 162F Construction Manual Page 6 DZUS BUTTONS Photo #1 Use a hand drill to open the 1/8" hole to 5/16" for the Dzus button. Photo #2 Make a drill template from a strip of flat metal, 1-3/4"...
  • Page 9 RotorWay International Section 1 Exec 162F Construction Manual Page 7 Photo #4 Use a large drill bit to countersink the 1/8" pop rivet holes. Photo #5 Use a hand drill and a 3/8" bit to open the Dzus button hole. Then install the spring wire with pop rivets.
  • Page 10 Section 1 RotorWay International Exec 162F Construction Manual Page 8 Photo #7 Install the Dzus button. Photo #8 Place the head of the Dzus button on a hard surface, and place the open end of the tool over the shank of the Dzus button. Hit the pointed end of the tool to lock the Dzus button to the grommet.
  • Page 11 RotorWay International Section 1 Exec 162F Construction Manual Page 9 Photo #10 Use a screwdriver to turn and free up the Dzus button. NUT PLATES Photo #11 Two or more parts held together with cleco. Photo #12 When installing a nut plate, hold it with a cleco.
  • Page 12 Section 1 RotorWay International Exec 162F Construction Manual Page 10 Photo #13 Use the nut plate as a template and drill the holes for the pop rivets. Photo #14 Using a large drill bit, countersink the holes for the pop rivets. Use a hand drill and open the hole for the size of screw or bolt to be used.
  • Page 13 RotorWay International Section 1 Exec 162F Construction Manual Page 11 Photo #16 When installing several nut plates, it is recommended to make a drill template from a flat strip of metal, 1-3/4" wide and 6" long. Drill a hole in the center close to one end for the size of screw being used.