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Luscombe N1901K,

November 1, 2010, Tach 1219.0, TTAF 2489.53 (corrected TTAF see this entry)

 

Dismantled aircraft. Removed wings, doors, empennage, landing gear assembly, control cables, panels, cowl, engine, instruments, fuel system, and all wiring from fuselage.

 

Corrected TTAF in log book based on logs and tachometer time based on discrepancy discovered in 1996. Tachometer was installed at 1270.53 in June, 1961. Tachometer reading when the aircraft was dismantled was 1219.0. The correct TTAF based on TTAF when the tachometer was installed and the final tachometer reading is 2489.53.

 

Luscombe N1901K, Tach 3998.6, TTAF 2489.53

 

Installed tachometer with markings for a Continental O-200 with a reading of 3998.6.

Empennage:

Disassembled horizontal stabilizer, installed zinc chromated, tubing reinforcements per AD 49-43-02, installed new SS trim cables and casings, P/N AN8016-3-36, RR upper skin P/N 58472-2, lower skin 58472-3, L/R leading edges 58472-5,58472-4, cleaned and applied self etching primer to all internal surfaces, installed new hinge brackets (P/N 18416-6), hinges (P/N 18441), and washers.

 

Opened vertical stabilizer, cleaned, inspected, applied self etching primer to all internal surfaces, installed new hinge brackets (P/N 18416-6), hinges (P/N 18441), and washers, Removed VOR antenna.

 

Installed Whelen 7105500 anti-collision LED light, P/N 01-0771055-00, S/N 0569, TSO-C96a Class III, IAW AC43.13-2A Chapter 4 and Whelen installation instructions. Modified rudder cap to provide clearance for anti-collision light. (see 337 dated November 3, 2010)

 

Installed new Luscombe, square rudder, P/N 08492, including Grimes aft navigation light, P/N S-ATC 20.

 

Removed Luscombe tailwheel, installed Scott 3200-00 tailwheel, P/N 1306, Scott tailwheel adapter, connector spring and chains (P/N 2151) per AVOX/Scott installation instructions. Lubricated with #2 grease per AVOX/Scott installation instructions. (see 337 dated November 3, 2010)

 

New wires to rear navigation light, anti-collision light.

RR Elevator pulleys with new pulleys and bushings

RR Stabilizer fairings, P/N 48404, 48404-1

RR all bolts, nuts, washers, eye bolts, clevis bolts, adel clamps, as appropriate

Alodize, prime, and paint all exterior aluminum surfaces prior to assembly.

Empennage installed, assembled, and rigged per Luscombe Operator's Handbook.

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Under floor:

RR all bolts, nuts, washers, adel clamps, as appropriate

RR brake cables

RR all brake cable pulleys, P/N AN210-1B

RR all brake pedal pads, P/N 19519-1

All cleaned and lubricated all moving pieces.

Adjusted parking brake cable tension.

Replaced heated and fresh air control cables with serviceable units.

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Aileron Control:

RR all bolts, nuts, washers, eye bolts, cotter pins, clevis pins, as appropriate

RR all pulleys A-120 (8), bushings AN211-2 (8)

RR all fairleads 18102, 181075

Pulley movement, clearance, and side play were inspected post assembly.

Aileron cables inspected for wear and failure. All cables were serviceable.

Control cable tension and control rigging set per Luscombe Operator's Handbook.

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Elevator Control:

RR all bolts, nuts, washers, eye bolts, cotter pins, clevis pins,

RR all pulleys AN210-3A (2), A-167 (2), bushing 18532-4

All bushings lubricated at assembly.

Pulley movement, clearance, and side play were inspected post assembly.

Elevator and trim cables inspected for wear and failure. All cables were serviceable.

Elevator trim indicator was set to read 0 when the trim tab was in the neutral position.

Control cable tension and control rigging set per Luscombe Operator's Handbook.

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Rudder Control:

RR all bolts, nuts, washers, eye bolts, cotter pins, clevis pins, as appropriate

RR all pulleys A-120 (2), A-167-SF (2), bushing AN211-2 (4)

RR springs 08511-10 (2)

RR rudder pads 19518P (4)

Pulley movement, clearance, and side play were inspected post assembly.

Control cable tension and control rigging set per Luscombe Operator's Handbook.

 

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Ailerons:

RR all bolts, nuts, washers, cotter pins, clevis pins, as appropriate

Repair P/N 58283-4, remove cracked and deformed segment, and form and splice patch, repair perform ICW AC 43.13.1B.

While stripped of all paint and primer, ailerons were inspected for cracks, corrosion, and damage. No cracks or corrosion were detected. The only repair required is documented above.

Alodize, prime, and paint all exterior aluminum surfaces prior to assembly.

Ailerons installed per Luscombe Operator's Handbook and Parts Manual.

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Doors:

RR all bolts, nuts, washers, cotter pins, clevis pins, door handles, as appropriate

Repair door frames, P/N 48051-99, 48051, replace defective tubing, fit door frames to airframe

Fabricate new exterior door skins P/N 18053-4, 18053-3 to fit frames

Fabricate new interior door skins to fit frames

Fabricate new door bolt catches, P/N 18829

Fit door handles to mechanism, drill one hole for roll pin to secure handle in correct orientation.

Install new windows

Alodize, prime, and paint all exterior aluminum surfaces.

Primed and painted all steel surfaces.

Assemble and install doors.

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Fuselage:

RR all bolts, nuts, washers, cotter pins, eye bolts, clevis pins, as appropriate

Remove Tail Tray P/N 28104, thoroughly clean, inspect, and prime aft most bay, install tail tray with same size rivets as removed.

Thoroughly clean, alodyne, prime with self-etching, epoxy primer

RR "D" windows P/N 19139

Remove baggage floor (09165) and hat throw shelf (59171-2), install extended baggage floor (see 337 dated November 3, 2010)

RR top center skin 08043-1700, match drill new sheet from undamaged old skin.

RR super structure cabin roof 08011-3, make roof from T-3, match drill from undamaged old part, install doubler for sky light

 

Clean spar front super structure (28018-2) and spar rear super structure (28019-2), thorough inspection, anodized, paint with self-etching primer as alternate compliance for AD 55-24-01,

 

Remove instrument panel (081030-102) and fabricate and install a new and better instrument panel (see 337 dated November 3, 2010.) Original panel was 0.040, 2024 type O. New Panel is 0.063, 2024 type T-3.

 

Install Firewall reinforcement (281023) and (181032-3) on port and starboard sides of firewall per Larsen Industries 150 H.P. STC STC-3A344CE (partial).

 

Installed new windshield, Great Lakes Aero, P/N SC-W/G-2033, ICA see aircraft P.O.H. or Luscombe service manual.

Install new heated air and fresh air flapper valve box assemblies on the firewall.

All interior surfaces thoroughly cleaned and painted with self-etching epoxy primer.

Alodize, prime, and paint all exterior aluminum surfaces.

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Landing Gear:

RR all bolts, nuts, washers, cotter pins, clevis pins, as appropriate

Remove entire assembly. Clean, inspect, self-etch prime, and paint.

Replace bushings (AN380-3, AN380-2)

Install new S-9 fork ends

Cleaned and zinc plated oleo spring 28309-2, piston tube assembly (28308-500)

Overhauled the oleo assembly with new garlock packing (#431), packing nut (18329-2)

Assembled and installed landing gear assembly per Luscombe drawings

Removed brake linings, installed new brake linings.

Installed Goodyear Flight Special II 600x6, 6 ply tires, and tubes, torqued wheel through-bolts to spec, inflated tires to 20 psi.

Inspected and lubricated wheel bearings.

Assembled and installed landing gear.

Serviced Oleo with 30 wt (Mobil 90 equivalent) oil, and #2 grease in bushings

Adjusted brake cables.

Verified brake operation.

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Wings:

Remove fuel tanks.

Thoroughly clean wings, inside and out.

Inspect wings and spars per AD 96-24-17 R1, "Appendix to AD 96-24-17 R1". No corrosion found.

RR aileron pulleys, bushings, nuts, bolts as discussed in "Aileron Control".

Deformations in leading edge were removed, minimal glazing required.

Remove all fuel fittings from fuel tanks. Cleaned tanks.

Fuel tank cavity (in wing) thoroughly cleaned and painted with self-etching epoxy primer.

Installed fuel tanks with new felt and all new fuel fittings.

Fabricated new fairings (482154-4, 482154-5, 582209-2, 582209-3)

Replaced defective landing light and navigation light wiring.

Install wings, struts, fairings per Luscombe Operator's Handbook and Parts Manual.

Aileron control rigging discussed in "Aileron Control".

Attached electrical wires, navigation lights, landing lights. Verified operation.

Alodize, prime, and paint all exterior aluminum surfaces.

 

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Avionics:

Install Airgizmo and Garmin 196 in radio stack and GA-56 antenna with doubler in cabin roof. Install RG-142 coax for GPS antenna.

Install Garmin GTX-320A transponder (S/N 83810808) and Trans-Cal altitude encoder P/N SSD120 in radio stack. Install transponder antenna, doubler, and new antenna coax.

Install Commant CI-101 VHF radio antenna with doubler in cabin roof. Install RG-142 coax for VHF.

Install new speaker in wing root.

Install Flightcom 403 intercom in radio stack.

Install intercom headset jacks, microphone jacks, push-to-talk (PTT) switches in control sticks, speaker/intercom switch.

Install ICOM, A-200 in radio stack, wire to intercom and speaker/intercom switch

Installed radio stack into airframe.

Verified VHF transceiver operations, transponder, GPS, intercom, PTT, speaker/intercom switch, dimmers, radio master. No defects detected.

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Other:

Inspected all control cables per AD 51-10-02

Installed new Gill 35 battery per Gill installation instructions.

Installed vertical card compass. Measured and recorded directional deviation.

Paint aircraft (most components painted prior to assembly.

Reupholster the seats, side panels, headliner, door seals, and carpet with aviation grade materials.

Install new ELT batteries. New RLT batteries due November 1, 2012.

Install wiring, switches, circuit breakers, dimmers ICW AC 43.13.1B, Chapter 11.

Install vacuum instruments, directional gyro, attitude indicator, suction gauge.

Remove clean and lap fuel valves.

RR all rubber fuel hoses.

RR all vacuum and static hoses and fittings.

Install Mitchell PMA 0-250 Fahrenheit Oil temperature gauge and sender

Install Mitchell PMA 0-80 PSI Oil pressure gauge and sender

Install Mitchell Amp-meter

 

 

Install:

MFG

Description

Part Number

Serial Number

Mitchell

oil pressure gauge

 

D1-211-5052

1199

Mitchell

oil temperature gauge

 

D1-211-5088

1391

Mitchell

amp meter gauge

 

 

 

 

Cessna

Tachometer (3998.6)

 

 

Cessna

Vacuum filter and regulator assembly

 

 

Bendix

Key start, magneto switch

 

 

Cessna

Primer

 

 

AIM

Attitude Indicator

300-3FC

2403

Cessna

Directional Gyro

 

 

EGC

Turn Coordinator (T&B)

1394T100

772-880

Trans-Cal Industries

Altitude Encoder

SSD120

A60170

United

Altimeter

5934P-1-A56

E9589

ACK

ELT

E-01

 

Garmin

Transponder

GTX-320A

83810808

Flightcom

Intercom

403

 

ICOM

Radio Tranceiver

A200

630982

AirGizmo

Portable GPS panel mount

396-496

 

 

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Engine Replacement:

 

Removed Continental C-90 engine and installed Continental O-200-A, S/N 214652-72A, in accordance with 43.13.1 and FAR 43 based on existing field approval date 09/10/1987 and alteration approval dated 09/03/1987. Installed using 2024 aluminum bushings as noted in alteration approval attached with 337. Updated nose bowl to provide clearance for vacuum pump. See 337 dated November 3, 2010.

 

Installed a Steve"s Aircraft gascolator, P/N SA3-00, S/N 1436 per STC SA1026SE. See 337 dated November 3, 2010.

 

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Engine:

 

Replace magneto points, internally time magnetos per Unison magneto documentation.

 

Install magnetos engine per Continental documentation, and time to 24 degrees per AD.

 

Install new intake tube seals (inner and outer).

 

Fabricate mixture control cable / primer fuel line support

 

Install new SS exhaust system for Continental powered Silvaire

 

Install new heat muffs, Univair.

 

Convert aircraft from generator to 50 amp alternator

 

Verified operation of Rapco, RA211-9 vacuum pump.

 

Installed a Brackett BA-4106 air filter assembly per Brackett STC-S71GL List No. 1, FAA-PMA Supplement No. 1, installation instructions.