Section 1, Bulkhead Assembly, SeaRey, LSA

Progressive Aerodyne, Inc.

3801 State Rd 19
Tavares, FL 32778

Document Number
Revision Description Remarks Date
12212011 Update Added page 10, showing bracket install on upper bulkhead 12/21/2011
09012012 Update Corrected Pgs 11, 16 photo captions, Pg 14 Step 8.5, Pg 16 changed 09/01/2012
bolt size and added washers, Pg 18 Step 12.1.
09102012 Update Corrected Pg 18, added step 12.3 bolt 09/10/2012
09272012 Update Corrected Pg 21, adjusted direction of bolt and order of parts 09/27/2012
11192012 Update Pg 7, 1.3; pg 10, 4.2; pg 12, 6.2; pg 13, 7.3; pg 15, 9.1; pg 18, 12.2 11/19/2012
04242013 Major Review Builder check verifying build, parts and quantities 04/24/2013
05102013 Update Corrected bolt size on pg 3 05/10/2013
05112013 Update Pg 6, new channel bracket 3 ½” 05/11/2013
08072013 Update Pg 14, added new part. Gear Leg Spacer Pad 08/07/2013

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 Section 1, Bulkhead Assembly, SeaRey LSA

1.0 Scope
This document will detail the steps necessary to assemble a SeaRey LSX Bulkhead assembly up through the Electric Gear Installation, but not
including the forward cockpit or assemblies aft of the bulkhead.

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:
 3/32 Drill Bit
 3/16” Drill Bit
 3/8” Drill Bit
 Awl
 Drill
 Hammer, Plastic
 Screwdriver, Phillips
 Socket , 3/8”
 Socket, 7/16”
 Socket , 1/2”
 Socket , 9/16”
 Tap, #4-40
 Wrench, 3/8” Open End
 Wrench, 7/16” Open End
 Wrench, 1/2” Open End
 Wrench, 9/16” Open End

3.2 Materials
The following general supplies will be necessary to perform this procedure:

 N/A

3.3 Procedure (see the following Instructions)

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 Section 1, Bulkhead Assembly, SeaRey LSA

Channel Bracket, 1 ¼” x 3 ½” 5330-026

Bolt AN4-24A N424A

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 Section 1, Bulkhead Assembly, SeaRey LSA

Bulkhead
Cross Tube,
Lower Bolt, AN4-24A

Channel
Bracket, 1-3/4”
Forward
Bolt, AN3-24A

Drill 3/16” Hole

Figure 1. Attaching Tail Wheel Channel Bracket to the Aft Side of the Lower Bulkhead

1.1 Place a Washer, AN4 (#N4W) over a Bolt, AN4-24A (#N424A) and insert through Channel Bracket, 1-3/4” (#5310-016). Insert the Channel
Bracket Assembly with bolt through the third 1/4” hole from the end of the Bulkhead Cross Tube, Lower (#5310-003).
1.2 On the forward side of the Bulkhead Cross Tube, Lower (#5310-003), place a Washer, AN4 (#N4W) and Nut, AN4 Lock (#N4LN) on the
bolt and tighten.
1.3 Approximately 1/4” from the bottom wall of the Channel Bracket, 1-3/4” (5310-016), drill a 3/16” hole completely through in line with the
Bolt, AN3-24A (#N424A) toward the bottom edge of the Bulkhead Cross Tube, Lower (#5310-003). Note: Square up channel bracket
with the Bulkhead Cross Tube, Lower
1.4 Place a Washer, AN3 (#N3W) over a Bolt, AN3-24A (#N324A) and insert through Channel Bracket, 1-3/4” (#5310-016) and Bulkhead
Cross Tube, Lower (#5310-003).
1.5 On the forward side of the Bulkhead Cross Tube, Lower (#5310-003), place a Washer, AN3 (#N3W) and Nut, AN3 Lock (#N3LN) on the
bolt and tighten.

Note: Torque Value on the AN3 bolts in this section should be between 15 inch lbs and 25 inch lbs of torque.
Note: Torque Value on the AN4 bolts in this section should be between 60 inch lbs and 70 inch lbs of torque.

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 Section 1, Bulkhead Assembly, SeaRey LSA

Aft
Bulkhead
Cross Tube,
Lower

Channel
Bracket, 1-3/4” Bolt, AN4-24

Cable Pulley

Figure 2. Installation of Tail Extension Pulley

2.1 Insert Tail Extension Cable Pulley (#3230-071) into Channel Bracket, 1-3/4” (#5310-016). Place a Washer, AN4W (#N4W) over a Bolt,
AN4-24 (#N424) and insert through the Channel Bracket, 1-3/4” (#5310-016), Tail Extension Cable Pulley (#3230-071), Channel Bracket,
1-3/4” (#5310-016), Washer, AN4W (#N4W), and Nut, Castle AN4 Lock (#NAN310-4) and tighten. Check that pulley rotates freely within
the Channel Bracket, 1-3/4” (#5310-016) and install the Cotter Pin.

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 Section 1, Bulkhead Assembly, SeaRey LSA

Bolt, AN4-25A Forward

Channel
Bracket, 1-
1/4 x 3 1/2”
Channel Bracket,
1-1/4 x 3 1/2”

Forward Channel Bracket,

1-1/4 x 3 1/2”

Figure 3. Installation of the Channel Bracket (Hull Mount)

3.1 Using the only (2) 1/4” holes in the Bulkhead Cross Tube, Lower (#5310-003) viewable on the Top and Bottom sides, Install the Channel
Bracket, 1-1/4 x 3 1/2” (#5330-026). Install Bolt AN4-25A from the bottom side with a Washer AN4 through the Channel Bracket, 1-1/4 x 3
1/2” (#5330-026), Bulkhead Cross Tube, Lower (#5310-003)
3.2 On the top side, place a Washer, AN4 (#N4W) and Nut, AN4 Lock (#N4LN) on the bolt and tighten.
3.3 Repeat the above steps to the other side.

Note: Torque Value on the AN4 bolts in this section should be between 60 inch lbs and 70 inch lbs of torque.

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 Section 1, Bulkhead Assembly, SeaRey LSA

Forward

Bolt, AN4-26A

Channel
Bracket, 1 x 2”

Lower Cockpit Bulkhead

Channel Outboard Cross Tube,
Bottom Lower

Figure 4. Channel Brackets to the Lower Bulkhead

4.1 Place a Washer, AN4 (#N4W) over a Bolt, AN4-26A (#N426A) and insert through Lower Cockpit Channel Outboard (#5310-036).
4.2 Insert the Lower Cockpit Channel Outboard with bolt through the second hole from the end of the Bulkhead Cross Tube, Lower
(#5310-003) having the longer end from the ¼” hole in the bracket facing down.
4.3 On the aft side, place a Channel Bracket, 1 x 2” (#5330-003) over the bolt, followed by Washer, AN4 (#N4W) and Nut, AN4 Lock (#N4LN)
on the bolt and tighten.
4.4 Repeat the above steps to the other side.

Note: Torque Value on the AN4 bolts in this section should be between 60 inch lbs and 70 inch lbs of torque.

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 Section 1, Bulkhead Assembly, SeaRey LSA

Bulkhead
Cross Tube, Top
Upper

Channel Bulkhead Angle

Bracket, 1 x 2” – see Figure 7

Channel
Bracket, 1 x 2”

Aft Bolt, AN4-26A

Figure 5. Channel Brackets to the Upper Bulkhead

5.1 Place a Washer, AN4 (#N4W) over a Bolt, AN4-26A (#N426A) and insert through Channel Bracket, 1 x 2” (#5330-003).
5.2 Insert the Channel Bracket, 1 x 2” (#5330-003) with bolt through the second hole from the end of the Bulkhead Cross Tube, Upper LSA
(#5310-085).
5.3 On the aft side, place a Channel Bracket, 1 x 2” (#5330-003) over the bolt, followed by Washer, AN4 (#N4W) and Nut, AN4 Lock (#N4LN)
on the bolt and tighten.
5.4 Repeat above steps for opposite end of Bulkhead Cross Tube, Upper.

Note: Torque Value on the bolts in this section should be between 60 inch lbs and 70 inch lbs of torque.

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 Section 1, Bulkhead Assembly, SeaRey LSA

Top

Root Support
Mounting Angle

Center

Root Support
Mounting Angle

Bulkhead
Bolt, AN4-25A Cross Tube,
Upper

Figure 6. Attaching Root Support Mounting Angles to the Bulkhead Cross Tube, Upper

6.1 Place a Washer, AN4 (#N4W) over a Bolt, AN4-25A (#N425A) and insert through the longer leg of the Root Support Mounting
Angle (#5320-011).
6.2 Rotate the Bulkhead Cross Tube, Upper LSA (#5310-085) 90 degrees so that there are (4) 1/4” holes visible.
Insert the Root Support Mounting Angle (#5320-011) with bolt through the second hole from either end and install Washer, AN4 (#N4W),
Nut, AN4 Lock (#N4LN).
6.3 Repeat steps above with the second hole from the opposite end.

Note: Torque Value on the bolts in this section should be between 60 inch lbs and 70 inch lbs of torque.
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 Section 1, Bulkhead Assembly, SeaRey LSA

Bulkhead
Cross Tube,
Retraction Lower
Plate Lower

Top

Aft
Bolt, AN4-30A
Retraction
Plate Lower

Figure 8. Attaching the Retraction Plate, Lower, Hydraulic / Electric to the Pilot Side Bulkhead Cross Tube, Lower

8.1 Place a Washer, AN4 (#N4W) over a Bolt, AN4-30A (#N430A) and insert through the Retraction Plate, Lower Hydraulic / Electric
(#3230-017).
8.2 From the forward side of the bulkhead (Pilot Side), continue inserting the bolt through the fourth factory pre-drilled hole from the end
of the Bulkhead Cross Tube, Lower (#5310-003).
8.3 On the aft side of the Bulkhead Cross Tube, Lower (#5310-003), place a Retraction Plate, Lower Hydraulic / Electric (#3230-017)
over the bolt.
8.4 Add a Washer, AN4 (#N4W) and Nut, AN4 Lock (#N4LN) and tighten.
8.5 Repeat above steps for the opposite end of the bulkhead.

Note: Torque Value on the bolts in this section should be between 60 inch lbs and 70 inch lbs of torque.

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 Section 1, Bulkhead Assembly, SeaRey LSA

Bulkhead
Cross Tube,
Lower

Forward

Bolt, AN4-27A

Channel
Bracket, 1-3/4”
Torque Tube
Plate, Lower LS
Top

Figure 9. Attaching the Channel Bracket, Torque Tube Plate to the Bulkhead Cross Tube, Lower

9.1 Place a Washer, AN4 (#N4W) over a Bolt, AN4-27A (#N427A) and insert through the Channel Bracket, 1-3/4” (#5310-016) passing
through the Forward side of the Bulkhead Cross Tube, Lower (#5310-003) using the center ¼” hole in the Bulkhead Cross Tube, Lower
(#5310-003).
9.2 On the aft side of the bulkhead, continue inserting the bolt through the Bulkhead Cross Tube, Lower (#5310-003), mounting the
Torque Tube Plate, Lower LS (#2710-021), so the plate angles to the forward side over the Bulkhead Cross Tube, Lower (#5310-003).
9.3 Add a Washer, AN4 (#N4W) and Nut, AN4 Lock (#N4LN) and tighten.

Note: Torque Value on the bolts in this section should be between 60 inch lbs and 70 inch lbs of torque.

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 Section 1, Bulkhead Assembly, SeaRey LSA

Bulkhead
Angle, 3-3/8”

Top

Forward

Bolt, AN4-25A

Bulkhead
Cross Tube,
Upper

Figure 7. Attaching Bulkhead Angles to Bulkhead Cross Tube, Upper

Note: In the following steps make sure the angle faces forward toward the head of the bolt. This now designates the front side of
the Bulkhead Cross Tube, Upper (5310-085).

7.1 Place a Washer, AN4 (#N4W) over a Bolt, AN4-25A (#N425A) and insert through one hole of the Bulkhead Angle, 3-3/8” (#5420-
003).
7.2 Insert the Bulkhead Angle, 3-3/8” (#5420-003) with bolt through the Top first hole from either end and secure with Nut, AN4 (#N4LN).
7.3 Repeat steps above to the opposite end of the Bulkhead Cross Tube, Upper LSA (#5310-085).

Note: Torque Value on the bolts in this section should be between 60 inch lbs and 70 inch lbs of torque.

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 Section 1, Bulkhead Assembly, SeaRey LSA

Bulkhead
Pylon Gusset Forward

Bolt, AN5-26A

Bulkhead Cross
Tube, Upper Bolts for alignment
purpose only -
remove
Actuator Bolt, AN5-26A
Mount Plate

Figure 10. Attaching the Bulkhead Pylon Gusset to the Bulkhead Cross Tube, Upper

Note: In the following step, the Bulkhead Pylon Gusset has a bend. When mounted to the Bulkhead Cross Tube, Upper, the Bulkhead Pylon
Gusset ‘leans’ forward or away from the Cross Tube.

10.1 Place a Washer, AN5 (#N5W) over a Bolt, AN5-26A (#N526A) and insert through the Bulkhead Pylon Gusset (#5310-026).
10.2 From the forward side of the bulkhead, continue inserting the bolt through the seventh hole from the end of the Bulkhead Cross Tube,
Upper LSA (#5310-085).
10.3 On the aft side of the Bulkhead Cross Tube, Upper LSA (#5310-085), place the Actuator Mount Plate (#3230-072) onto the AN5 Bolt.
Add a Washer, AN5 (#N5W), Nut, AN5 Lock (#N5LN) and tighten.
10.4 Repeat steps for the opposite side of the bulkhead.

Note: Torque Value on the AN5 bolts in this section should be between 120 inch lbs and 140 inch lbs of torque.

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 Section 1, Bulkhead Assembly, SeaRey LSA

Bulkhead
Upright Gusset
Gear Leg Spacer
Pad
Goes here on
Bolt, AN4-7A both inboard sides Gear Leg
Spacer Pad

Bolt, AN4-7A

Fender
Washer

Bulkhead
Upright Angle Bolt, AN4-7A
Bolt, AN4-7A
Bolt, AN4-7A

Figure 11. Assembly of the Bulkhead Upright Angles to the Bulkhead Upright Gusset

Note: There are left and right Bulkhead Upright Angles for each assembly with a ¼” hole at top. Leave bolts loose until final assembly.

11.1 Assemble the Bulkhead Upright Angle, Left (#5310-053) to a Bulkhead Upright Gusset (#5310-055), using a Fender Washer, ¼”
(#FW100-14) over a (Qty 4) Bolt, AN4-7A (#N407A), Gear Leg Spacer Pad (#3230-115), Bulkhead Upright Gusset (#5310-055), Bulkhead
Upright Angle, Left (#5310-053), add a Washer, AN4 (#N4W), Lock Nut, AN4 (#N4LN) and leave loose.
11.2 Assemble the Bulkhead Upright Angle, Right (#5310-054) to a Bulkhead Upright Gusset (#5310-055), using a Fender Washer, ¼”
(#FW100-14) over a (Qty 4) Bolt, AN4-7A (#N407A), Gear Leg Spacer Pad (#3230-115), Bulkhead Upright Gusset (#5310-055), Bulkhead
Upright Angle, Right (#5310-054), add a Washer, AN4 (#N4W), Lock Nut, AN4 (#N4LN) and leave loose.
11.3 Repeat above steps to assemble Bulkhead Upright Angles/Bulkhead Upright Gussets for the remaining side of the bulkhead.

Note: Torque Value on the bolts in this section should be between 60 inch lbs and 70 inch lbs of torque.

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 Section 1, Bulkhead Assembly, SeaRey LSA

Bolt, AN4-31A Bolt, AN4-32A

Bulkhead Cross
Tube, Upper

Bulkhead
Upright Angle

Bolt, AN4-32A

Main Gear Bulkhead

Support Plate Upright
Gusset and
Main Gear
Support Plate
Bulkhead
Upright Gusset

Figure 12. Assembly of the Bulkhead Upright Angles/Bulkhead Upright Gussets to the Bulkhead Cross Tube, Upper

12.1 Attach the Bulkhead Upright Gusset/Bulkhead Upright Angles, Left and Right, (previously assembled in steps 11.1 - 11.3) to the Bulkhead
Cross Tube, Upper LSA (#5310-085), using a Washer, AN4 (#N4W) over a Bolt, AN4-31A (#N431A), and insert through parts, securing
with a Washer, AN4 (#N4W) and a Lock Nut, AN4 (#N4LN).
12.2 Assemble Main Gear Support Plates to Bulkhead Cross Tube Upper in this order: Bolt AN4-32A (#N432A), Washer, AN4 (#N4W), Main
Gear Support Plate (#3210-001), Bulkhead Upright Gusset, Bulkhead Cross Tube Upper, Bulkhead Upright Gusset, Main Gear Support
Plate (#3210-001), Washer, AN4 (#N4W), Lock Nut, AN4 (#N4LN).
12.3 Install bolt inboard of the previous installed bolt. Bolt AN4-32A (#N432A), Washer, AN4 (#N4W), Main Gear Support Plate (#3210-001),
Bulkhead Upright Gusset (5310-055), Bulkhead Cross Tube Upper, Bulkhead Upright Gusset, Main Gear Support Plate (#3210-001),
Washer, AN4 (#N4W) and Lock Nut, AN4 (#N4LN).
12.4 Repeat mirror image on the other end of the Bulkhead Cross Tube, Upper. Pay close attention to the Upright Angles Left and Right being
in the correct positions and tighten up all the bolts left loose on this page and the previous page.

Note: Torque Value on the bolts in this section should be between 60 inch lbs and 70 inch lbs of torque.

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 Section 1, Bulkhead Assembly, SeaRey LSA

Bulkhead
Upright Angle

Bulkhead Cross Bulkhead Cross

Tube Lower Tube Lower
Bolt, AN4-31A

Figure 13. Assembly of the Bulkhead Upright Angles/Bulkhead Cross Tube, Upper to the Bulkhead Cross Tube, Lower

13.1 Assemble the Bulkhead Cross Tube, Lower (#5310-003) to the lower portion of the Bulkhead Upright Angle using a Washer, AN4
(#N4W) over a Bolt, AN4-31A (#N431A), and insert through assembly securing with Washer, AN4 (#N4W) and a Lock Nut, AN4.
13.2 Repeat mirror image on the other end of the Bulkhead Cross Tube, Lower. Pay close attention to the Upright Angles left and right being
in the correct positions.

Note: Torque Value on the bolts in this section should be between 60 inch lbs and 70 inch lbs of torque.

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 Section 1, Bulkhead Assembly, SeaRey LSA

Bulkhead
Upright
Support Plate

Rivet, SB6-8

Figure 14. Bulkhead Assembly, Attaching the Bulkhead Upright Support Plate to the Upright Angles

14.1 Place the Bulkhead Upright Support Plate, (#5310-056) in position on the Bulkhead Upright Angles lining up the holes in the plate
with the holes in the angles.
14.2 Secure the Bulkhead Upright Support Plate, (#5310-056) to the Bulkhead Upright Angles using ten (10) Rivets, SB6-8 (#SP-66)
for each side.
14.3 Repeat steps for the remaining end of the bulkhead.

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 Section 1, Bulkhead Assembly, SeaRey LSA

Bulkhead
Diagonal Tube

Bolt, AN4-41A

Fender 1” Saddle
Washer
Forward

Figure 15. Attaching the Bulkhead Diagonal Tube to the Bulkhead Cross Tube Lower

15.1 Place a Washer, AN4 (#N4W) over a Bolt, AN4-41A (#N441A) and insert through the forward side Retraction Plate (previously installed),
Lower Hydraulic / Electric (#3230-017) and into the Bulkhead Cross Tube, Lower (#5310-003).
15.2 Coming through the aft side of the bulkhead cross tube, continue inserting the bolt through Retraction Plate Lower (previously installed)
into the fifth factory pre-drilled hole from the end of the Bulkhead Cross Tube, Lower (#5310-003).
15.3 On the aft side of the Retraction Plate, Lower Hydraulic / Electric (#3230-017), add a Fender Washer 1/4 x 1” SS (#FW100-14), Saddle, 1”
(#5310-024), Bulkhead Diagonal Tube (#5310-015), Washer, AN4 (#N4W) and Nut, AN4 Lock (#N4LN) and tighten.
15.4 Repeat steps for the opposite side of the bulkhead.

Note: Torque Value on the bolts in this section should be between 60 inch lbs and 70 inch lbs of torque.

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 Section 1, Bulkhead Assembly, SeaRey LSA

Bulkhead Pylon Gusset Bulkhead Cross Tube, Upper

Bolt, AN4-40A
Actuator Mount Plate

Bulkhead
Diagonal Tube

1” Saddle and (2)

1/8” Plastic Spacers

Figure 16. Attaching the Bulkhead Diagonal Tube to the Bulkhead Cross Tube Upper

16.1 Place a Washer, Thin AN4 (#960C416L) over a Bolt, AN4-40A (#N440A) and insert through the Bulkhead Pylon Gusset (#5310-026),
Bulkhead Cross Tube, Upper (#5310-085). The assembly is going from the forward side aft
16.2 On the aft side of the bulkhead, continue inserting the bolt through the Actuator Mount Plate (#3230-072), (2) Plastic Spacer, 1/8”
(#5530-005), Saddle, 1” (#5310-024), Bulkhead Diagonal Tube (#5310-015), Washer, Thin AN4 (#960C416L) and Nut, AN4 Lock
(#N4LN) and
tighten.
16.3 Repeat steps for the remaining side of the bulkhead.

Note: Torque Value on the bolts in this section should be between 60 inch lbs and 70 inch lbs of torque.

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 Section 1, Bulkhead Assembly, SeaRey LSA

Main Gear Spacer, 3/8” x

Wear Pad Spacer, 3/8” x
1-1/2” 1-1/2”
Bolt, AN3-31A

Figure 17. Attaching the Main Gear Wear Pads

Note: In the following steps, once installed, the Main Gear Wear Pads must be flush with the inside face of the Main Gear Support Plates!

17.1 Place the Main Gear Wear Pad (#3230-001) on the inside face of the Main Gear Support Plate (#3210-001), aligning the edges.
17.2 Using the 3/16” holes pre-drilled in the Main Gear Support Plate (#3210-001) as a guide, mark the Main Gear Wear Pad(s)
(#3230-001).
17.3 Drill the Main Gear Wear Pad(s) (#3230-001) to 3/16”.
17.4 From the forward side of the bulkhead and inner bolt hole, place a Washer, AN3 (#N3W) over a Bolt, AN3-31A (#N331A) and
insert through the Main Gear Support Plate (#3210-001), through each of the Main Gear Wear Pad(s) (#3230-001), and finally
exiting the aft side Main Gear Support Plate (#3210-001), adding a Washer, AN3 (#N3W); Nut, AN3 Lock (#N3LN) and tighten.
Install second bolt assembly, same as previous, in outboard hole, adding Spacer, 3/8” x 1-1/2” (#3220-013).
17.5 Repeat steps for the remaining side of the bulkhead.
Note: Torque Value on the AN3 bolts in this section should be between 15 inch lbs and 25 inch lbs of torque.

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