Section 13, Elevator Frames, Right and Left, SeaRey, LSA

Progressive Aerodyne, Inc.

3801 State Rd 19
Tavares, FL 32778

Note: Elevator Gap Seals Inboard and Outboard (#5520-018, 5520-019) and Elevator Control Horn assembly will be installed after fabric covering and painting (Section 20)

Document Number
Revision Description ECO Date
01 Initial Creation TBD 10/26/2009
1.01 Added notation about rivets extending through on Elevator Trailing Edge, page 10. JD 11/20/2009
02 Update 01262012 01/26/2012
03 Pg 7, step 5.1, adjusted bolt size to AN4-17A 03/24/2014

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 Section 13, Elevator Frames, Right and Left, SeaRey, LSA
1.0 Scope
This document will detail the steps necessary to assemble a SeaRey LSX Elevator frame assembly up to, but not including covering.

Note: Pictures depict a completed SeaRey LSX elevator for the right side. When building the left side elevator, pay close attention to mirror the rivets,
as they will be visible through the fabric after covering!

Note: For an overall component location, see Figure 9.

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:
 Socket, 3/8”
 Socket 7/16”
 Wrench, Open End, 3/8”
 Wrench, Open End, 7/16”
 Rivet Gun
 Awl
 Center Punch
 Drill Bit, 3/32”
 Drill Bit, 3/16” (Long)
 Allen Wrench, 3/16”
 Cleco Pliers
 Clecos, 1/8”

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

 N/A

3.3 Procedure (see the following pages)

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 Section 13, Elevator Frames, Right and Left, SeaRey, LSA

Elevator Inboard
28” Leading Edge

Inboard Outboard
Nutplate 1/4-28

Nutplate 1/4-28

Figure 1. Attaching Nutplate to Elevator Leading Edge LS

1.1 Locate the 1/4” hole drilled 28” from the Inboard end. This denotes the inboard end of Elevator Leading Edge LS (#5520-013).
Note: in the following step the Nutplate should be on the same side of the tube as the drilled 1/2” holes.
1.2 From the side of the tube opposite the drilled 1/2” holes, insert Bolt AN4-13A (#N413A) through the hole located at 28” from the
inboard end as defined in Step 1.1. Then thread Nutplate 1/4-28 (#NP1/4-28) lightly onto Bolt AN4-13A.
1.3 Align Nutplate 1/4-28 (#NP1/4-28) along the leading edge tube as shown in Figure 1.
1.4 Using a 3/32” drill bit, drill through ONE side of the mounting lug hole.
1.5 In the hole just drilled, rivet using Rivet CCR-264-SS-3-5 (#264CR35).
1.6 Drill the remaining mounting lug in Nutplate 1/4-28 (#NP1/4-28) using the 3/32” drill bit.
1.7 Rivet Nutplate to tube using Rivet CCR-264-SS-3-5 (#264CR35).
1.8 With Nutplate 1/4-28 riveted firmly in place against Elevator Leading Edge, remove Bolt AN4-13A.

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 Section 13, Elevator Frames, Right and Left, SeaRey, LSA

Bolt, AN3-13A

Elevator Rib #1
Support Strap, 1/2” Inboard LS

Figure 2. Inserting Tube Connector into Elevator Rib #1

2.1 Press Threaded Insert, 7/16” Steel (#5520-008) into Tube Connector 1” (#5520-009) aligning as shown in Figure 2.
2.2 Insert Tube Connector 1” (#5520-009) into Elevator Rib #1 Inboard LS (#5520-015), aligning the Threaded Insert with the
predrilled 3/16” hole.

NOTE: It may be necessary to shave the ridges down on the Tube Connector to properly fit inside the Elevator Rib.

2.3 Install Bolt, AN3-13A: Noting the orientation of the bolt in Figure 2, insert Bolt, AN3-13A (#N313A) completely through Elevator
Rib #1 Inboard LS (#5520-015).
2.4 Place the shorter leg of Support Strap, 1/2” (#5510-001) over Bolt, AN3-13A then secure with Washer, AN3 (#N3W) and Nut,
AN3 Lock (#N3LN).

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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 Section 13, Elevator Frames, Right and Left, SeaRey, LSA

Bolt, AN3-13A

Elevator
Rib #3 LS
Support Strap, 1/2”

Figure 3. Building Elevator Rib #3 LS with Support Strap (will be mounted outboard)

3.1 Press Threaded Insert, 7/16” Steel (#5520-008) into Tube Connector 1” (#5520-009) aligning as shown in Figure 3.
3.2 Insert Tube Connector 1” (#5520-009) into Elevator Rib #3 LS (#5520-017), aligning the Threaded Insert with the 3/16” hole.

NOTE: It may be necessary to shave the ridges down on the Tube Connector to properly fit inside the Elevator Rib.

3.3 Install Bolt, AN3-13A: Noting the orientation of the bolt in Figure 3, insert Bolt, AN3-13A (#N313A) completely through Elevator
Rib #3 LS (#5520-017), locking Threaded Insert, 7/16” Steel (#5520-008) into place.
3.4 Place the shorter leg of Support Strap, 1/2” (#5510-001) over Bolt, AN3-13A then secure with Washer, AN3 (#N3W) and Nut,
AN3 Lock (#N3LN).

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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 Section 13, Elevator Frames, Right and Left, SeaRey, LSA

Bolt, AN3-13A

Elevator
Rib #3 LS

Figure 4. Building Elevator Rib #3 LS without Support Strap (will be mounted in center)

4.1 Press Threaded Insert, 7/16” Steel (#5520-008) into Tube Connector 1” (#5520-009) aligning as shown in Figure 4.
4.2 Insert Tube Connector 1” (#5520-009) into Elevator Rib #3 (#5520-017), aligning the Threaded Insert with the 3/16” hole.

NOTE: It may be necessary to shave the ridges down on the Tube Connector to properly fit inside the Elevator Rib.

4.3 Place Washer, AN3 (#N3W) over Bolt, AN3-13A (#N313A). Insert completely through Elevator Rib #3 LS (#5520-017), locking
Threaded Insert, 7/16” Steel (#5520-008) into place. Secure with Washer, AN3 (#N3W) and Nut, AN3 Lock (#N3LN).

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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 Section 13, Elevator Frames, Right and Left, SeaRey, LSA

Elevator Rib
#1 Inboard LS
Drill / Rivet

Rivet AB6-4A Location:

Inboard End
Elevator Leading
Bolt, Edge LS
AN4-17A

Figure 5. Securing the Support Strap

5.1 Place Washer, AN4 (#N4W) over Bolt, AN4-17A (#N417A). From the side opposite the ½” holes, Insert the bolt / washer
assembly through Elevator Leading Edge (#5520-013) Inboard end and into the Threaded Insert, securing Elevator Rib #1
Inboard LS (#5520-015) and tighten.

Caution! In the following step, you will ONLY be drilling through one side of the tube!
5.2 Using the hole in Support Strap, 1/2” (#5510-001) as a guide mark a hole on the Elevator Leading Edge. Take the Bolt AN4-
17A back out and remove the Support Strap out of the way. Drill a 3/16” hole into Elevator Leading Edge LS (#5520-013) where
the mark was placed only into one side of the tube. Reinstall the Bolt AN4-17A and Elevator Rib #1 Inboard and tighten.

Caution! In the following step, you may need to add an AN3 Washer!
5.3 If there is a small gap between Support Strap, 1/2” (#5510-001) and Elevator Leading Edge LS (#5520-013), add one Washer,
AN3 (#N3W) to fill the gap. If there is no gap present, continue on to step 5.4.
5.4 Rivet Support Strap, 1/2” (#5510-001) to Elevator Leading Edge LS (#5520-013), using Rivet, AB6-4A (#P-64).

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 Section 13, Elevator Frames, Right and Left, SeaRey, LSA

Elevator Rib
#3 LS
Drill / Rivet

Rivet AB6-4A
Location:
Outboard End
Elevator
Bolt,
Leading Edge
AN4-17A

Figure 6. Adding the Elevator Rib #3

Note: Use Rib #3 from the previous step Figure #3 that has a Support Strap on it.
6.1 Place Washer, AN4 (#N4W) over Bolt, AN4-17A (#N417A). Insert the bolt / washer assembly through Elevator Leading Edge LS
(#5520-013) and into the Threaded Insert, securing Elevator Rib #3 (#5520-017).

Caution! In the following step, you will ONLY be drilling through one side of the tube!
6.2 Using the hole in Support Strap, 1/2” (#5510-001) as a guide mark a hole on the Elevator Leading Edge. Take the Bolt AN4-
17A back out and remove the Support Strap out of the way. Drill a 3/16” hole into Elevator Leading Edge LS (#5520-013) where
the mark was placed only into one side of the tube. Reinstall the Bolt AN4-17A and Elevator Rib #1 Inboard and tighten.

Caution! In the following step, you may need to add an AN3 Washer!
6.3 If there is a small gap between Support Strap, 1/2” (#5510-001) and Elevator Leading Edge LS (#5520-013), add one Washer,
AN3 (#N3W) to fill the gap. If there is no gap present, continue on to step 6.4.
6.4 Rivet Support Strap, 1/2” (#5510-001) to Elevator Leading Edge (#5520-013), using Rivet, AB6-4A (#P-64).

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 Section 13, Elevator Frames, Right and Left, SeaRey, LSA

Bolt, AN4-17A

Elevator
Rib #3 LS

Figure 7. Adding the Elevator Ribs

7.1 Place Washer, AN4 (#N4W) over Bolt, AN4-17A (#N417A). Insert the bolt / washer assembly through Elevator Leading Edge
(#5520-013) and into Threaded Insert, securing Elevator Rib #3 LS (#5520-017), placing as shown in above photo.

Threaded Insert, Elevator Rib #2 LS Rivet SBL4-4

7/16 Aluminum

7.2 Fully insert Threaded Insert, 7/16” Aluminum (#AL-23DC) into Elevator Rib #2 LS (#5520-016) and mark the tube 1-1/4” from the
end.

Note: In the following step, the 1/8” drilled hole MUST be aligned in the same plane as the flattened end of the ribs as shown in the
bottom right picture above!
7.3 Drill a 1/8” hole through Elevator Rib #2 LS (#5520-016) and into the threaded Insert all the way through the Rib at the mark made in step 7.2.
7.4 Rivet Threaded Insert, 7/16” Aluminum (#AL-23DC) into Elevator Rib #2 (#5520-016) using Rivet, SBL44 (#SL-44).
7.5 Repeat steps 7.2 through 7.4 for the remaining two (2) Elevator Rib #2 LS (#5520-016).

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 Section 13, Elevator Frames, Right and Left, SeaRey, LSA
Aft end Rib Elevator Rib #2 LS
Bolt, 1/4-28 x 3/4” Allen Tubes are flat

Elevator Rib
#2 LS

Elevator Rib #2 LS
Elevator Leading
Edge

Figure 8. Adding the Elevator Ribs

8.1 Insert Quantity of (3) Elevator Rib #2 LS (#5520-016) into the 1/2” hole(s) drilled in Elevator Leading Edge LS (#5520-013).
8.2 Place Washer, AN4 (#N4W) over Bolt, 1/4-28 x 3/4” Allen, S.S. (B075-428A), then insert the Bolt / Washer assembly through
Elevator Leading Edge (#5520-013) into Threaded Insert in Elevator Rib #2 LS. Repeat for remaining (2) Elevator Rib #2. Align
the aft ‘flattened edges’ horizontally (as shown in Figure 8) of the Elevator Ribs before tightening the Allen Bolts.

Note for the assembly on the following page:

When installing the 1/8” rivets that secure the Elevator Trailing Edge, the rivets WILL NOT extend through the aft side of the
hole. Drilling completely through is needed to allow the rivet to slightly protrude, PRIOR to pulling the rivet. Once the rivet is
pulled, the aft side of the rivet is flush (or slightly recessed).

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 Section 13, Elevator Frames, Right and Left, SeaRey, LSA

Section 3.
One rivet, in recessed lip.
Inboard Outboard

Rib #2
Rib #3
Rib #2 Rib #2
Rib #1 Rib #3

Section 1.
Two rivets, close spacing. Section 2.
This corner should be even. Two rivets per side, diagonal spacing.

Figure 9. Adding the Elevator Trailing Edge

See Note on previous page before completing the following steps.

9.1 Place Elevator Trailing Edge LS (#5520-014) over the rib trailing edges, seating it fully against the ribs.
9.2 In Figure 9 above, locate the inboard edge labeled Section #1. Check the fit of the trailing edge, making sure Elevator Rib #1
Inboard (#5520-015) fits evenly in the corner with Elevator Trailing Edge.
9.3 Drill a 1/8” hole completely through this junction as shown and rivet with Rivet, SBL44 (#SL-44). Plan your spacing to allow the
second rivet head to sit next to the first rivet. Mark, drill 1/8” hole, and rivet using Rivet, SBL44 (#SL-44).
9.4 In Figure 9 above, locate the area labeled Section #2. Perform this procedure on the outboard Rib #3 first. Check the fit of the
trailing edge, making sure Elevator Rib #3 (#5520-017) fits evenly in the corner with Elevator Trailing Edge (#5520-014).
9.5 Drill a 1/8” hole completely through this junction as shown, in one corner of the recessed lip of Elevator Trailing Edge (#5520-014).
Rivet with Rivet SBL44 (#SL-44). Mark your second rivet diagonally at the aft edge, drill, and rivet with Rivet SBL4-4 (#SL-44).
9.6 Repeat step 9.5 on remaining Elevator Rib #3 (#5520-017).
9.7 In Figure 9 above, locate the area labeled Section #3. Drill a 1/8” hole completely through the recessed lip in Elevator Trailing
Edge (#5520-014). Rivet with Rivet, SBL44 (#SL-44).
9.8 Flip the elevator over and again perform steps 9.3 through 9.7 while making sure the rivets do not interfere with each other.

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