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COCKPIT AND PILOT INSTALLATION
1.
Use medium sandpaper to lightly sand the bottom of the
roll bar to remove the paint.
2.
Use 30-minute epoxy to glue the roll bar in the cockpit.
Position the roll bar using the marks made on the cockpit
fl oor.
3.
Lightly sand the bottom of the backrest with medium
sandpaper to remove the paint. Use 30-minute epoxy to
glue the backrest slightly forward of the roll bar.
4.
Use medium CA to glue the instrument panel into the
cockpit. Sand the outside edge of the instrument panel if
necessary to fi t it tightly into position.
5.
Use 30-minute epoxy to glue the pilot in the cockpit.
Position the pilot back against the backrest.
Van's RV-4 30cc
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Use a tapered reamer (DYNT2110) to make a 1/4-inch
(6mm) hole at the rear edge of the canopy to allow warm
air to escape from inside the canopy.
7.
Use canopy glue to attach the canopy to the cockpit. Use
low-tack tape to hold the canopy in position until the
adhesive fully cures.
COWLING AND SPINNER INSTALLATION
1.
Slide the cowling into position. Fit the spinner backplate,
propeller, propeller washer and nut on the engine. Align
the cowling so there is a 1/8-inch (3mm) gap between
the spinner backplate and cowling. Tape the cowling to
the fuselage to prevent it from changing position.
2.
The locations for the cowl mounting screws have been
pre-drilled in the cowling. Use a drill and 3/32-inch
(2mm) drill bit to drill the locations in the fuselage for the
cowling screws.
3.
Thread a #4 x 3/8-inch sheet metal screw into each of
the holes. Remove the screws and apply a few drops of
thin CA in each hole to harden the surrounding wood.
Once the CA has fully cured, attach the cowling to the
fuselage using the #4 x 3/8-inch sheet metal screws and
a #1 Phillips screwdriver.
Add a final #4 x 3/8-inch sheet metal screw to
attach the cheek cowl to the fuselage at the rear. A hard
point will need to be installed in the fuselage using a
mixing stick and 5-minute epoxy or medium CA.
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