VORTEX GENERATOR INSTALLATION MANUAL BEECHCRAFT BARON

D'SHANNON AVIATION 1309 COUNTY ROAD 134 BUFFALO, MN 55313 800-291-7616

MARCH 24, 1992

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TABLE OF CONTENTS

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INTRODUCTION DEFINITIONS (GLOSSARY) KIT CONTENTS LIST OUTBOARD WING SECTION LAYOUT INBOARD WING SECTION LAYOUT 58TC & 58P SUPPLEMENT WING TEMPLATE APPLICATION TAIL LAYOUT AND TEMPLATE APPLICATION RIVET OR SCREW HEAD INTERFERENCE SURFACE PREPARATION ATTACHING THE V/G'S CLEANUP AIRSPEED INDICATOR INSTALLATION PAPERWORK PAINTING VORTEX GENERATORS FIGURES 1 THROUGH 10

INTRODUCTION This manual is provided to simplify the installation of VORTEX GENERATORS on Beechcraft Barons in accordance with SUPPLEMENTAL TYPE CERTIFICATE SA4026NM. The manual is separated into sections describing the sequence of operations. First, you will be placing pieces of masking tape on the aircraft skins to provide a convenient marking surface. Next, you will establish layout marks at specified distances from known locations on the airframe and stretch pieces of thread between them as guide lines for positioning the templates which locate the V/Gs accurately. The painted surfaces which are left exposed by the openings in the templates are then roughened with strips of abrasive and washed with isopropyl alcohol to remove residue. Then the V/Gs are bonded in place. The final steps after removing the disposable templates involve exchanging the airspeed indicator on all but the 58TC & 58P and completing the paperwork. Most of the information required for installation is contained in this manual. The applicable installation drawing is used primarily for dimensional reference. If you have any questions about the procedure, call us at once at 1-800-2917616. Our goal is to make the installation as easy as possible. We welcome your comments and suggestions. The kit contains everything you will need except the following items: 1 Pint isopropyl alcohol 1 Roll paper towels or equal Step ladder for working access to top of tail Hand tools for airspeed indicator change Phillips screw drivers, #1, & #2 offset open end wrenches 1/4" to 11/16" Teflon thread tape
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DEFINITIONS L.E. SEAM: L SHAPED TOOL: The seam nearest the leading edge on the inboard sect of the wing. The right-angled tool provided by us used to establish perpendicular offsets forward of the spar cap line to position the layout thread line. Also used to bridge the nacelle fillet to simplify measurements from the side of the nacelle. The curved fairing between the engine nacelle and the wing skin. The spar cap line, which is used as a reference for the wing template layout, is the aft edge of the wing spar cap and the skin lap extending from the outboard end of the spar cap toward the wing tip.

NACELLE FILLET: SPAR CAP LINE:

STREAM WISE SEAM: The fore and aft skin seam several inches inboard of the nacelle fillet on the inboard section of the wing. TEMPLATE: V/G: WING SPAR CAP: Disposable tools of adhesive backed vinyl to aid in accurate placement of VGs. Par numbers 10001 to 10010L & R. VORTEX GENERATORS. Part numbers 1001 to 1006. The wing spar cap is visible on the upper surface of the wing as a narrow strip about 1-1/2" wide running span-wise from the nacelle to the wing tip attachment.

KIT CONTENTS LIST 1 1 1 1 BASIC MATERIALS Package of VORTEX GENERATORS Package of templates Instruction manual Drawing package: DL-100 Drawing List VG-100A VG Installation (55 & 58 only) VG-101 VG Installation (58TC & 58P only) 1100 A/S Indicator Markings (55& 58 only) 1200 Placard Overlays (55 & 58 only) PS-100 Process Specification Stall Warn. Adjustment (shop Manual Excerpt) Documentation package: 1 Copy of S.T.C. SA4016NM 2 FAA Form 337 1 Logbook label for VG installation 1 Logbook label for A/S indicator (55 & 58 only) 1 Placard overlay (55 & 58 only) 1 Airplane Flight Manual Supplement (8 1/2" x 11") 1 Airplane Flight Manual Supplement (4 1/2" x 7") Airspeed indicator (55 & 58 only) A/S Indicator shipping box (55 & 58 only) On-board spare parts list 1 Instruction sheet 1 Adhesive sample size kit 1 Cotton-tipped swabs 8 Spare VORTEX GENERATORS 1 P.M.A. Tag
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CONSUMABLES 1 1 1 2 1 1 1 1 Roll 3/4" masking tape Roll thread Pencil Strips 5/16" x 9" #320 abrasive paper Loctite DEPEND adhesive kit Box cotton-tipped swabs Packet knife blades Pair vinyl gloves

INSTALLATION TOOL KIT 1 1 1 1 1 1 1 1 Steel tape (6" to 129") Steel tape (2 1/2" to 55") Vacuum base vise Exacto knife handle Set needle files Chisel 1/2" Layout tool (10-1/2" x 6") for 55 & 58 Layout tool (11-1/2 x 7") for 58TC & 58P

OUTBOARD WING SECTION In this section you will create the layout line and index marks for the alignment of templates on the outboard wing sections. Note that the layout line is 1" forward of the leading edge line for the Vortex Generators as shown on the installation drawing since the templates position the V/Gs 1" aft of the layout line. Note: For 58TC & 58P see supplemental section for layout dimensions in steps 1 through 4. 1) Starting on either wing, place a piece of masking tape about 16" long on the wing skin adjacent and parallel to the outboard edge of the Nacelle Fillet extending from the leading edge to the Spar Cap Line. (See Figure 1) 2) Use the "L" shaped layout tool with the short edge of the tool aligned with the Spar Cap Line to scribe a pencil mark on the tape 10-1/2" forward of the Spar Cap Line within 1/2" of the Nacelle Fillet. This mark will be referred to as mark #1. (See Figure 1) 3) Place a piece of masking tape about 10" long on the wing skin adjacent and parallel to the inside edge of the wing tip fence extending from the leading edge to the Spar Cap Line. On earlier planes there is no fence, so apply the tape along the fore and aft skin seam about 6" inboard from the wing tip. (See Figure 2) 4) Align the long edge of the "L" shaped layout tool with the Spar Cap Line and use the short leg to locate a pencil mark 6" forward of the Spar Cap Line and within 3/4" of the fence or fore and aft skin seam. This will be referred to as mark #2. (See Figure 2)

5) Apply a long piece of masking tape span-wise, starting from the inboard pencil mark #1 running to the outboard pencil mark #2. This tape should be approximately centered on an imaginary line between the two marks, but neither end should cover the marks. If the inboard end of the tape is attached first, the tape can be unwound without it touching the wing until the outboard end is centered above the outboard mark. Standing at the wing-tip and sighting down the tape will allow you to pull the tape straight between the marks before lowering it into position. Note that this is not critical; one half tape width deviation either side of center is acceptable. (See Figure 3) 6) Position the "L" shaped layout tool on edge with the long leg uppermost and parallel to the long span-wise tape which was just installed. The short leg should be vertical with the small end resting on the long piece of tape. Slide the tool inboard until it touches the side of the nacelle just above the Nacelle Fillet. Make a pencil mark 7" outboard of the outboard edge of the nacelle on the long piece of tape which was just applied. This will be referred to as mark #3. (See Figure 4) 7) Position the long (6" to 129") measuring tape on the wing skin at the forward edge of the span wise masking tape with the 7" mask on the measuring tape aligned with the pencil mark 7" out board of the nacelle (mark #3). Extend the other end of the tape outboard to mark #2. Secure the measuring tape at both ends with a short piece of masking tape. (See Figure 3) 8) Make pencil marks across the full width of the long masking tape at each dimension referenced in the chart on the installation drawing. (See comments below on fuel filler cap locations for E 55s and 58s). Remove the measuring tape.
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9) Secure one end of a piece of thread on the inboard pencil mark (mark #1) with a short piece at masking tape. Stretch the thread tightly to the outboard pencil mark (mark #2) and secure it with tape. Place several short pieces of tape to hold the thread down wherever it is suspended above the wing by rivets skin laps, or wing bow, being careful not to deflect the thread from a straight line between the ends. In rare cases the deicing boots extend far enough aft along the top surface of the wing to interfere with the line of V/Gs. You may check this by temporarily placing any one of the outer wing templates in several locations along the thread line between the nacelle and wing tip without removing the backing paper. If the rectangular windows which locate the V/Gs expose a portion of the pneumatic boot, it will be necessary to relocate the layout line aft to eliminate the conflict. Note that the black bonding material along the edge of the boots can be removed or a small corner of the V/G can be trimmed to avoid relocation. Relocation is only required if the V/Gs will touch the inflatable portion of the boot. The thread line may be relocated up to 1/2" aft without serious deterioration in V/G System benefits. If more is required you should call us. It is imperative that any changes to the location on one wing be duplicated exactly on the opposite wing. If possible, only the inboard end of the line should be move aft. In any event, keep the relocation to a minimum.

Special Conditions for E-55 and 58: (refer also to section on template application) Some of the late model E-55 Barons have a fuel filler cap centered 99.75" outboard from the nacelle. In this instance, the layout dimensions listed on the installation drawing for 58s should be used along with the 2.4" templates (P/N 1007) to span the cap. Conversely, some of the early 58s have only a single filler cap at the 99.75" location. In either instance, if there is no fuel filler cap in the vicinity of 128" outboard from the nacelle, make a pencil mark on the tape at 128" and apply a 1.15" template (P/N 10003). Note that the extra pair of V/Gs are not listed on the layout dimension chart, but that enough templates and V/Gs are included in the kit. This completes the layout of the outboard section. Repeat steps 1 through 9 on the opposite wing.

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INBOARD WING SECTION In this section you will create the layout line for the alignment of template on the inboard wing section. Note that the layout line is 1" forward for the Vortex Generator line as shown on the installation drawing since the templates position the V/Gs 1" in from the edge. For 58TC & 58P Barons refer to the supplemental section for alternate procedures. Refer to Figure 5 for steps 1 through 6. 1) Place a 6" piece of masking tape on the inboard wing parallel to and several inches outboard of the fuselage centered approximately 6" aft of the L.E. Seam (See Definitions). 2) Place another piece of tape centered about 6" aft of the L.E. Seam approximately 1/2" inboard of the Stream Wise Seam (See Definitions). 3) Place the "L" shaped layout tool so that the 10-1/2" edge is aligned with the L.E. Seam and so that the notch in the 6" edge overlies one of the pieces of tape. Make a pencil mark at the notch. This will be referred to as mark #4. 4) Flip the layout tool end for end, align the 10-1/2" edge with the L.E. Seam and make a pencil mark at the notch on the other piece of tape. This will be referred to as mark #5. 5) Secure one end of a piece of thread over mark #4 with masking tape. Stretch the thread over the outboard pencil mark (mark #5) and secure tightly within 1" of the Nacelle Fillet. 6) Press the thread down onto the wing skin at mark #5 and secure with a short piece of tape. Since the inboard template will align with this thread and locate on the Stream Wise Seam, this concludes the layout of the inboard wing. Repeat Steps 1 through 6 on the opposite wing.

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58TC & 58P SUPPLEMENT OUTBOARD WING SECTION The procedure is the same as for the 55 series and straight 58 planes except that the layout line distance forward of the spar cap line at the inboard end is 11-1/2" and 7" at the outboard end. The layout tool for the 58TC & 58P will produce the correct dimensions if used in the same manner described for the 55 and 58. You will also note that the first five templates outboard of the nacelle are for V/Gs P/N 1005 & 1006. All V/Gs are installed with the curved end forward. The inboard pair of V/Gs are parallel to each other, and all the others in the "V". The order of templates starting at the nacelle and proceeding outboard is: one template (P/N 10010L or R for left and right wing), four templates (P/N 10009), one template (P/N 10004), six templates (P/N 10003), one template (P/N 10007) and three templates (P/N 10003). INBOARD WING SECTION The procedure is similar to that described for the 55 and 58. The difference is that the layout line is not parallel to the L.E. Seam. You will be making two reference marks for the thread line at specified spanwise locations. One is 6" and the other is 2-1/2" aft of and perpendicular to the L.E. Seam. Place the layout tool on the wing so that the long (11-1/2") edge is aligned with the L.E. Seam and the edge with the notch is closest to the nacelle. Slide the tool outboard until the notch is directly over the streamwise skin Seam (see Figure 9). Lift the tool slightly and place a small piece of tape on the wing under the notch. Reposition the tool and make a pencil mark on the tape where the notch overlies the Streamwise Skin Seam. Now slide the tool inboard until the corner between the 11-1/2" edge and the 7" edge is at the intersection of the L.E. Seam and the Stream Wise Seam. Lift the inboard edge of the tool and place another small piece of tape under the corner
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2-1/2" away from the L.E. Seam. Lower the inboard edge and make a pencil mark at the corner (see Figure 10). Attach a 24" piece of thread on the wing with two pieces of tape so that it aligns with both pencil marks. Align the inboard template (P/N 10008L or R) so that the forward edge just touches the tread and the notch in the template is on the Stream Wise Seam. Continue as described for the 55 and 58. WING TEMPLATE APPLICATION In this section, you will be applying the templates onto the wing skin surface. The layout and application of the templates to the tail is covered in the next section. The paper backing may be removed by folding over a small (3/16") "dog ear" on one corner of the template toward the paper backing side, pressing it flat between thumb and forefinger, then folding it back the other way. This should cause the vinyl to separate from the backing. During this procedure, do not be alarmed if the rectangular opening for the V/Gs are over an area of wing walk or if there are rivets or screw heads in the way. These occurrences will be dealt with in the surface preparation section. INBOARD SECTION: The templates for the inboard sections (P/N 10006L & R for 55s & 58s; P/N 10008L & R for 58TC & 58P) are marked with arrows pointing outboard and forward to clarify orientation. Remove the paper backing and position the template on the aft side of the thread with the notched edge just touching the thread line and the notch centered on the Stream Wise Seam (see Figure 6). Since the wing is bowed in this area, you may find it easier to hold the outboard end and
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the middle at the forward edge with the inboard portion folded over the top, adhesive side up. This will allow centering the notch and alignment with the thread. If the outboard half is aligned properly with the thread, the inboard half will wind up where it belongs. Repeat this process on the other wing. OUTBOARD SECTION: The templates for the outboard wing are applied on the aft side of the thread with the notched edge toward the thread line and the notch centered on the pencil marks you made on the long strip of masking tape. There are five templates (P/N 10005) which go on the first five marks starting at mark #3 and proceeding outboard. Next comes one template (P/N 10004) followed by eleven templates (P/N 10003) on the 55 series planes. Note the exceptions discussed earlier concerning the late E-55s and the early 58s. On later 58s there are only ten templates (P/N 10003), and one wide template (P/N 10007) to span the fuel filler cap.

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TAIL LAYOUT AND TEMPLATE APPLICATION The layout of the tail is much simpler than the wings you will see. 1) Remove the backing paper from the top tail template (P/N 10002) and place it at the top aft corner of the left side of the vertical stabilizer. Locate the template so that the angled edge aligns with the top of the stabilizer and the edge with the notch aligns with the aft edge of the stabilizer skin nearest the rudder hinge line. (see Figure 7) 2) Place a piece of masking tape along the side of the stabilizer so that the aft edge of the tape aligns with the aft edge of the stabilizer skin. This tape should run from just below the notch on the top template to within 3" of the horizontal stabilizer. Next unroll the short steel measuring tape (2-1/2" to 55") and secure it with masking tape on top of the masking tape you just applied, positioning it about 1/2" forward of the skin edge with the 3" mark next to the notch in the top template (see Figure 8). Make pencil marks perpendicular to the measuring tape extending to the skin edge every 3" down to the 54" mark. Remove the measuring tape. 3) Apply the sixteen additional tail templates (P/N 10001) starting just below the top template with the notches centered on the pencil marks and the aft edges aligned with the aft edge of the skin. If there is no interference from a tail mounted antenna, apply the templates continuously and disregard the lowest reference mark at 54". If necessary, skip one template to avoid antenna interference and add it to the bottom of the stack at the 54" mark.

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RIVET OR SCREW HEAD INTERFERENCE In some cases you will find that there are rivets or screw heads showing through the templates where the V/Gs will be attached. This generally ocurs on the wings of the earlier 55 series airplanes, on the vertical stabilizers of all models, and near the fuel filler caps on the 58 series airplanes. If the locations were consistent we would provide V/Gs with the appropriate clearance already machined. However, production variations make this impossible. Place a V/G next to the interfering rivet aligned with the template cut-out along the long axis and mark the area on the base of the V/G to be removed. Remember that there are left and right V/Gs distinguished by the cusp on the top edge. The rule for placement is that the cusp always turns into the relative wind and the radiused end always faces forward. For example, on the outboard section the two V/Gs on each template have the tops curling away from each other, and on the inboard section the V/Gs always point toward the nacelle and curl toward the fuselage. Now, using a small vacuum base vise and one of the needle files, remove enough of the base material to clear the obstruction. The structural strength is not a major factor as long as at least 50% of the base remains for adhesion. (The drawing shows 75%, but that was an arbitrary choice by us). However, remove as little material as necessary in the interest of a neat job. Test each modified V/G for fit and set it aside in preparation for the next step.

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SURFACE PREPARATION WING WALK AREA: In some instances the wing walk is under a portion of several inboard V/Gs. The 1/2" chisel blade is the same width as the opening in the template and can be used to remove the material down to the underlying paint or chromate. Be very careful not to gauge the aluminum skin for obvious reasons. The chisel edge must be sacrificed in dealing with the abrasive wing walk material. One method that has worked well involves holding the chisel vertically in both hands, beveled side aft while resting both forearms on the wing and working from back to front with a 1/8 turn twisting motion. Think of this as "walking" the chisel toward you bearing lightly on alternate corners of the blade; inboard corner, counter-clockwise twist, outboard corner, clockwise twist, etc. The residual material can be removed with the abrasive in the next step. ABRADING PAINTED SURFACE The next step is to abrade the painted areas inside the template cut-outs so that the adhesive will have a roughened surface for a better bond. Fold a strip of abrasive about 1" from one end with the rough side out. Fold the doubled portion toward the short side so that a small pad of less than 1/4" length is formed. Holding the abrasive between thumb and forefinger so that the rough side of the long end is against your palm and the rough side of the short end is against the fleshy part of your forefinger should allow pressing the small pad against the painted area with the side of your thumb. Note that there will be four layers of the abrasive paper between our thumb and the pain. By straightening out the strip and refolding after each opening is abraded, a "fresh" sanding pad will be available each time. The object is to remove the surface gloss and provide some "tooth" for adhesive, while not destroying the template opening. It is only necessary to roughen about 75% of the exposed surface in each opening, so it is not required to spend more than about ten seconds at each spot.
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REMOVING RESIDUE After all of the template openings have been abraded, the adhesion areas must be washed with isopropyl alcohol. This is best accomplished by soaking a paper towel and wiping over each template. Turn the towel frequently to prevent re-depositing the sanding residue. ATTACHING THE V/Gs Now you are ready to install the V/Gs using the two parts Loctite adhesive provided in the kit. The activator is in the small aerosol spray can and the adhesive is in the syringe. The first step is to spray the activator on the areas exposed by the templates. The working life of the activator once sprayed from the container is about two hours, so you will have plenty of the time to complete each section. 1) Start on either outboard wing section. Using two sheets of paper toweling as a shield against overspray, one on each side of the line of templates, spray just enough activator to cover each rectangular area; the less the better. Short, quick bursts while making one sweep over the area seem to work best. It is not necessary to wet the whole area; alight frosting is preferred, if possible. 2) Next you should lay out all the V/Gs (P/N 1001, 1002, 1005 and 1006, if applicable) in order about 3" behind their respective locations so that they will be close at hand. Remember the rule for placement of the V'Gs: the cusp always points into the relative wind and the radiused end always points forward.

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3) Starting at either end of the wing, apply a very small amount of adhesive on the bottom of the first V/G. The proper amount to apply can only be learned from experience, but it is probably less than you will think at first. The object is to apply the least amount that will spread over the complete surface without squeezing out around the edges when the V/G is pressed into place. To start, try the equivalent of one half drop of water. 4) Press the V/G into place so that it fits within the opening in the template and hold for about three to five seconds. The bond is not immediate, so some repositioning is possible. If you work quickly you should be able to install four to eight V/Gs before the first one is set. This timing is important in case you have to wipe up any adhesive that has squeezed out before it is completely set. The cotton-tipped swabs can be used for this purpose. 5) Proceed in groups of four to eight until finished with this section. Then peel up the templates beginning at the first end. Proceed to the opposite wing and repeat the procedure. 6) Next you will attach the V/Gs to the inboard sections. Start by spraying activator through the template openings on both inboard sections. Then lay out the V/Gs (P/N 1003 and 1004, or 1005 and 1006, as applicable) a short distance behind their respective locations, remembering the rule that the radiused end points toward the nacelle and the cusp curls toward the fuselage.

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7) Since the inboard wing V/Gs are longer, the curvature of the wing causes a small gap at the ends. This requires that a generous amount of adhesive be used at the ends to assure gap filling, which is desired more for cosmetic reasons that structural. A thin film in the center section of the V/G with a 1/16" bead across each end will probably be enough. It is most effective in this instance to start the cleanup of the surplus adhesive immediately after pressing the V/G in place, holding it in position with one hand while cleaning up with cotton-tipped swabs with the other. Complete both inboard sections and remove the templates. 8) The tail section can be completed in similar fashion. The only differences are that you will have to lay out the V/Gs in separate piles (P/N 1001 and 1002) on the horizontal stabilizer for handy access, and that you may have to hold each V/G in place a little longer so it will stick without sliding.

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CLEANUP After all of the templates have been removed, the area round the V/Gs should be wiped clean with isopropyl alcohol. The activator and the adhesive are both soluble in isopropyl alcohol, as is the activated adhesive, for about the first five or ten minutes after contact. Cotton-tipped swabs dipped in the isopropyl alcohol can be used to rub the perimeter of the V/G bases and soaked paper towels can be used to wipe the areas where there is overspray or residual gum from the templates. If there are still traces of hardened adhesive or template material after the alcohol wash, the Exacto knife can be used to trim next to the base of the V/G. Be very careful in this operation not to cut through the paint on the wing. For hardened globules of adhesive, a small wooden stick sharpened to a chisel point will allow removal without harming the paint. Please take extra care with the cosmetic aspects of the job. Since this is a new and unusual modification, many people will be taking a close look at the installation. A neat job will be appreciated by everyone.

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AIRSPEED INDICATOR The next step is to install the exchange airspeed indicator if it is included as part of your kit. Currently, the S.T.C. requires remarking the airspeed indicator on the 55 series and the straight 58 airplanes. The 58TC and 58P are not included in this requirement. 1) Remove the glare shield by removing the two attach screws that fit into the fuselage door and window posts and any attaching screws that may be above the engine power instruments. On the later planes the center of the glare shield is held in place with a velcro strip which should be parted carefully, since the strip is often not bonded well. 2) The defroster duct is normally secured to the glare shield plenum with a hose clamp. However, on many planes the duct is not attached or the clamp is missing. Plan now for a proper re-installation as maximum defroster output can be important in instrument or winter flight conditions. 3) If there is glare shield lighting, the wires can be parted at a Molex connector which may only be accessible from under the panel on the pilot's side. If the compass light is the only electrical device, the wires will generally have an individual quick connector. 4) If the pressure and static lines are the same size, be careful to mark them prior to removal to prevent a critical error on re-assembly. Sometimes it is convenient to remove small panel mounted devices such as marker beacon or DME indicators to gain access to the inboard post light if installed.

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5) After the original indicator is out of the panel, remove the fittings for use with the new instrument. Teflon thread tape is a good choice as a sealer, however, the tape should not cover the first thread to prevent fouling the internals of the instrument. Note the comments on static system back flushing at the end of this section. 6) When re-installing the glare shield, the defroster duct and clamp can generally be positioned before the glare shield fully in place. Final adjustments and tightening of the clamp can be done as follows: Put your head and shoulders under the panel on the pilot's side with feet out the door. Lie on left side with face near rudder pedals and reach up and to the right above the center pedestal with your right arm to reach the duct and clamp. Try not to think of getting stuck in this position and remember that we do this work because we love it. 7) A static line leak check will be required to comply with FAR 91.171 (a) (2). Note that this is not the same as the altimeter and encoder instrument accuracy checks and can be accomplished by an airframe mechanic per FAR 91.171 (b) (3) with further reference to FAR 43 Appendix E (a) (1-4). Keep in mind that entrapped moisture can condense causing fluctuations in the airspeed indications if the system drains are plugged. You may choose to back flush the static line with low pressure air during the instrument change.

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PAPERWORK 1) There is an operating limitation placard on the pilot's left side wall which includes the line: MIN CONTROL SPEED SINGLE ENGINE (Vmca) - MPH ( - KTS) This speed must be corrected on 55 and 58 aircraft only if the airspeed indicator limitations are changed and the FAA Approved Flight Manual Supplement Airspeed Limitations are to be observed. It may be required to trim the overlay to fit neatly within the available space. 2) You will also find a logbook label covering the VORTEX GENERATOR installation which should be placed in the Major Modification section of the aircraft log toward the front of the book. If there is no such section, it may be placed in chronological order in the maintenance section. 3) If an exchange airspeed indicator is part of this kit, you will find a separate logbook entry label to record that procedure. Place this label in chronological order in the maintenance section. 4) On 55 and 58 aircraft, the Aircraft Flight Manual Supplements are only to be used when the airspeed indicator has been re-marked to reflect the airspeed limitations contained in the supplement and the Vmca placard installed. There are two copies of the AIRPLANE FLIGHT MANUAL SUPPLEMENT included with the documentation package. One copy is enlarged to 8-/2" x 11" for ease of reading the charts(s). The copy should be given to aircraft owner/operator. The other copy should be placed in the AIRPLANE FLIGHT MANUAL behind the supplements divider and immediately following the log of pages.

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5) There are two copies of the FAA Form 337 included with the drawing package that will require the installer's signature and the return to service endorsement. After completion, one copy is to be sent to your FAA Flight Standards District Office and the other is to retained with the aircraft records along with the copy of S.T.C. SA4016NM and the installation drawings. 6) The on-board spare parts kit should be given to the owner/operator or left in the plane. Be certain that the spare V/Gs (generally 8 or 10) are placed in this kit. PAINTING VORTEX GENERATORS For one set of Vortex Generators cut two pieces of special blue vinyl masking tape about 84 inches long. This tape works better than standard masking tape to seal the bottom of the foot of the V/Gs against paint intrusion and to minimize the transfer of adhesive. Fold over about one inch of both ends of each tape so that it sticks to itself. This simplifies handling and fastening. Place each tape, sticky side up, on a firm surface such as cardboard or plywood about 6 inches apart and fasten one end securely with a thumb tack through the doubled portion. Pull the tape taut and secure the other end in a similar manner. Add a thumb tack to the middle of the tape as well. CAUTION! If there is loose dirt, dust or lint on the cardboard or plywood it will contaminate the paint being sprayed on the V/Gs. Also, if there is a crown or bow to the tape it may flutter when exposed to the paint spray stream. Use additional tacks or tape to hold the long pieces of tape in place.

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Place one half of the large V/Gs and one half of the small V/Gs on each tape (i.e. P/N 1003 with P/N 1001 and P/N 1004 with P/N 1002) end to end lengthwise so that all of the tops curl in the same direction with approximately 1/8 " gap between. Spray paint in the normal manner, but avoid excessive paint buildup because this will result in a "feather" of paint extending out from the foot of the V/Gs when they are removed from the tape. If there are "feathers" the V/Gs will not fit into the openings in the templates. So, it will be necessary to remove them by sanding lightly. Place a fine (320 grit or so) piece of sand paper on a flat surface and draw each edge of the V/G along the abrasive with the base or foot elevated to a 45 degree angle. This will remove the excess paint without disturbing the portions to remain. If there is any adhesive on the underside of the foot it may be removed with lighter fluid. Small traces of paint on the underside will not affect the adhesion process as long as the bottoms are flat. Paint buildups can be removed by light sanding.

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MOTECH DRAWING LIST

DL-100 Rev. 2/24/88

REVISION VG-100 VG-101 1000 VORTEX GENERATOR INSTALLATION Layout dimensions 55 & 58 Series VORTEX GENERATOR INSTALLATION Layout dimensions 58TC & 58P Series VORTEX GENERATORS Part numbers: 1001, 1002, 1003, 1004 1005, 1006 AIRSPEED INDICATOR MARKINGS Charts for: 55, A, B, C, D, E 58 PLACARD OVERLAYS Part Numbers: PL-1001, PL-1002, PL-1003 PROCESS SPECIFICATION Adhesive specifications A 12/3/87 A 2/22/88

1100

A 2/23/88

1200

A 2/23/88

PS-100

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MOTECH

DL-100 5/3/87

PROCESS SPECIFICATION ADHESIVE Properties (cured state) : Impact strength Peel strength Tensile shear strength 11 ft - lb/sq in 28 lbs/in Aluminum 0.000 gap 2500 lbs/sq in 0.024 gap 500 lbs/sq in Temperature range (continuous) -51C to +121C Solvent resistance Air ref. 100% Gasoline 22% Water 61% Glycol/water 56% 25% Variation in properties allowed as production batch tolerance.

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STALL WARNING SYSTEM ADJUSTMENTS The stall warning switch is carefully adjusted when the airplane is test flown at the factory. Should it require readjusting, proceed as follows: Locate the switch installation on the under surface of the left wing and loosen the two Phillips-head screws, one on either side of the vane. If the stall warning has been coming on too early, pull the vane back and down. If the stall warning has been coming on too late, push the van up and forward. Moving the vane with the Phillips-head screws loosened moves the entire unit up or down inside the wing causing the switch to be closed earlier or later. Retighten the screws after making each adjustment. NEVER TRY TO ADJUST THE SWITCH BY BENDING THE VANE. As a rule of thumb, moving the vane 1/4" will change the time the stall warning actuates by about 5 mph of indicated air speed. The only way test the accuracy of the setting is to fly the airplane into a stall, noting the speed at which the warning horn and light come on and the speed at which the full stall occurs. The stall should be made with the flaps and gear up and power off. Prior to stalling decelerate no faster than one mph per second. It may be necessary to make several alternate adjustments and test flights before the desired setting can be reached. The stall warning should actuate, ideally, at 7 to 9 mph ahead of the complete stall, although from 5 to 10 mph ahead of the complete stall will meet FAA requirements. The switch setting should be checked and adjusted as necessary whenever a wing or wing leading edge is replaced or extensively repaired, or if a new switch is installed. The switch should require no adjustment in normal service.

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V.G. SYSTEMS INNOVATIVE TECHNOLOGY FOR PERFORMANCE, UTILITY AND SAFETY INSTRUCTIONS FOR REPLACEMENTS OF MISSING V/G'S If vortex generators from the V/G kit become dislodged they may be replaced with the spares which are included herewith. ________________________________________________________________ 1. ADHESIVE: The enclosed adhesive conforms to Motech Process Specifications PS-100. Application instruction is on container. Use swabs to clean up excess adhesive immediately after positioning V/G's. 2. POSITIONING: Refer to the appropriate V/G JVC drawing for installation specification. If the footprint of the missing piece does not define the position for the replacement piece on the opposite side and mark a paper template to be used to position the missing V/G. ___________________________________________________________________ Call if you have any questions. We are happy to help at any time.

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V.G. SYSTEMS INNOVATIVE TECHNOLOGY FOR PERFORMANCE, UTILITY AND SAFETY

IMPORTANT

The V/G system is designed to reduce stall and improve low speed handling qualities through control boundary layer airflow. It is assumed that the airplane conforms to its original Type Data Certificate because of the FAA's requirement that aircraft receive at minimum annual inspections to maintain airworthiness. Should this aircraft not conform to its original Type Data Certificate in the areas of control travel/trim/tabs, control cable tension, or wing incidence, the modified aircraft may not be able to attain airspeeds contained in V.G. Systems information. V.G. Systems recommends that installing mechanics and owner/pilots take this into consideration, and that these items be inspected and adjusted if necessary according to the appropriate aircraft maintenance manual.

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