Installation and Continued Airworthiness manual
Contents
1. Inspect for freedom of rotation amp condition of pulleys Inspect for signs of leakage and wear around the exit for the rudder retract cable Pulleys and Bushings Internal Cable Tubing Hulls amp Struts Inspect for damage surface Float exterior coat gel coat UV protection keel wear strips chine wear strips ay Inspect for evidence of Float interior damage from the interior vantage point xX Inspect seals cracks in Access Panels amp pump out tubes attachment Pump Out System lof pump out tubes tube routing X Spray coat protection Deck Blocks Deck according to Note 1 Plates and Hardware Hardware according to Note 2 If working saltwater protect more frequently x Inspect for damage corrosion Struts Inspect seals latches internal damage from baggage X AEROCET ISSUE A DATE 7 22 05 Inearparated tata 11 of 12 y FILS nO Dra TITLE Service amp Maintenance Manual aa gt A 10032 REV STON B a T SUBTITLE Model 3500 or 3500L Floats Sp 0 4 DATE INSPECTION TIME HOURS MONTHS _ INTERVALS a occurs first ee a 12 eee Bloat eles Inspect for corrosion of all neven parts wear fatigue or fray Placards Cabin Placards Inspect for placement amp bas legibilit X Note 1 Spray coat of a migrating corrosion material ACF 50 Boeshield T9 or Corrosi2. Because of the composite structure in the design of the floats hull corrosion and leakage are basically eliminated The floats should be kept clean with soap and water The sides and the bottoms from the step aft can be waxed to help in the cleaning process The bottoms of the floats from the step forward should not be waxed as this gives unpredictable water performance Stains from the waterline on down may be removed using marine fiberglass stain remover We have used a product called FSR with good success Do not use abrasive cleaners or pads these will scratch the white gel coat surface The gel coat color surface should always be maintained on the floats for ultraviolet protection The metal chine strips are abrasive wear surfaces used to protect the floats from docks and pilings These are extrusions bonded on using a one part urethane adhesive These should be kept intact The keels have UHMW plastic wear strips bonded on for protection and optional wear strips can be added up from the keel in the step area where the float would nest in the rocks on the beach These wear strips should be observed on preflight or if you suspect damage They should never be allowed to wear through to the gel coat surface on the float Replace as necessary See Sec 8 Fig All float access panels are to be removed upon annual inspection to view for hidden damage and to comply with the maintenance and water rudder sections During this time assure that
3. Float Sealant for Bolts and Chine Strip attachment Sika Manufacturing Sikaflex 292 2 Rust corrosion Protection ACF 50 Corrosion X Boeing Co Boeshield T9 Bolt Protection PUR AL KETONE Distributed by Lake amp Air LPS Industries LPS 3 Zip Chemical Co Zip D S029NS 4 Composite Materials for Hull Repair Contact Aerocet Inc for resin cloth gel coat resin thickeners
4. or the resin may never completely cure resulting in a reduction of strength WARNING Be careful with the MEKP catalyst Contact with eyes must be prevented Blindness may result Flush eyes immediately contact a physician immediately Never mix MEKP catalyst into the resin without eye protection EROCET Lo ISSUE PAGE DATE 7 22 05 nicorpomise Lo Pee ee DE a ll E Pre wo o TITLE Service amp Maintenance Manual ioe ste 10032 REVISION REVISION DATE SUBTITLE Model 3500 or 3500L Floats p Ae SF gy 5 5 Preparation of Fiberglass Materials 1 Fiberglass shall be trimmed on a clean table to prevent contamination 2 When laps are necessary lap widths of at least 1 2 shall be maintained for fiberglass pieces in any given ply and no more than one of the component plies shall be lapped at any one place The number of laps shall be kept to a minimum 5 6 Surface Coat Application Gel Coat 1 All surface coats must be applied to a thickness of 10 to 15 mil Use a mil gauge and check often Waterline down is very critical to prevent blistering from water absorption 2 All surface coats must be catalyzed with 2 MEKP Thinning of surface coats can only be done to manufacturers recommendations 5 7 Keel amp Wear Strip Bonding 1 Prepare keel by sanding surface with 80 grit paper 2 Bond keel amp wear strips on using a mixture of Hydrex resin and Aerosil 202 thickener A thick epoxy resin clea
5. a resin glass bubble mixture Apply the final laminates accordingly to finish the repair 5 3 Impregnation of Fabric Resin impregnation can be accomplished by laying cloth cut to a suitable pattern on a flat table and applying resin mixture with a squeegee so as to achieve an even impregnation It may also be done similarly directly on the part with the cloth is being applied using either a squeegee or brush providing voids and starved areas are not produced It is very helpful to apply a thin coat of resin to the area to be laminated Then lay the cloth down rolling the cloth into the resin Any air in the laminate should be squeegeed or brushed out See section 8 4 regarding resin mixing 5 4 Resin Mixing Gel times or pot life is the time it takes the resin to set up in the container after proper and thorough mixing with accelerators and catalysts Gel times can be adjusted significantly by varying the amounts of these materials Gel times also will vary significantly with the batch size if left in a bucket or with a very thick laminate TYPICAL GEL TIMES HYDREX 33 253 100gm castings only laminate times typically double 33 MEKP i 50 F 70 F 80 F 5A 38min 28 min 23 min 1 00 100gm 20 min 15 min 1 50 100gm 30 min 21 min 14 min 11 min 2 00 100gm 23 min Note Under no circumstances should more than 2 0 catalyst mixture be used Also do not use less than the recommended minimum amount of catalyst 75
6. enough supply backing to hold the shape of the original contour Put a parting agent on this backing to assure its release Replace the fabric on a ply for ply basis overlapping 1 2 minimum on each succeeding ply using impregnation of fabric as described in section 8 3 Any smooth areas need to be sanded with 80 grit sandpaper to assure proper bonding If damage has occurred where there is sandwich construction involving the core work each layer separately Fix either the outside or inside skins Then cut to fit like core material to replace the damaged core Bond the core onto the repaired skin using the proper resin and AIEROCET ISSUE oe yo DATE dayne Incorporated TITLE Service amp Maintenance Manual REVISION FILE NO REVISION __DATE SUBTITLE Model 3500 or 3500L Floats 3 4 Cuts Fractures or Punctures 1 4 diameter or Larger Contd thickener A mixture of Hydrex resin and Aerosil 202 thickener should be applied to the bonding surface of the core using a squeegee Torin Corebond alt OK A film of approximately 015 should be used Pressure needs to be applied for the bond to assure proper adhesion tothe skin eliminating air voids This pressure can be applied to small area core bonding by weights ex lead shot bags with a release film to keep from sticking to any excess Larger areas require core bonding using a vacuum bag Consult Aerocet Inc for this procedure Fill any seam voids with
7. leak through the pump out plugs where the nylon pull line penetrates and may also seep through the access panel seals Condensation will also generate water inside the float compartments More than 4 or 5 full pumps of water using an aircraft float pump should raise concern for maintenance In contrast if a pump out tube is cracked or broken there will not be a significant sucking sound when the pump is removed from the pump out cup If there is question regarding the integrity of the pump out tube investigate Attention should be given to any bolts that pass through the stern or other external float structures These should be sealed into place using a single part urethane such as Sikaflex 292 It should also be noted that more water is typically pumped from the stern and bow compartments because they are often covered with water during operation and allow more seepage through the plugs and seals Pump out plugs must have some venting capability to allow for expansion and contraction of the air in each compartment during flight If the pilot when on the water runs over rocks or debris he must assess the damage as soon as possible Continuing into a high speed situation with the floats will typically exaggerate the damage due to high water pressure SECTION 3 Float Handling and Jacking In order to service the landing gear parts and to do retraction tests the floats are jacked up and blocked using a floor jack with at least 1 ton capacity R
8. AEROCET SSUE eee oo aa ica are 7 22 05 oa Piper a ote Tae STE NOS TITLE Service amp Maintenance Manual d 10032 i REVISION gt Rfvrs1on f DATE SUBTITLE Model 3500 or 3500L Floats EE ERE r SERVICE MANUAL AND INSTRUCTIONS FOR CONTINUED AIRWORTHINESS FOR AEROCET 3500 or 3500L SEAPLANE FLOATS Aerocet Inc PA Box 2119 265 Shannon Lane Priest River Idaho 83856 Phone 208 448 0400 Fax 208 448 1644 JIEROCET me Te pare 7 22 05 Incorporated TITLE Service amp Maintenance Manual REVISION i SUBTITLE Model 3500 or 3500L Floats DATE LOG OF REVISIONS PAGE REV PAGES DESCRIPTION DATE AFFECT PS ant ae Initial Release 7 22 05 ina O ill JIEROCET Incorporated PILE NO TITLE Service amp Maintenance Manual ae l we SUBTITLE Model 3500 or 3500L Floats REVISION DATE E Table of Contents Float Hull Danae Continued Airworthiness Service Schedule General Practices and Product ss for Service ve fH f EA i is ig FR oat SETIN Model 3500 or 3500L Floats AAEROCET A z fests Incorporated _ gt PAGE ___ Dare 7 22 05 Fe FILE NO TITLE Service amp Maintenance Manual aes Ree SECTION 1 Introduction and General Float Information This service and maintenance manual is applicable to Aerocet Model 3500 or 3500L Twin Seaplane Floats and their general application to a variety of air
9. aise only one float at a time chock the opposite float properly and assure proper balance The best lift point is 3 inches ahead of the step on the keel This locates the jack directly under the main bulkhead in the float If space permits use a board in between the jack and the keel After raising the float block the float in a couple of places ahead of the step Usea sawhorse to support the after body of the float to keep the plane from tipping back Locate the sawhorse support under one of the back bulkheads which are located 17 amp 45 forward from the stern During initial installation or for maintenance it may be convenient to use the lifting rings on the top of the fuselage These provide the proper points to attach a lifting harness to elevate the complete airplane The hoist should have a capacity of least 2 tons and a proper lifting harness to assure that the pull on the lift rings is vertical The airplane may be otherwise lifted with either a launching dolly or large forklift under the spreader bars Care should be taken to lift as closely as possible to the float hulls without touching the hulls POST SETS ee ee JIEROCET PAGE hi DATE 7 22 05 Incorporated S 6 of 12 FILE NO eat ee TITLE Service amp Maintenance Manual a ged Baao REVISION i RRV s DATE SUBTITLE Model 3500 or 3500L Floats a 0 SECTION 4 Water Rudder Retraction and Steering System 4 1 General Description The water rudd
10. all the pump out tubes are not cracked especially around the fitting to the pump out cup that they pass through their respective locators to keep them in the low spots and have no blockages If a pump out tube is cracked AIEROCET PAGE a ae Incorporated Ronit 13 DATE 7 22 05 Ter L NK FILE NO ee TITLE Service amp Maintenance Manual A 10032 REVISIO ma AM d SUBTITLE Model 3500 or 3500L Floats oe 0 DATE SECTION 2 Float Hull Maintenance cont d it will not pull the water out of its respective compartment resulting in extra weight and CG problems Replace as necessary Any penetration to the float structure delamination of the layers of cloth or gel coat wearing through must be repaired according to hull repair Section 8 Significant damage warrants consultation from Aerocet Inc Winter storage where temperatures may drop below freezing is addressed by adding a quart of RV antifreeze through each of the pump out cups Taping over the pump out holes will minimize the amount of moisture that will enter each of the six compartments Do not use masking tape Float locker latches and seals are to be maintained as needed The locker latches are adjusted by spacing the black catch ramp the correct distance to maintain an indent as the locker latches the white dots to the outside Investigation should be prompted if excessive water is pumped from any of the pump out cups during pre flight Water can
11. ater patch kits may be used in an emergency if the damage is relatively small but the repair must be replaced with correct materials for equal strength status Damage larger than 4 in size requires consulting Aerocet Inc for proper laminate orientation and assuring number of laminates in the damaged area 5 2 Repair Types and Procedures All repaired areas on the exterior must be surface coated gel coated with a minimum of 10 mil thickness to assure UV protection 1 Resin Starved Areas Exposed Fibers or Small Impact Damaged Soft Spots 1 2 Dia or less Lads Le If necessary sand surfaces to remove gloss Use brush squeegee or hypodermic to work resin into defective area use same resin as the original laminate 2 Small Bruises Punctures Less than 1 4 diameter or Surface Voids Leds hive 2d 2 4 Jae Sand surface surrounding defect to remove gloss Use same fabric as the original part Cut patches to fit correction area extending a minimum of 1 2 past the damaged area All patch corners must be rounded Apply a light brush coat of resin similar to original Place one or more plies on detail covering correction area using impregnation of fabric as described in section 8 3 3 Cuts Fractures or Punctures 1 4 diameter or Larger ERA eMe 3 4 Cut back material as required to ascertain extent of damage Trim back plies to a smooth oval 1 2 per ply generally If the area is large
12. ation 4 4 Rudder Rigging Reference 35 CPL 24001 Sheets 1 3 and appropriate STC drawings i The rudder steering rigging should align the rudders straight ahead with the airplane rudder centered Cables should be just taught There should be no pre stretching of the springs which connect them to the airplane rudder system This keeps the friction low not hampering yaw stability The rudder retract cables should be rigged so that the rudders are close to the stops when retracted and that the cables are just becoming slack in the down position All cables should be examined for deterioration especially around the pulleys at the stern of the float ISSUE __DATE 7 22 05 REVISION DATE AIEROCET Incorporated TITLE Service amp Maintenance Manual SUBTITLE Model 3500 or 3500L Floats SECTION 5 Repairing Composite Float Hulls 5 1 General Description Composite float repair done correctly will obtain the strength required to put the float back into service and cosmetically show little or no evidence of damage ever taking place The materials used for original construction and repair are conventional to the industry Any damage on the bottom of the float should be repaired immediately because of the tremendous water pressures encountered Contact Aerocet Inc prior to beginning a repair to obtain correct materials resin resins have shelf lives catalyst cloth gel coat resin thickeners Epoxy underw
13. ers are used for steering when taxiing on the water They are steered through 3 32 stainless cables that connect to the airplanes rudder system and are retracted manually through a lever in the cockpit again using 3 32 stainless cables They should always be retracted before take off and never deployed until off the step Damage may result if a take off or landing is attempted with the rudders down Typically this damages the blade and the stainless tiller post Internal sealed tubing in which the 3 32 cable passes through prohibits water transfer between the two rear water tight compartments in each float 4 2 Rudder Assembly and Internal Cable Tubing Reference 35 CPL 24001 Sheets 1 3 and appropriate STC drawings i 2 Assemble and disassemble water rudders according to drawings See 35 24000 or 35 24001 Assure that water rudders are free in movement and rudder links and springs don t have excessive wear Any hardware replaced that passes through the rear bulkhead should be sealed with a one part urethane sealant Regarding the internal cable tubing look for any breaks or wear points especially where the retract cable comes out the inside of the float and replace as necessary 4 3 Rudder Pulleys Reference 35 CPL 24001 Sheets 1 3 i Bs Check freedom of pulleys in all locations Remove and clean if there is any buildup in the bushing to pulley interface Remove any pulleys that have wear flats from lack of rot
14. on X Note 2 Coat hardware with PUR AL KETONE or LPS 3 AIEROCET ee ISSUE Incorporated us PAGE DATE 7 22 05 fat TITLE Service amp Maintenance Manual H REVISION ON SUBTITLE Model 3500 or 3500L Floats __ DATE Revision 6 1 Exceptional Inspections In a variety of circumstances it is necessary to perform prompt inspections for damage Details relating to these investigations are addressed in Section 2 Section 8 of this manual and Table 1 above It is the responsibility of the pilot to determine the severity of damage and the flightworthiness of the aircraft in the field Inspections and repairs are to be performed as necessary and per practices outlined throughout this manual A list of possible scenarios includes but is not limited to the following Landing completed on grass or other runway surfaces Harsh landings on either runway or water Impact with a submerged object during taxi take off or landing on water Suspected damage incurred during tie down or mooring e g damage from wind or wave action oo es ee Ta Excessive water during pump out on pre flight inspection 6 2 General Practices 1 Metal Parts check for corrosion stress cracks or metal distortion elongation of holes rivet damage 2 Critical Bolts check for corrosion rust wear torque 3 Composite Parts check for stress cracks gel coat presence UV protection punctures 6 3 Product Listings 1
15. planes Strut geometry boxing flying wires water rudder retract routing are unique for each STC or TC application to aircraft Installation of the Aerocet Model 3500 or 3500L Twin Seaplane Floats should be done according to the FAA approved drawings supporting these different applications The Aerocet Model 3500 or 3500L Twin Seaplane Floats are all composite float hulls separated by spreader bars and are mounted to various airplanes with aerodynamic aluminum struts These are rigidly mounted Boxing flying wires are used to stabilize the mounting of the floats to the airplane The float design utilizes a double fluted bottom contour from the step forward and has a flat top deck design with built in antiskid Water rudders are mounted on the stern of each float for water taxi operations Each float offers a single large locker for storage and six compartments for safety Access to the insides of these compartments is facilitated through access panels on the deck or through the storage locker hatch cover The floats incorporate pump locations into each compartment which are used to remove any excess water from condensation leakage from the access panel gaskets bolts or pump out plugs or leakage from a damaged float hull Steering of the airplane is done by the aircraft rudder at high taxi speeds or high RPM s while at slower speeds the water rudders are deployed for effective maneuvering on the water SECTION 2 Float Hull Maintenance
16. r type non yellow may be used as well 3 Saturate the fiberglass backing on the keel or wear strip and put a thick film on the mating surface 4 Hold the keel strip in place using an abundance of masking tape Remove tape before the resin cures to a totally hard condition allowing clean up of excess material to be achieved with greater Case 5 Wear strips are more difficult to hold in place during cure with the floats on the airplane This can be achieved using tape and small lengths of wood to create leverage See diagram below Lo STRIP WASKING TAPE WEAR STRIPS FLEXIBLE wood STRIP OR SERIES OF BLOCKS BOTTOM OF FLOAT HULL SHOWING ee WEAR STRIP INSTALLATION i T ROLE Ne DSTA r ON TANEET a i N i fs EROCET ma ISSUE E poe pare 7 22 05 incorporated 7 l 10 of 12 TITLE Service amp Maintenance Manual Ce oe ee T02 REVISION REVISION DATE SUBTITLE Model 3500 or 3500L Floats are ee 0 SECTION 6 Continued Airworthiness Service Schedule General Practices and Product Listings for Service 6 1 Service Schedule Table 1 TABLE 1 INSPECTION TIME HOURS MONTHS INTERVALS Whichever occurs first Inspect for damage and freedom of movement check right after a take off or landing with the rudders Water Rudders amp Tiller Posts Inspect for fraying especially around the stern pulleys amp cable guards cotter pins TN
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