RALLY ASSEMBLY MANUAL

INTRODUCTION
STORMAIRCRAFT recommends to follow step-by-step procedures described into this
manual, from wings and all moving surfaces assembly to fuselage assembly.

WING JIG
It is advised to assemble the wing into a jig to obtain an optimal result. Follow instructions
below to build wing jig by wood.

1- Prepare a rugged wood basement (3600x1280x30mm). Glue and nail three wood
strips to basement as shown below to assure stability (check levelling).

2- Take a wood plate (at least 1500x300x30mm) and position on fuselage wing profile
and mark it. Cut the wood plate to obtain the wing extrados as shown below. Make
the same with other six wood plates (you need seven plates as main ribs number).

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Glue at 90° the seven cut wood plates to wood support in correspondence of wing main
ribs (see “ main ribs installation” section in next pages).

Glue and nail two wood reinforcement strips, one for each side, to each extrados woods
plates as shown below. Let the glue dry.

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WING
Prepare wing spar. Cut spar edges in order to obtain a total length of 3440mm.

IMPORTANT: cut both edges but do not cut the reinforced inboard wing spar section.

Make a 24mm (length) x 8mm (width) hole on wing spar lower section to pass wing strut
connection 0101 (04-010-00/H hardware kit) at 2114.5mm from inboard.
Insert wing strut connection through dedicated hole and align it with wing strut connection
reinforcement (14-030-00 for left wing or 24-030-00 for right wing). Remove wing strut
connection reinforcement and position reinforcement 0256 (04-010-00/H hardware kit) to
wing spar connection 0101 opposite side. Clamp wing spar connection 0101 and
reinforcement 0256 to spar; drill wing spar and reinforcement 0256 through wing strut
connection holes. Remove clamp and glue wing strut connection and its reinforcement to
wing spar with structural adhesive. Sand wing strut connection and reinforcement before
gluing. Clean with acetone wing spar area in correspondence of wing strut connection
and reinforcement position before gluing. Insert M6x45 bolts through holes previously
drilled and screw them.

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Prepare wing strut connection support cutting both edges leaving 60mm from wing strut
connection outline. Clean and send the wing strut connection support section to glue to
spar and glue it to the spar using structural adhesive. Let the glue dry.

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Position spar reinforcements 0109-1 and 0109-2 (RH and LH) to wing spar leading edge
section as shown below.

Position fuselage fittings 1019 to spar inboard reinforcements 0109. Drill, glue and screw
with M6 and M8 bolts fuselage fittings 1019 to wing spar.

RAL
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Position upper wing skin on wood jig (if prepared) and drill fuel tank cap hole and pitot
hole (if you are assembling the right wing).

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Glue with structural adhesive fuel tank ring cap to wing upper skin.

Install fuel float unit sensor (04-090-00/H Fuel float hardware kit) on first rib, as shown
below. Keep in mind nose ribs are numbered from 1 to 8 starting from inboard.

Remind to install fuel float sensor at 90° from ground line so it can work correctly. Glue
with structural adhesive fuel float unit and fuel pipe fitting 0040 (04-050-00/H Fuel tank
Hardware kit) to rib and make a round corner with glue in excess.

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Now you can glue nose ribs to wing spar. Position nose ribs as shown below; keep in
mind ribs are numbered 1 to 8, starting from inboard section. (first and fifth ribs delimit
wing tank area). Drill pitot tubes holes on spar as shown below.

Moisten area to glue and glue with structural adhesive nose ribs to spar. Let the glue dry.

Mark nose ribs position on spar in order to ease main ribs positioning successively.

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IMPORTANT: Keep particular attention to fuel tank area ribs (rib 1-2-3-4-5), proofing this
area with 3M Scotch-clad EC776 or similar (make sure it is fuel resistant) diluted with
acetone and with a flat brush generously lay the product on the whole tank area, spar and
relevant ribs, taking care to lay it also on the hole walls. Let dry and repeat the same
operation a second time.

Tip: Lay the proofing product only after glue is dry. Making this operation with care
you will avoid fuel leaks. Repeat a second time.

When glue is dry insert wing spar with nose ribs installed inside lower wing skin 14-060-
10 (if you are assembling the left wing) or the 24-060-10 (if you are assembling the right
wing), moisten the area to glue and glue with structural adhesive wing spar and nose ribs
to wing upper skin. Make this operation in two people. If you are assembling right wing it’s
advised to install pitot before gluing nose ribs to wing skin. For instruction about pitot
installation see “Pitot Installation” section in next pages.

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CHECK SPAR AND RIBS CORRECT POSITION
Lay a board on the spar, then lay weights uniformly distributed lengthwise. These weights
will allow adhesive to leak out between skin and cap and to obtain a 1 mm thickness
between these parts. Using adhesive tape, keep leading edge skin very tight to nose ribs.
Lay a board on trailing ribs, then lay weights uniformly distributed lengthwise. After
wearing a glove, pass your finger along glued areas so as to form a right and left stripe on
each trailing rib and on visible part of main spar. Perfectly seal first and last tank rib.

NOTE: Use structural adhesive suggested in this construction manual.

Make a sample at each gluing process and check its features.
Consider the temperature and the humidity level of your workshop.

FOLLOW STRUCTURAL ADHESIVE MANUFACTURER’S INSTRUCTIONS AND

RECOMMENDATIONS VERY CAREFULLY

When glue is dry, position main ribs and glue them with structural adhesive to wing spar
and skin in correspondence of nose ribs (excluding nose rib n°2). Let the glue dry.

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Prepare wing controls. Start assembling first control, the 04-110-02 one. Insert spacer
0208 (04-110-02/H 180° wing control rod hardware kit) inside bearing support SL000000-
07 and close bearing support with two bearings, one for each side. Rivet with solid rivet 3
control bracket 180° SL200080-01 to bearing support as shown below.

Screw the assembled control to control support 0103 with M5x70 bolt.

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Follow same procedure for second wing control, the 04-110-01 one. Insert spacer 0208
(04-110-01/H 75° wing control rod hardware kit) inside bearing support SL000000-07.
Close bearing support with two bearing, one for each side. Rivet with solid rivet 3 control
bracket 75° SL200040-03 to bearing support as shown below.

Screw the assembled control to control support 0015 with M5x70 bolt.

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Glue with structural adhesive control reinforcement plates 0211 to main rib n°6, one for
each side, in correspondence of pre-drilled holes and aligned to ribs profile. Sand and
clean before gluing. Screw the control to control reinforcement and main rib with M5x35
bolts. Put some structural adhesive between control support and reinforcement plate.

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Follow same procedure for other wing control. Glue with structural adhesive control
reinforcement plates 0210 to main rib n°4, one for each side, in correspondence of pre-
drilled holes on rib. Sand and clean before gluing. Screw control support to control
reinforcement plate and rib with M5x35 bolts. Put some adhesive between control support
and reinforcement plate.

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Before closing wing it’s necessary to install wing control rod 04-120-00/2. Take two end
rods SL000000-01 (04-120-00/H Wing control rod hardware kit) and insert M6 male
bearings, one for each end rod, and screw them with stop nut. Rivet with cherry rivets 3.2
end rods to control rod 04-120-00/2. Check distance between wing controls before
riveting end rods, positioning control at 0. Install the assembled rod to wing controls with
M6x35 bolts (04-120-00/H hardware kit).

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Prepare lower wing skin, installing flap and aileron connections reinforcements 0251 and
0252. Glue with structural adhesive reinforcements and dedicated spacers 0277 and
0278 as shown below.

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Glue fuel pipe blow down fitting close to first nose rib and wing spar (internal to wing tank
area). Do not rivet the fitting, use holes to let adhesive come out.

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PITOT INSTALLATION (RH WING)

Drill wing upper skin to install pitot. See below for pitot position. Drill wing spar to pass
pitot tubes (static and dynamic). Pass tubes through main ribs and through holes on spar.
Connect static and dynamic tubes to pitot and rivet it (from outside) to wing skin with
cherry rivets 3.2. Fasten pitot tube to main ribs with plastic clamps provided with 04-070-
00/H Pitot hardware kit.

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CONNECTING WING CONTROL RODS

Install male bearings to end rods SL000000-01, screwing them with stop nut M6 (04-120-
00/H wing control rods hardware kit). Rivet with cherry rivets 3.2 assembled end rods to
control rod 04-120-00/1. Screw assembled control rod to first wing control with M6x35
bolt.

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Follow same procedure for wing control rod 04-120-00/2, the one between the two wing
controls. Check exact dimension between the two controls and adjust rod length if
required. Install male bearings to end rods SL000000-01, screwing them with stop nut M6
(04-120-00/H wing control rods hardware kit). Rivet with cherry rivets 3.2 assembled end
rods to control rod 04-120-00/2. Screw assembled control rod to first wing control with
M6x35 bolt.

Install male bearings to wing control rod 04-120-00/3, the shorter one with diameter size
of 10mm, one for each end. Screw male bearing to control rod with M6 stop nuts. Insert
the assembled rod through dedicated hole (see next pages for wing lower skin inspection
holes). Screw the control rod to wing second control with M6x35 bolt. To connect wing
control rod 04-120-00/3 to aileron see “Connecting aileron to wing” section in next pages.

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Now you can glue with structural adhesive wing lower skin to upper skin. It’s advised to
put some weight over the skin so to compress the two skins and let glue in excess come
out.

When glue is dry, drill inspection holes on wing lower skin as shown below

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