Assembly Manual Sample (PDF) - Kitfox Aircraft

Kitfox Super Sport 

KITFOX AIRCRAFT 

KITFOX SUPER SPORT 

LANDING GEAR INSTALLATION 

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Kitfox Aircraft LLC ©2006 

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Kitfox Aircraft LLC 

Contents 

Section A. Main Landing Gear Assembly ........................................................................................................ 4 

Section B. Wheel and Brake Assembly .......................................................................................................... 10 

Section C. Tailwheel Installation .................................................................................................................... 14 

Section D. Nose Gear Assembly .................................................................................................................... 16 

Section E. Tail Skid Installation ..................................................................................................................... 26 

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Section A. Main Landing Gear Assembly 

The Super Sport aircraft can have either a conventional or tricycle landing gear 

configuration. The configuration can be changed at any time during assembly 

or even after the aircraft has been completed and flown. 

These instructions describe the installation of the landing gear as though this 

were the final assembly, however the gear will have to be removed to cover and 

paint the aircraft. Therefore, all illustrations showing finalization of hardware 

(such as torqued nuts, cotter pins, safety wire, etc.) are there for your future 

reference. 

The Super Sport main landing gear consists of a single-piece aluminum gear 

bow that is mounted to the fuselage between two points that allow the gear to 

pivot as loads are applied. 

Axles bolt to the gear legs to mount the wheels and disc brake assemblies. 

This gear design has proven to be extremely rugged, has low aerodynamic drag, 

and is virtually maintenance free. 

This section is illustrated with the landing gear in its normal, upright position. 

You may find it advantageous to invert the fuselage while installing the gear - 

this helps keep the hardware in place while you get the nuts threaded on the 

bolts. If you choose to invert the fuselage, invert the illustrations as well to 

reduce confusion while you are working. 

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NOTE 

PORT FACES 

FORWARD 

DISC BRAKE 

ASSEMBLY 

FWD 

AXLE 

ASSEMBLY 

WHEEL & TIRE 

ASSEMBLY 

WHEEL ATTACH 

HARDWARE 

Figure A-1 

Main Gear Assembly Overview 

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Completion Date 

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1. Cut four Delrin ® separator disks from the supplied material. A bandsaw 

works well for the initial cut. Clean up the edges with sandpaper or a 

file. Make sure that the disks do not exceed the 2" outside dimension. 

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SEPARATOR DISK 

(FABRICATE FROM 

P/N 13016.106 DELRIN, x 4) 

1 

ø 2" (51mm) 

Figure A-2 

Separator Disk Fabrication 

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2. Ream the four fuselage gear attach bushings to .3750". Drill out the 

5 

/16" holes in P/N: 13016.102 lower pivot blocks to 3 /8" 

3. Press the four roll pins into the gear leg at the locations shown. Use an 

arbor press if one is available. If not, the pins can be carefully driven in 

with a small hammer. If you use a hammer to drive the pins in, hold them 

with a pair of pliers initially to keep your fingers out of the way. 

4. Attach the gear leg to the fuselage with the hardware called out in Figure 

A-3. Note that the gear is not symmetrical - the tapered face must be 

installed toward the rear. Figure A-3 shows the tricycle (aft mounting) 

configuration. The conventional landing gear configuration is similar, 

although longer bolts are used. 

NOTE 

To help you achieve the proper fit of the gear leg between the rocker and 

separator disks, the mounting hole through the rocker disks has been 

drilled .010" off center. If the gear leg seems too tight or too loose between 

the disks, rotate one or both of the disks on each side 180° until the 

leg is held with as little play as possible without binding. 

NOTE 

There are threaded holes in the Delrin ® gear rocker blocks. They will not 

affect the installation - they are from the tooling process. Deburr the threaded 

holes as required to remove any remaining material on the surface from 

the threading process. 

OPTIONAL WHEEL PANTS 

If you are installing wheel pants, refer to the instructions that came with 

the wheel pant kit before installing the axles. 


_______________ 

5. Bolt the axles and brake torque plates to the gear legs using the 

hardware shown. The plates should be oriented at about the 4 o’clock 

position, viewed from the axle end. Torque the nuts to 50 to 70 inchpounds. 

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IF GEAR LEG HAS TWO SETS OF 

HOLES, PRESS PINS INTO INNER 

SET AND FILL OUTER SET WITH 

STRUCTURAL ADHESIVE 

FWD 

AN380-2-2 COTTER PIN (x 2) 

AN310-5 NUT (x 2) 

AN960-516 WASHER (x 2) 

.3750" (x 2) 

FUSELAGE 

3 

2 

SECTION 


50-70 IN/LB 

P/N 91310.000 

ROLL PIN (x 4) 

5 

GEAR LEG 

AXLE ASSEMBLY DETAIL 

P/N 13012.101 

AXLE 

TORQUE 

PLATE 

BRAKE LINE PORT (x 2) 

P/N 13016.103 

GEAR ROCKER DISK (x 2) 

P/N 13016.104 

GEAR ROCKER (x 2) 

P/N 13016.102 

LOWER PIVOT BLOCK 

DRILL OUT TO .375" (9.5mm) 

P/N 13016.101 

UPPER PIVOT BLOCK 

P/N 13016.106 

SEPARATOR DISK (x 2) 

4 P/N 13013.201 

GEAR SPRING 

TAPERED FACE IS 

ORIENTED REARWARD 

AN960-416 WASHER 

AN365-428 NUT 

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FWD 

AN4-21A BOLT 

Figure A-3 

Main Landing Gear and Axle Installation 

NOTE 

- USE AN6-40 BOLTS TO MOUNT MAIN GEAR IN AFT 

POSITION FOR TRICYCLE CONFIGURATION (SHOWN) 

- USE AN6-51 BOLTS TO MOUNT MAIN GEAR IN FORWARD 

POSITION FOR CONVENTIONAL CONFIGURATION (NOT SHOWN) 

Kitfox Super Sport


Section B. Wheel and Brake Assembly 

1. Working on a clean workbench, remove the wheel bearing retaining 

spring ring, the cover washers, the felt wiper, and the bearing from the 

wheel halves. Work on one wheel half and bearing at a time to prevent 

mixing the parts. Pack the bearing with wheel bearing grease by putting 

a golf ball sized lump of grease in the palm of one hand and pressing the 

edge of the bearing into the grease. Rotate the bearing a little and repeat 

the packing motion. You should see the grease oozing up between the 

rollers. Turn the bearing over and pack the grease in from the other side, 

all the way around. When the bearing is fully packed with grease, put 

it and the rest of the bearing hardware back into the wheel half and 

reinstall the retaining ring, making sure that it is fully seated in its 

groove. Repeat for the bearing in the other wheel half and repeat the 

whole process on the other wheel. 

2. Remove the nuts and bolts holding the wheel halves together and 

separate the wheel. Insert a tire tube into a tire, dusting the tube with tire 

talc to eliminate friction between the two. If the tire has a red dot painted 

on the sidewall, align the valve stem with the dot. Press the valve stem 

through the hole in the wheel half, and then press the wheel half fully 

into the tire. It is helpful to put a very small amount of air in the tube, 

just enough to help it hold its shape. Press the opposite wheel half into 

the tire from the other side, visually aligning the mounting holes. Pass 

a bolt through the wheel halves and brake disc, press the halves 

together, and start a nut on the bolt threads. Install the other bolts in a 

similar manner and torque them to 90 inch-pounds. 

CAUTION 

Be careful not to pinch the tube between the halves of the wheel as 

they come together. Listen and feel for crisp, metal-to-metal contact 

of the wheel halves before tightening the bolts. If you have difficulty 

ensuring that the tube is not caught between the wheel halves, a ring 

of thin cardboard can be taped in place around the wheel half split 

line to help guard the tube. 

WARNING 


_______________ 

Never inflate the tire unless all the wheel bolts are installed and properly 

torqued. Always deflate the tire before loosening any wheel bolt. 

The wheel halves will be very forcefully ejected by the tire pressure if 

these precautions are overlooked. 

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WHEEL 

BEARING 

DETAIL 1 

GREASE (x 2) 

2 

WHEEL ASSEMBLY 

HARDWARE 

BRAKE DISC 

BEARING 

WASHER 

FELT WIPER RING 

WASHER 

RETAINING RING 

P/N 39019.000 

WHEEL (INNER HALF) 

TIRE 

TUBE 

P/N 39019.000 

WHEEL (OUTER HALF) 

90 IN-LB 

Figure B-1 

Wheel and Tire Assembly 

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3. Slip the inner brake pads onto the caliper pins if they were removed for 

any reason. Lubricate the brake caliper pins with a dry film lubricant 

such as LPS-1. 

4. Slide the brake caliper onto the brake torque plate from the inboard side. 

The caliper should have its bleeder fitting oriented downward. 

5. Slide the wheel and tire assembly onto the axle, followed by the axle 

spacer and the axle nut. Tighten the axle nut firmly and rotate the tire 

by hand to squeeze out the extra grease from the bearing rollers and 

races. Loosen the nut one-half turn, then re-tighten it slowly until all 

play has been removed from the bearings. This play can be felt by 

grasping the tire at the top and pushing it in and out. When the nut is 

adjusted, advance or retreat it just far enough to align the closest cotter 

pin hole. Double check the bearing play and readjust as required. A 

very small amount of play is preferable to having the bearing being too 

tightly preloaded. 

6. Install a cotter pin to secure the axle nut. 


_______________ 

7. Set the outer brake pad in place, trapping the brake disc between the two 

pads. Secure it with the bolts that were supplied with the wheel and 

brake kit. Torque the nuts to 75 to 80 inch-pounds for final assembly. 

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BRAKE LINE FITTING PORT 

BLEEDER FITTING ON OPPOSITE SIDE (BOTTOM) 

75-80 IN-LB 

4 

BRAKE ASSEMBLY 

3 

INNER BRAKE PAD 

7 

OUTER BRAKE PAD 

LPS-1 

LUBRICANT 

BRAKE DISC 


(TIRE & TUBE REMOVED FOR CLARITY) 

AXLE ASSEMBLY 

AN380-4-8 

COTTER PIN 

6 

P/N 13012.102 

SPACER 

5 

P/N 91258.000 

1-1/4 x 16 AXLE NUT 

Figure B-2 

Wheel and Brake Installation 

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Section C. Tailwheel Installation 

The tailwheel assembly consists of an aluminum tail spring, a steerable, fullswiveling 

tailwheel, and steering chains and springs that are connected to the 

rudder to allow maneuverability of the aircraft during ground operations. 

1. Round the corners of the tailspring clamp plate with a file. 

2. Ream the mounting holes in the clamp plate to .1875" 

3. Ream the fuselage bushing to .3125" for the tailspring mounting bolt. 

4. Ream the two holes in the fuselage mounted tailspring clamp plate to 

.1875". 

5. Install the tailwheel springs using the hardware shown. Torque the 

tailspring clamp plate bolts to 20 to 25 inch- pounds and the forward tail 

spring attach bolt to 100-140 inch-pounds. 

6. Bolt the tailwheel assembly to the tailwheel spring using the bolt, nut, 

and washer shown. Torque the tailwheel mounting bolt to 270 to 300 

inch-pounds. 

NOTE 

The steering springs and chains will be installed when the aircraft is complete 

and is at its empty weight (refer to the Final Assembly chapter for the 

weight and balance definitions and procedures) prior to initial taxi testing. 


_______________ 

7. Install a tailwheel steering chain to each lower control horn on the 

rudder using a P/N: 10055.000 wire clip. Attach a steering spring 

between each steering arm on the tailwheel and the corresponding 

chains with a minium of slack. Leave two or three extra links on the 

chain to allow for further adjustments until you are satisfied with the 

ground handling characteristics of the aircraft. 

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AN5-22A BOLT 

3 

.3125" 

20-25 IN-LB 

AN365-1032 

AN365-1032 NUT (x 2) 

AN960-10 WASHER (x 2) 

1 

P/N 82099.000 

TAILSPRING CLAMP 

2 

.1875" 

1/4" (7mm) R 

SECTION 


FUSELAGE 

4 

.1875" 

"C" CHANNEL SHIM 

SUPPLIED WITH 

TAILWHEEL 

P/N 10001.124 

BUSHING (x 2) 

AN960-716 WASHER (x 2) 

6 

270-300 IN-LB 

AN364-720 NUT 

P/N 10768.000 

TAIL WHEEL ASSEMBLY 

7 

P/N 33009.000 

TAILWHEEL STEERING 

SPRING (x 2) 

AN7-21A BOLT 

P/N 13022.101 

TAILWHEEL SPRING 

AN960-516 WASHER (x 2) 

5 

P/N 82099.000 

TAILSPRING CLAMP 

TO LOWER 

RUDDER HORN 

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100-140 IN-LB 

AN365-524 NUT 

AN3-12A (x 2) 

P/N 10055.000 

ATTACHMENT CLIP (x 2) 

Figure C-1 

Tailwheel Installation 

P/N 33005.000 

TAILWHEEL STEERING 

CHAIN (x 2) 

Kitfox Super Sport


Section D. Nose Gear Assembly 

The nose gear assembly consists of a steel fork mounted to a streamlined steel 

tube strut. The strut is attached to the fuselage by pivot blocks, and an 

elastomeric shock assembly handles the shock absorption. 

The wheel bearings are completely sealed, keeping the grease in and the dirt and 

moisture out. 

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GEAR ASSEMBLY PIVOTS 

ENGINE MOUNT 

SHOCK ASSEMBLY 

NOSE GEAR STRUT 

WHEEL AND TIRE 

FORK ASSEMBLY 

Figure D-1 

Nose Gear Assembly 

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1. Press the pivot bearings into the pivot brackets. Use an arbor press if one 

is available. A smooth-jaw vice can be used to press the bearings in, but 

you must be careful to keep the parts in alignment to prevent binding 

and distortion of the bearings. Secure the bearings with a liquid bearing 

locking compound. 

2. Ream the four pivot bracket mounting tabs on the fuselage to .1875". 


_______________ 

3. Slip the pivot brackets onto the gear strut pins with the flanged side of 

the bearing toward the strut. Bolt the pivot blocks to the fuselage with 

the proper bolts, washers, and nuts as shown. Torque the nuts to 50 to 

70 inch-pounds. 

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P/N 33030.000 

PIVOT BRACKET (x 2) 

LIQUID BEARING 

LOCK (x 2) 

1 

50-70 IN-LB 

AN365-428 

NUT (x 4) 

2 

.2500" 

P/N 33038.000 

PIVOT BEARING (x 2) 

FUSELAGE TABS 

AN960-416 WASHER (x 8) 

AN4-21A BOLT (x 4) 

3 

P/N 35027.000 


Figure D-2 

Nose Gear Strut Installation 

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NOTE 

The engine mount must be installed to complete the installation of the 

nose gear assembly. 

4. To allow the nose gear piston to move freely in the piston rod bearing, 

file the inside of the bearing to the profile shown. 

5. Press the piston rod bearing into the engine mount weldment as shown. 

A large C-clamp can be used, however you must keep the parts in 

alignment to prevent the bearing from binding in the mount. 

6. Thread the check nut onto the rod end all the way and thread the rod end 

into the piston shaft as far as it will go. Attach the piston/rod end 

assembly to the nose gear strut using the hardware shown. 


_______________ 

7. Install the elastomer springs and friction washers onto the nose gear 

piston in the order shown. The AN4-5A bolt, washers, and rubber stop 

washer are installed by lining up the piston in the piston rod bearing and 

compressing the elastomer springs by using the strut as a lever. 

Carefully thread in the AN4-5A bolt a minimum of one turn and then 

you can relax pressure on the strut. Use a liquid thread locker on the 

AN5-4A bolt to back up the lock washer for final assembly and torque 

the bolt to 60 to 85 inch-pounds. As with the main gear legs, the system 

is very robust and virtually maintenance free. 

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LIQUID THREAD LOCK 

AN5-4A BOLT 

7 

60-85 IN-LB 


P/N 32010.000 WASHER 

P/N 44024.000 

RUBBER STOP WASHER 

P/N 33032.000 

PISTON ROD BEARING 

ENGINE MOUNT 

5 

LIQUID BEARING LOCK 

P/N 33032.000 

PISTON ROD BEARING 

P/N 34017.000 

PLASTIC WASHER 

4 

P/N 34011.000 

ELASTOMER SPRING (x 4) 

P/N 32710.000 

FRICTION WASHER (x 3) 

6 

P/N 35020.000 

NOSE GEAR PISTON 

AN316-5 

CHECK NUT 

P/N 93000.000 

ROD END 

NOSE GEAR 

STRUT 

AN4-7A BOLT 


AN365-428 NUT 

Figure D-3 

Nose Gear Shock Mount Installation 

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8. Fabricate a foam plug from some scrap 1 /2" material and shape it to fit 

in the end of the nose gear strut. This plug will serve as a moisture barrier 

to protect the interior of the strut from corrosion. Bond the plug in place 

with structural adhesive and let cure. When positioning the plug, be sure 

to get it far enough into the pivot shaft to clear the cotter pin hole. 

9. Press the nose wheel fork bearings in place using a liquid bearing lock 

to secure the installation. The upper fork bearing will need to have a flat 

section filed into the flange to clear the wheel pant attach tab. 


_______________ 

10. Lubricate the lower end of the nose gear strut with wheel bearing 

grease. Assemble the stack of Belleville washers, being very careful to 

orient them as shown. Place a thrust washer above and below the stack. 

Install the fork assembly and washer stack on the gear strut and secure 

with the axle nut and cotter pin. Attach a fish scale to one of the ends 

of the axle. Tighten the nut until it requires a pull of 10 to 12 lbs on the 

fish scale to keep the fork moving. Note that the force required to start 

the fork moving will likely be higher than this. You may wish to only 

temporarily install the cotter pin in the strut at this time, as the nut may 

need slight adjustment later once taxi testing begins and all of the 

components have 'seated' in their proper positions. 

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BEARING 

GREASE 

FOAM PLUG 

MOISTURE BARRIER 

P 

PREP 

8 

1/2" (13mm) 

FILE TO CLEAR 

NOSE WHEEL FORK 

PIVOT STOP 

9 

P/N 33031.000 

FORK BEARING (x 2) 


PIVOT STOP 

P/N 53014.101 


10 

LIQUID BEARING LOCK (x 2) 

P/N 98007.000 

THRUST WASHER (x 2) 

P/N 98003.000 

BELLEVILLE WASHER 

STACKING DETAIL 

P/N 98003.000 

BELLEVILLE WASHER (x 6) 

P/N 91258.000 

AXLE NUT 

AN380-4-8 

COTTER PIN 

Figure D-4 

Nose Gear Fork Installation 

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11. Remove the nuts and bolts holding the halves of the nose wheel together 

and separate them. Insert the inner tube into the tire, dusting the tube 

with tire talc to eliminate friction between the two. If the tire has a red 

dot painted on the sidewall, align the valve stem with the dot. Press the 

valve stem through the hole in the wheel half, then press the wheel half 

fully into the tire. If the valve stem comes equipped with a nut and 

washer, remove them and press the stem through the wheel hole. Once 

the stem is in place, reinstall the nut and washer and carefully tighten. 

It is helpful if you put a very small amount of air in the tube, just enough 

to help the tube hold its shape. Insert the bearing spacer into the wheel 

and press the opposite wheel half into the tire from the other side, 

visually aligning the mounting holes. Put a bolt through the wheel 

halves, press the halves together, and start a nut on the bolt threads. 

Install the other bolts in a similar manner and torque the nuts to 100 to 

140 inch-pounds. Inflate the tire to 20-25 psi. 

CAUTION 

Be careful not to pinch the tube between the halves of the wheel as 

they come together. Listen and feel for crisp metal-to-metal contact of 

the wheel halves before tightening the bolts. If you have difficulty 

ensuring that the tube is not caught between the wheel halves, a ring 

of thin cardboard can be taped in place around the wheel half split 

line to help guard the tube. 

WARNING 

Never inflate the tire unless all the wheel bolts are installed and properly 

torqued. Always deflate the tire before loosening any wheel bolt. 

The wheel halves will be forcefully ejected by the tire pressure if these 

precautions are overlooked. 


_______________ 

12. Install the two spacers into the wheel and install the wheel assembly 

onto the fork. Slide the nose wheel axle into the wheel until the same 

amount of axle shows on both sides of the fork. Install a washer and an 

axle nut evenly onto each end of the axle. Put a cotter pin through one 

of the axle nuts to hold it in place and adjust the wheel bearing preload 

by tightening the other nut until all bearing play is eliminated. Rotate the 

tire to ensure that it does not bind or drag, then install the final cotter pin. 

Again, do not completely bend over the legs of the cotter pins until final 

assembly. 

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11 

WHEEL HALVES (x 2) 


HARDWARE (x 3) 

100-140 IN-LB 

5 x 5.00 TIRE 

5 x 5.00 TUBE 

P/N 31002.000 SPACER 

P/N 13035.201 

SPACER (x 2) 

AN960-1016 

WASHER (x 2) 

12 

NOSE GEAR 

FORK ASSEMBLY 

P/N 13035.101 

NOSE WHEEL AXLE 

Figure D-5 

Wheel and Tire Installation 

AN320-10 NUT (x 2) 

AN380-4-5 COTTER PIN (x 2) 

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Section E. Tail Skid Installation 

A tail skid is mounted to the aft, lower empennage to prevent damage in the 

event of over-rotation during takeoff or landing. It also provides an excellent tiedown 

point for the tail of the aircraft. 

1. Ream the forward attachment bushing in the fuselage to .3125". 

2. Ream the mounting holes in the clamp plate and the tail skid plate to 

.1875". 

3. Attach the tail skid to the fuselage at the aft attachment plate. 

4. Align the tail skid so the forward attachment tab is centered over the 

forward attachment bushing. Match-drill the forward attachment tab on 

the tail skid with a 5 /16" bit. Remove the tail skid and deburr. 


_______________ 

5. Install the tail skid using the hardware shown. The skid will need to be 

removed during the fuselage covering process. 

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AN365-524 NUT 


20-25 IN-LB 

AN365-1032 

AN960-10 WASHER (x 2) 

2 

3 

.1875" (x 4) 

P/N 51069.101 

AN3-4A BOLT (x 2) 

1 

.3125" 

4 

AN5-14A BOLT 


5/16" 

Figure E-1 

Tail Skid Installation 

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