Glasair GLASTAR User manual

KIT: P/N 938-02000-01

KIT INSTRUCTIONS: P/N 063-09019-01

REVISION: C DATE: 8/28/08 PAGE: 1

GLASTAR / SPORTSMAN

CABIN AIR VENT KIT

ORIGINAL EQUIPMENT INSTRUCTIONS

PARTS LIST: PLEASE REFER TO THE PACKING LIST

This kit provides all the necessary parts and hardware for installing pilot-

and passenger-side cabin air vents. The system draws fresh air into the

cabin through two small but very effective NACA-style scoops on the

fuselage sides. Airflow can be controlled by the pilot and passenger using

two adjustable eyeball ventilators. These ventilators are oversized to

provide ample airflow in hot climates, even at the slower end of the

GlaStar / Sportsman’s wide performance envelope.

The cabin air vent system can be installed in a GlaStar / Sportsman at any

stage of completion, but it is most easily accomplished immediately after

the fiberglass fuselage shells have been bonded together and fastened to

the welded steel-tube cage structure.

KIT: P/N 938-02000-01

KIT INSTRUCTIONS: P/N 063-09019-01

REVISION: C DATE: 8/28/08 PAGE: 2

Step 1: Cut Out the NACA Scoop in the Fuselage

Side

Figure 6 on the last page of these instructions is a full-size template

of the NACA scoop for the cabin air vents. Glue this template to a

piece of stiff cardboard and cut it out.

Figure 1 shows how the template should be positioned on the

outside of the fuselage shell. The narrow forward edge of the

template should be positioned 3 ½” aft of the cowling attach flange

joggle, and the centerline of the template should be parallel to and

8” below the waterline of the aircraft.

CAUTION: The NACA scoop cutout location given above is taken

from one of our GlaStar / Sportsman demonstrators. However, early

customer experience suggests that, due to variations in the position of

the cage relative to the shells, the specified cutout location may lead to

interference between cage tubes and the cabin air vent boxes.

Therefore, treat this location as provisional until you have verified

clearance, as described below.

Tape the template in position on the exterior of the fuselage shell.

Then position the appropriate air box on the inside of the shell

opposite the template so that the NACA scoop-shaped portion of

the box is aligned with the template (see Figure 3). The box should

clear all cage tubes when pressed against the fuselage shell.

Check both sides and adjust the position of the cutout as necessary

before cutting into the shell. It is acceptable to move the location

as much as several inches from that specified above; however,

take reasonable care to keep the centerline of the cutout parallel

with the aircraft waterline. When you are satisfied that both boxes

will clear, trace around the perimeter of the template with a marking

pen. Then cut all the way through the fuselage shell, removing the

material inside the marked line. Cut slightly inside he line initially

and then finish up the cutout with a file and sandpaper.

CAUTION: Take care not to damage the cage structure behind the

fuselage shell as you make the NACA scoop cutout.

Completed: Left [ ] Right [ ]

KIT: P/N 938-02000-01

KIT INSTRUCTIONS: P/N 063-09019-01

REVISION: C DATE: 8/28/08 PAGE: 3

FIGURE 1: POSITIONING THE AIR BOX FOR INSTALLATION

5-½”

KIT: P/N 938-02000-01

KIT INSTRUCTIONS: P/N 063-09019-01

REVISION: C DATE: 8/28/08 PAGE: 4

Step 2: Prepare the Air Box for Installation

The air boxes are installed inside the fuselage shell on each side of

the aircraft to receive the air drawn into the system through the

NACA scoops. The air box in turn provides mounting surface for

the eyeball ventilators.

Prepare the air box for installation by, first trimming the edges down

to the scribe line provided. This will result in a bonding flange

around the entire perimeter of the part approximately 5/8” wide.

Second, use coarse sandpaper, to remove the gelcoat from the

flange all the way around the part.

Sand bonding

flange with 36 grit

KIT: P/N 938-02000-01

KIT INSTRUCTIONS: P/N 063-09019-01

REVISION: C DATE: 8/28/08 PAGE: 5

FIGURE 2: CUTTING THE VENTILATOR OPENING IN THE AIR BOX

K1000-3

Nutplates (4)

places

Next, as shown in Figure 2 cut a hole for the eyeball ventilator in

the square aft face of the box. Find the center of the face by

marking diagonal lines from the corners, and then use a 2 ¾” hole

saw to cut a circle centered on that point.

Finally, fit the eyeball ventilator into the opening and align the

edges of the square ventilator mounting flange with the edges of

the air box. Mark the four corner hole locations and then drill them

through the air box with a #10 bit.

Pass-drill #10

(4) places

Use temporary

screws or #10 clecos

to hold in position

KIT: P/N 938-02000-01

KIT INSTRUCTIONS: P/N 063-09019-01

REVISION: C DATE: 8/28/08 PAGE: 6

Position #10

nutplate jig 45°

to corner

Countersink #40

holes for

AN426AD3-3 rivets

Using standard procedures, install a K1000-3 nutplate at each hole

on the inside of the air box. Use 3/32” AN426AD3-3

flush-head rivets.

KIT: P/N 938-02000-01

KIT INSTRUCTIONS: P/N 063-09019-01

REVISION: C DATE: 8/28/08 PAGE: 7

Cleco K1000-3

nutplates in

position

Completed: Left [ ] Right [ ]

Use hand rivet

squeezer to

secure nutplates

REVISION: C DATE: 8/28/08 PAGE: 8

FIGURE 3: BONDING THE AIR BOX

TO THE FUSELAGE SHELL

Step 3: Install the Air Box

The air box is molded with a dogleg in it to aim the eyeball ventilator

directly at the occupants of the aircraft, as well as to allow them to

reach it easily for adjustment. This geometry also allows the box to

fit inside the cage structure at the mounting location. Figure 3

shows the general layout of the air box relative to the cage.

Align the pre-molded

NACA scoop section of

the air box with the cutout

you made in Step 1.

Verify that the air box

clears the cage structure

and relieve the mounting

flange, if necessary, to

achieve a good fit. When

you are satisfied, use a

#40 bit to drill four index

holes through the

mounting flange of the air

box and the inner

fuselage laminates only.

You will insert clecos into

these holes to hold the

box in position during the

bonding process.

Remove the air box and use coarse sandpaper to roughen the

inside of the fuselage shell around the NACA scoop cutout. Then

clean both the shell and the air box mounting flange with Acetone.

KIT: P/N 938-02000-01

KIT INSTRUCTIONS: P/N 063-09019-01

REVISION: C DATE: 8/28/08 PAGE: 9

Mix a small batch of thick resin / milled fiber mixture and spread it

evenly over the air box mounting plate. Position the box against

the fuselage side and use four clecos to pin it in place. Then, using

the NACA scoop and the eyeball opening for access, reach inside

the air box and make a smooth fillet wherever excess resin / milled

fiber mixture has oozed out. Let cure.

Completed: Left [ ] Right [ ]

KIT: P/N 938-02000-01

KIT INSTRUCTIONS: P/N 063-09019-01

REVISION: C DATE: 8/28/08 PAGE: 10

Step 4: Fill and Contour the Edges of the NACA

Scoop

To harden the edges of the fuselage where the NACA scoop cutout

has been made and to provide a solid basis for contouring these

edges as required, it is necessary to route out some of the foam

core of the fuselage shell all the way around the perimeter of the

scoop cutout. Use a utility knife or a metal pick to gouge out a

trough between the inner and outer laminates approximately ¼”

deep all the way around the cutout. At the aft edge of the cutout,

increase the depth of this trough to about ½”.

Once you have removed the foam core as described above, fill the

resulting troughs back in with Bondo or resin/Q-cell paste mix or

some other similar body filler. After this has cured, sand a smooth,

square corner into the upper and lower edges of the cutout, sand

and fill as necessary to achieve a smooth blending of the fuselage

side into the NACA scoop portion of the air box, but don’t worry that

there remains a fairly steep slope at this point from the fuselage

side into the scoop.

After the scoop has been sanded to your satisfaction, you can

primer or re-gelcoat the exposed surfaces.

Completed: Left [ ] Right [ ]

Make this radius ¼” diameter

(reverse airfoil shape)

Sand / blend corners into

fuselage with 1/8” radius

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