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SECTION A Installation Instructions A. Introduction.
Insure that the intended aircraft
is included in the eligibility of the STC.
Installation to be accomplished by an FAA licensed Airframe Mechanic and
inspected by an FAA licensed Airframe and Powerplant Mechanic with Inspection
Authorization or by an FAA Part 145 Repair Station. Review all of the installation instructions
before beginning the installation process.
Pay particular attention to “NOTES”.
Inventory the kit prior to beginning to insure it is complete. Upon completion of the installation, an FAA
Form 337, Major Repair and Alteration form will need to be completed and
submitted to the FAA. A sample of the
completed form is included in SECTION D.
For questions, comments or problems with this installation please
contact Mtn View Aviation, B. Description of the Product. The Door Steward™ for the Cessna Cardinal models 177 is a
product improvement installation that greatly improves the operation of the
aircraft doors. It is supplemental to
the factory original stops. The
installation consists of a gas spring attached to brackets mounted on the door
and the airframe. When the door is
unlatched the gas spring gently but firmly opens the door to or near the full
open position, depending on the resistance of the original factory stops. The gas spring while in the open position
protects the aircraft and occupants from unexpected openings and closings by providing
resistance to considerably higher wind gusts and prop wash than the original
stops. While the gas spring installation
was designed to help control the inadvertent opening of the door in a tailwind,
it is always advisable to avoid these tailwind situations or be prepared to
assist the gas spring in limiting the opening speed. The gas spring is extremely simple and
reliable. The weight of each door
installation is 1.0 Lb. Closing the door
compresses the gas spring. The gas
spring can easily be removed from its brackets to facilitate removal of the
aircraft door, replacement of a defective gas spring or to conduct other
maintenance. C. Tools and Equipment Requirements. 1. #2
Screwdriver 2. Drill
Motor, #30 and #21 hi-speed drill and drill stop. 3. 1/8”
and 5/32” Clecos and Cleco Pliers 4. Cherrymax G-27 Hand
Riveter or suitable equivalent 5. Deburring
tool(s) and Hand files 6. Open
end wrenches (7/16” and ½”) 7. 5/32
Blind hole spotter (supplied in the kit) or equivalent 8. Small
to medium ball pein hammer D. Installation Steps. 1. Refer
to the Aircraft Manufacturer’s Maintenance Instructions for information
regarding standard practices, precautions and notes. 2. It
is the installer’s responsibility to insure that this approved installation
does not interfere or conflict with any other installed equipment or options
previously installed on the aircraft.
Many aircraft will have a small bracket on the bottom of the L/H
instrument panel for the headset and may need to be relocated inboard so as not
to conflict with the airframe bracket (P/N 177C103-1) 3. Gain
access to the door frame directly below the instrument panel by removing any
interior panels and or covers. Any door wind
lace material will need to be removed in the area of the airframe bracket
installation. 4. The
airframe bracket (P/N 177C103-1) is to be located on the door frame, approximately
¾” above the factory door stop upper bracket.
The aft facing portion of the door frame should be flat with a couple existing
countersunk rivets in that area. Any
existing countersunk rivets should not conflict with the rivet pattern on the
bracket. The inboard side of the bracket will be in an area where two #5
(5/32”) rivets will need to be removed in order to allow the bracket to come
into full contact with the door frame. Refer to below photos regarding airframe bracket location
Picture 1. Shows a ¾” mark made above the
existing upper door stop bracket and
both #5 existing rivets removed. Picture 2. Shows the 5/32” blind hole
spotters inserted into the empty holes. 5. Using
a #21 Drill remove the two 5/32” rivets located behind where the inboard flange
of the airframe bracket is to be mounted. (ref. Picture 1.) 6. Place
a supplied 5/32” blind hole spotter in each of the removed rivet holes. (ref.
Picture 2.) Position the airframe bracket into position, insuring the bracket
is in full contact with the aft face of the door frame and transfer the hole
locations to the airframe bracket by tapping with a small ball pein hammer on
the bracket opposite the blind hole spotters location. Inspect the bracket to see that the blind
hole spotters left a mark indicating the location to drill. The marked position for the #21 holes should
be located diagonally aft and away from the predrilled #30 holes also located
on this inboard flange. Drill the
airframe bracket with the two #21 holes located. 7. Cleco
the bracket in place with two #21 Clecos and drill the six #30 holes on the aft
flange and the two additional #30 holes on the inboard flange using the bracket
as a template. 8. Cleco
the bracket with #30 clecos as you drill. 9. Remove the airframe
bracket and debur all holes and remove any chips. 10. Install
the drilled airframe bracket with the eight CR3213 4-4 and two CR3213 5-4 cherrymax
rivets provided in the kit.
Picture
3. 12. Inspect the installation
for security. (See Picture 3.) 13. Reinstall
interior panels and modify as required to accommodate the new bracket. 13. Install
the 5/16”-18 10mm Ball Stud (P/N MVA-9003) in the airframe bracket with the
ball stud on top and a washer and the self locking nut on the bottom. Tighten
to 80-90 in. lbs. 14. Remove
the arm rest from the cabin door. 15. Locate
the door bracket (P/N 177C102-1 L/H or 177C102-2 R/H) behind the arm rest and
reinstall the arm rest with the door bracket between the door and the arm rest
using the new 1⅛” screws supplied with the kit. The door bracket hole for
the ball stud is slotted to allow setting the full open position within the
range of the slot. 16. Install
the tube end of the gas spring onto the airframe bracket ball stud and install
the safety clip (P/N MVA-9002). On the
left hand door installation it is easier to snap the uninstalled ¼”-20 ball
stud (P/N MVA-9004) into the rod end of the gas spring, insert the safety clip
and then put the ball stud shank through the door bracket slot from the
bottom. Add a washer and then the self
locking nut. Do not tighten the nut down
until you establish the full open position, which should be just as the factory
door stop reached its full open position.
It is best if the gas spring reaches full open just prior to the
original stop location so that in a tailwind open situation the gas spring will
have already slowed the door down when it arrives at the original factory stop. Tighten the nut to 40-50 in. lbs.
E. Post Installation Inspection and Operation. 1. Operate the door through several opening and closings to insure smooth and proper operation. Close and latch the door and inspect the interior of the aircraft. Insure the gas spring is not going to hinder or interfere with the operation of the seats, seat belts or any other feature. 2. Open the door. With the original factory door stop and the original flat metal spring installed, the gas spring may not push the door open into the full open detent, this is normal. Slight pressure on the door will assist the gas spring into the full open detent position. 3. If all inspections are satisfactory,
proceed to the final steps. F. Final Steps. 1. Install the safety clips (P/N MVA-9002) into the end fittings of the gas spring, if not already done. 2. Install the supplied Door Steward™ Equipped decal to the exterior of the aircraft near the door latch assembly of
the door(s) altered. The purpose of this
decal will be to provide an indication that when the door latch is opened; the
door will want to push open on its own. 3. Install
the following SECTION B, Maintenance, Inspection & Repair Instructions and
SECTION C, Parts List, in the aircraft maintenance records. 4. Complete
the FAA Form 337, Major Repair and Alteration using the included sample in
SECTION D, as a guide. 5. Enter
the installation on the installed aircraft equipment list and add the weight
change to the empty weight of the aircraft.
Each door kit adds +1.0 lbs to the empty weight of the aircraft at
station +85.6 If installing both left
hand and right hand kits total weight change is +2.0 lbs at station +85.6. 6. Complete
the logbook entry in accordance with CFR 14 Part 43, Maintenance, Preventive
Maintenance, Rebuilding and Alteration. ________________________________________________________________ END
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Dave Paradis Ph: (503) 981-4550
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