A320 FLIGHTDECK SHELL SEGMENTED KIT

ASSEMBLY MANUAL

CLIENT DISTRIBUTION V1.13

This manual has been prepared to assist in the assembly of the A320 flightdeck segmented kit shell. Please note;

THIS KIT IS UNSUITABLE FOR USE WITH MOTION SYSTEMS DUE TO THE REDUCED STRUCTURAL INTEGRITY OF THE KIT. CONTACT SIMQUIP FOR INFORMATION ON THE A320 MX FLIGHTDECK SHELL.

• The following is required for the successful assembly of the segmented kit shell;

• 2-3 persons to assist in the assembly • A Philips head or star screwdriver or a cordless drill with a Philips head

driver. • A flat surface 6m x6m to assemble the shell. • A 5mm drill bit

Assembly notes;

Please study the parts list and assembly breakdown on the next pages before commencing assembly of the shell;

Do not tighten any of the assembly screws and bolts unless instructed. During initial assembly nuts and bolts should not be done up tight.

ID numbers for the assembly;

• Parts beginning with ‘00’ do not have captain or first officer orientation (ie: they are located on the centreline of the flightdeck.

• Parts beginning with ‘1’ are located on the captain side of the shell • Parts beginning with ‘2’ are located on the first officer side of the shell

Please note;

Some panel sections may slightly change shape or flatten during shipment. This may affect the alignment of some section connecting holes, but should not affect the overall shape of the assembled shell.

KIT CONTENTS

ID DESCRIPTION QTY 001 FWD BULKHEAD 1 002 FWD NOSE SECTION 1 003 CENTRE PILLAR 1 101 CAPT AFT SIDEWALL LWR SECTION 1 102 CAPT ‘A’ PILLAR 1 103 CAPT ‘B’ PILLAR 1 104 CAPT ‘C’ PILLAR 1 105 CAPT ROOF SECTION 1 106 CAPT FWD SIDEWALL SECTION 1 201 FIRST OFFICER AFT SIDEWALL LWR SECTION 1 202 FIRST OFFICER ‘A’ PILLAR 1 203 FIRST OFFICER ‘B’ PILLAR 1 204 FIRST OFFICER ‘C’ PILLAR 1 205 FIRST OFFICER ROOF SECTION 1 206 FIRST OFFICER FWD SIDEWALL SECTION 1 M5 X 30MM CSK BOLTS 50 M5 FLANGE NUT 50

STAGE 1- ASSEMBLY OF FRONT SECTIONS

For stage 1 you will need segments 001,002,106 and 206.

If any bracket holes do not correctly align, run the M5 drill through

Stand segment 001 (Front bulkhead) in the upright position and align the tabs on sections 106 and 206 with the pre-drilled holes on section 001.

Insert the supplied M5 x 30mm countersunk bolts and thread on M5 flange nut (do not do up tight at this stage). Once sections 001,106 and 206 are joined attach section 002 to the assembly.

Once stage 1 is completed the structure will be freestanding and should look like the following image;

STAGE 2- CONNECTION OF AFT SIDEWALL SECTIONS

This stage involves the attachment of sections 101 and 201.

Align the bolt holes in section 101 with the 5mm holes in the aluminium attach bracket of section 106 and 206 respectively. Loosely bolt the sections in place with the supplied M5 x 30mm countersunk bolts and thread on M5 flange nut (do not do up tight at this stage). The assembly bracket should be hidden

from view on the outside of the shell, but clearly visible in the inside of the shell. See the assembly image on the next page.

STAGE3-ATTACHMENT OF THE ROOF PILLARS

This stage involves the attachment of the roof support pillars 003,102,103,104,202,203,204.

Each pillar bracket has its respective fibreglass section glued and riveted to it. Locate each pillar in place and bolt the sections with the supplied M5 x 30mm countersunk bolts and thread on M5 flange nut You may firmly tighten the lower pillar bolts. The shell should look like the following drawing at this stage;

IMPORTANT

Before commencing stage 4, tighten up all connection nuts and bolts for each section.

IMPORTANT

Measure the rear width of the shell assembly. It should be approximately 2.7m (98”)wide. If it is not roughly this width manually move the rear sections apart to achieve the desired width.

STAGE 4-ASSEMBLY AND ATTACHMENT OF THE ROOF SECTION.

This stage involves the assembly of roof sections 105 and 205.

Stand both sections on their ends as shown in the following image.

Join the two halves and align the holes in the roof section with the join bracket holes and bolt the sections together with the supplied M5 x 30mm countersunk bolts and thread on M5 flange nut You may firmly tighten the nuts and bolts in place. The aluminium join bracket should only be visible from the inside of the roof section. Using at least 3 persons, lift the roof section into place making sure that the pillar brackets are on the inside of each side of the roof section. Align all pillar bracket holes and bolt firmly in place.

The shell should look like the following drawing at this stage;

STAGE 5-FILLING OF JOIN LINES.

Once you are satisfied that the shell is correctly assembled, the join lines can be made virtually invisible by injecting each join line with filler/adhesive from the supplied tube of white Sikaflex 11FC. Not only with the filler make the segment join lines almost invisible, but it will increase the robustness and integrity of each join.

CLEANUP

The shell kit is composed of fibreglass with a thin layer of protective gelcoat.

Our shell kits ship with white as the default colour. Sometimes the segments can become dirty from industrial waste and fallout Once assembled you may clean the shell with detergents and a high powered jet washer. If you want a high gloss on your shell, you can machine polish the shell with a sponge pad and fibreglass machining polish. Cleanup should be performed before the installation of the optional window kit.

INSTALLATION OF OPTIONAL WINDOW KIT

• The following is required for the successful assembly of the Window kit ;

• 2 persons to assist with the installation • A Philips head or star screwdriver or a cordless drill with a Philips head

driver. • A 5mm drill bit to adjust any holes that are misaligned

Each window pane is marked with its position. Each pane should be installed with its identifying label on the inside of the shell.

It is important to use the supplied washer for each window mounting point. The washer will help with load bearing and prevent the nut from damaging the window once tightened.

After each window pane in installed you can then remove the brown paper protective film to expose the crystal clear view.

IF YOU ARE EXPERIENCING ANY DIFFICULTIES WITH ASSEMBLY, PLEASE CONTACT US AT info@simquip.com.