REPORT XLS-2-2200-21-500 

Revision B, November 18,2005 

INSTALLATION INSTRUCTIONS 

FOR 

XLSCO.,LLC 

HORIZONTAL STABILIZER SUPPORT FITTING SYSTEM 

FOR 

COLONIAL C-1, COLONIAL C-2, LAKE LA-4, LAKE LA-4A, 

LAKE LA-4P, AND LAKE LA-4-200 

AIRCRAFT 

XLS Company, LLC 

Report XLS-2-2200-500 

Installation Instructions and Instructions for Continued Airworthiness 
Revision Date 

None 06-28-05 

A 10-15-05 

B 11-18-05 

Log of Revisions 

Description 

Initial Release 

IFC in separate document 

Added Colonial C-1 

page 2 

Pages Affected 

All 

5, 6 

3, 4 

XLS Company, LLC 

Report XLS-2-2200-21-500 

Revision B, November 18, 2005 
Introduction 

The XLS Company, LLC Horizontal Stabilizer Support Fitting System is an improved fitting 

or fitting assembly for installation on Colonial C-1 , Colonial C-2, Lake LA-4, Lake LA-4A, 

Lake LA-4P, and Lake LA-4-200 aircraft. Installation ofthe XLS Company, LLC Horizontal 

Stabilizer Support Fitting System is an approved replacement fitting system meeting the 

requirements of AD 2005-12-02 paragraphs (e)(1)(i), (e)(2)(ii), or (e)(3). 

Read through these instructions before starting work. All work should be performed by an 

experienced airframe mechanic with the proper tools, including riveting tools with the 

capacity to set AN470AD6 rivets. 

Installation Instructions 

Determine which XLS kit is to be installed on your aircraft and obtain additional 

hardware and materials. 

1. Remove the inspection panels on either side of the vertical stabilizer about the 

horizontal stabilizer attachment area. If the stabilizer attachment fittings are 

installed on either side of a single piece welded steel fitting (fitting for supporting 

the elevator control horn) order XLS Kit XLS-K -2200-221 (this will cover most 

aircraft prior to SIN 655). If the inboard lugs of the horizontal stabilizer fittings 

are sandwiched between the ears of a two piece steel fitting order XLS Kit XLS-K2200-21. 

2. Additional hardware required with XLS Kit XLS-K-2200-221 will be 40 

AN470AD6-12 (MS20470AD6-12) rivets and 4 AN6-11 bolts. Additional 

material required will be zinc chromate primer paint. 

3. Additional hardware required with XLS Kit XLS-K-2200-21 will be 28 

AN470AD6-10 (MS20470AD6-10) rivets, 12 AN173-11 close tolerance bolts, 12 

AN960-10 washers, 12 AN365-1032 self locking nuts, and 4 AN6-13 bolts. 

Additional material required will be zinc chromate primer paint. 

Remove existing horizontal stabilizer support fittings(Colonial C-1 part number 1-

2200-14 or Colonial C-1 part number 2200-14 or Colonial C-2, Lake LA-4, LA4A, LA-4P, LA-4-200 part number 2-2200-21 ). Prior to removing the horizontal 

stabilizers and fittings verify that the top edge of the horizontal stabilizer spars are 

horizontal when the airplane is level. 

4. Remove horizontal stabilizers in accordance with Colonial/Lake service manual 

and Appendix ofRevo Service Bulletin B-78. 

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XLS Company, LLC 

Report XLS-2-2200-21-500 

Revision B, November 18,2005 
5. Carefully remove rivets holding 1-2200-14 or 2200-14 or 2-2200-21 horizontal 

stabilizer support fittings to the rear spar of horizontal stabilizer. Do not oversize 

or elongate holes on the rear spar of the horizontal stabilizer. 

6. Clean rear spar of horizontal stabilizer in the area of spar attach fittings and treat 

for corrosion, if required, as outlined in AC 43-4A, section 5. 

Prepare new fittings for installation. 

7. Note that the spar fittings supplied by XLS have been alodined and epoxy primed 

for corrosion protection. Be careful when handling the painted parts so they won't 

get scratched. 

8. Temporarily secure the XLS replacement fittings onto the rear spars of the 

horizontal stabilizers. 

The XLS-K-2200-221 kit has two horizontal spar attach fittings, part numbers 

XLS-2-2200-221L and XLS-2-2200-221R. The XLS-2-221-221L fitting goes 

onto the left stabilizer spar with the larger radius comers facing forward. 

Similarly the XLS-2-221-221R fitting goes onto the right stabilizer spar with 

the larger radius comers facing forward. Place the fittings centered between 

the upper and lower flanges of the horizontal stabilizer rear spars with the 

centers of the 3/8 inch bolt holes 15/16 ± 1/16 inboard of the beam end. Mark 

the placement of rivet holes onto the fittings to match the existing holes in the 

rear spar. Check edge distances of marked holes. Edge distance on the farthest 

outboard rivets may be ~ inch minimum. All other rivet holes should have a 

minimum edge distance of3/8 inch. Drill #11 holes perpendicular to the faces 

of the fittings where the marks were made. An alternate method of properly 

locating the rivet holes is to bolt the old stabilizer fitting to the new one with 

AN6 bolts through the 3/8 inch holes in the fittings. The new rivet holes may 

be located through the old holes in the old fitting. The alternate method only 

works if the horizontal stabilizer was found to be horizontal when the airplane 

was level prior to removing the stabilizer. 

The XLS-K-2200-21 kit has two horizontal spar attach fittings, two ~in thick 

doublers, and two spacers. Place an XLS-2-2200-21 fitting centered between 

the upper and lower flanges of the left horizontal stabilizer rear spar with the 

centers of the 3/8 inch bolt holes 15/16 ± 1/16 inboard of the beam end. Note 

that the XLS-2-2200-21 fitting is not symmetrical. The leg with the outside 

edge perpendicular to the inboard edge is placed along the top edge of the 

stabilizer spar. Mark the placement of rivet holes onto the fitting to match the 

existing holes in the rear spar. Drill #11 holes perpendicular to the faces of the 

fittings where the marks were made for the 14 outboard holes. Drill 3116 dia. 

holes where the marks were made for the 6 inboard holes. An alternate method 

of properly locating the rivet holes is to bolt the old stabilizer fitting to the new 

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XLS Company, LLC 

Report XLS-2-2200-21-500 

Revision B, November 18, 2005 
one with AN6 bolts through the 3/8 inch holes in the fittings. The new rivet 

holes may be located through the old holes in the old fitting. The alternate 

method only works if the horizontal stabilizer was found to be horizontal when 

the airplane was level prior to removing the stabilizer. Temporarily bolt the 

horizontal control hom fitting onto the forward and rear sides of the XLS-2-

2200-21 fitting along with the XLS-2-2200-121 doubler aft of the center 

fitting. Use the AN6-13 bolts to align all the parts. Verify that the doubler 

matches the fitting. If it doesn't, tum it over. Slip a XLS-2-2200-321 spacer 

between the XLS-2-2200-21 fitting and XLS-2-2200-121 doubler until it butts 

against the steel center fitting. Drill 3/16 dia. holes through the spacer and 

doubler to match the 6 inboard holes on the XLS-2-2200-21 fitting. Ream the 

6 inboard holes through the fitting, spacer, and doubler to 

0

·

194 diameter. 

0.190 

Repeat procedure for the right hand fitting, spacer and doubler. 

9. Disassemble the fittings, doublers, and spacers as required and paint bare aluminum 

portions with zinc chromate primer and allow to dry. Keep right hand and left 

hand assemblies separate to prevent confusion on installation. 

10. Rivet the fittings onto the horizontal stabilizer spars. Install the rivets "wet" for 

increased corrosion protection (paint the rivet shanks with zinc chromate primer 

and install and set the rivets while the paint is still wet). For installations using the 

AN173 bolts, install the bolts "wet". Install proper number of washers on AN173 

bolts and tighten locknuts onto the bolts. 

Final installation. 

11. Install horizontal stabilizers onto airplane and check control surface travels as 

listed in Revo Service Bulletin B-78. Install seals and inspection plates removed 

earlier. 

12. Fill out logbooks and submit Form 337. There is a 0.6 pound weight increase on 

the aft side of the horizontal stabilizer spar (258 inches aft of datum) with the 

installation of the XLS Kit XLS-K-2200-221. There is a 0.90 pound weight 

increase on the aft side of the horizontal spar (258 inches aft of datum) with the 

installation of the XLS Kit XLS-K-2200-21. Keep a copy of the STC with aircraft 

logs. Note that XLS fittings and doublers are marked with serial numbers. Be sure 

to record serial numbers in log book to help maintain accurate record of fittings 

and doublers time in service. 

INSTRUCTIONS FOR CONTINUED AIRWORTHlNESS 

See XLS Report XLS-2-2200-21-IFC for Instructions for Continued Airworthiness. 

page 5 

XLS Company, LLC 

Report XLS-2-2200-21 -500 

Revision B, November 18, 2005