### 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 Compan y , LLC Report XLS-2-2200-500 Insta ll ation Instructions and In structions for Co ntinu ed AirworthinessRevision Date None 06-28-05 A 10-15-05 B 11-18-05 Log ofRevisions Description Initial Release IFC in separate document Added Colonial C-1

page 2 Pages Affected All 5, 6 3, 4

XLS Compan y, LLC Report XLS

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- 500 Revision B, November 18 , 2005Introduction The XLS Company, LLC Horizontal Stabilizer Support Fitting System is an impro ved fittin g or fitting as sembly for in stall ation 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 repl acement fittin g sys tem meeting the requirements of AD 2005-12-02 paragraph s (e)(1)(i) , ( e)(2) (ii) , or (e)(3). Read through these instruction s 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 b e installed on your aircraft and obtain add itional hardware and materia ls. 1. Remove the insp ection panel s on either side ofthe vertical stabilizer about the hori zontal stabili zer attachment area. If the stab ili zer attachment fittings are installed on either side of a sing le piece welded steel fitting (fitting for supporting the e levator control horn) order XLS Kit XLS-K-2200-22 1 (this wi ll cover most aircraft prior to 

### SIN 655). Ifthe inboard lugs of the hori zo ntal stabilizer fittings ar

e sandwiched between the ears of a two piece steel fitti ng order XLS Kit XLS-K

2200 -2 1. 2. Additional hardware required with XLS Kit XLS -K-2200-221 will be 40 AN470AD6-12 (MS20470AD6 -1 2) rivets and 4 AN6 -11 bolts. Additional material required will be zinc chromate primer paint. 3. Addi tio nal hardware required with XLS Kit XLS -K- 2200-21 will b e 28 AN470AD6-10 (MS20470AD6-10) rivet s, 12 AN173-11 close tolerance bolts , 12 AN960

- 10 washers, 12 AN365-1032 self locking nuts, and 4 AN6

- 13 bolts. Additional materi al required wi ll be zinc chromate primer paint. Remove existing hori zo ntal 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 -2 1 )
. Prior to removing the horizontal stabilizers and fittings verify th at the top edge ofthe hori zo ntal stabilizer spars are hori zontal when the airplane i s level. 4. Remove horizontal stabili zers in accordance with Coloni al /Lake service manual and Appendix ofRevo Service Bulletin B -78.

page3 XLS Compan y, LLC Report XLS-2-2200-21-500 Revision B , November 18 ,2 00 55. Carefully remove rivets holding 1-2200-14 or 2200-14 or 2-2200-21 horizontal stabilizer support fittings to the rear spar ofhori z ontal stabilizer. Do 

### not oversize or elongate holes on the rear spar ofthe horizontal stabilizer. 6. C lean rear spar ofhorizontal stabilizer in the area of spar attach fittings and treat for corrosion, ifrequired , 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 ofthe 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 ofrivet holes onto the fittings to match the existing holes in the rear spar. Check edge distances ofmarked 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 ho les perpendicular to the faces ofthe fittings where the marks were made. 

### An alternate method ofproperly 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 o ld holes in the old fitting. The alternate method only works ifthe 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 ofthe left horizontal stabilizer rear spar with the centers ofthe 3/8 inch bolt holes 15/16 

### ± 1/16 inboard ofthe 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 p laced along the top edge of the stabilizer spar. Mark the placement ofrivet holes onto the fitting to match the existing holes in the rear spar. Drill #11 ho les perpendicular to the faces of the fittings where the marks were made for the 14 outboard holes. Dri ll 3116 dia. holes where the marks were made for the 6 inboard holes. An alternate method ofproperly locating the rivet holes is to bolt the old stabilizer fitting to the new page4 XLS Company , LLC Report XLS

-2-2200-21

- 500 Revision B, November 18, 2005one with AN6 bolts through the 3/8 inch holes in the fittings. The new rivet holes may be located through the old hole s in the old fitting. The alternate method only works ifthe hori zontal stabilizer was found to be hori zontal 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 ofthe 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 b etween 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-2-2200-2 1 fitting. Ream the 6 inboard holes through the fitting, spacer, and doubler to 0

· 194 diameter. 0.190 Repeat procedure for the right hand fittin g, spacer and doubl er. 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 in stallation. 10
. Rivet the fittings onto the horizontal stabilizer s par s. 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 , in stall the bolts "wet". Install proper number of washers on AN173 bolts and tighten locknuts onto the bolts. Fi nal 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 stabi li zer 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 ofthe hori zontal spar (258 inches aft ofdatum) with the installation of the XLS Kit XLS-K-2200-21. Keep a copy ofthe STC with aircraft lo gs. Note that XLS fittings and doublers are marked with serial numbers. Be sure to record serial numbers in lo g 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-2-22 00-21 -500 Revision B, November 18 , 2005