CIVIL AVIATION AUTHORITY – SAFETY REGULATION GROUP

MICROLIGHT TYPE APPROVAL DATA SHEET (TADS)

NO: BM4 ISSUE: 7

TYPE: Gemini Flash

(1) MANUFACTURER: Mainair Sports Ltd now supported by P & M Aviation Ltd. Unit B, Crawford Street, Rochdale, Lancashire, OL16 5NU. (2) UK IMPORTER: N/A

(3) CERTIFICATION: BCAR Section S, Advance Issue March 1983 BCAR Section S, Paper, 11 October 1988 (4) DEFINITION OF 440 Dual Master List of Drawings, Issue 7 BASIC STANDARD: Flash Wing Master Drawing List, Issue 5

(5) COMPLIANCE WITH THE MICROLIGHT DEFINITION

(a) MTOW 344 kg (pre Mod 21A) 370 kg (post Mod 21A) (b) No. Seats 2 (c) Maximum Wing Loading 23.92 kg/m² (d) Vso 24 kts (25 mph) (e) Permitted range of pilot weights 55 – 90 kg per seat. (f) Typical Empty Weight (ZFW) (Flash 440) 145kg (Flash 447) 145kg (Flash 503) 145kg (Flash 462) 145kg (g) ZFW + 172 kg crew + 1 hr fuel (440) 337kg (litres / kg) (447) 328 kg (503) 332 kg (462) 336 kg (h) ZFW + 86 kg pilot + full fuel (440) 263 Kg ( litres / kg) (447) 263 kg (503) 263 kg [278 kg with mod 99] (462) 263 kg [278 kg with mod 99] (i) Max ZFW at initial permit issue 178 Kg

TADS BM4 Issue 7 Page 1 of 13 CIVIL AVIATION AUTHORITY – SAFETY REGULATION GROUP

MICROLIGHT TYPE APPROVAL DATA SHEET (TADS)

NO: BM4 ISSUE: 7

(6) POWER PLANTS

Gemini Flash 440 Gemini Flash 440 Gemini Flash 447 Gemini Flash 447 Gemini Flash 447 Gemini Flash 447 Designation Engine Type Fuji Robin Fuji Robin Rotax 447 Inverted Rotax 447 Inverted Rotax 447 Upright Rotax 447 Upright EC44PN EC44PN Upright Inverted Reduction Gear 2.67:1 2.67:1 2.58:1 2.58:1 2.58:1 2.58:1 Exhaust System Rota Flow Rota Flow Rotax 2 x 90 Rotax 2 x 90 Rotax Side Rotax Side Underslung Underslung Underslung Underslung Mounted Mounted Intake System Unique Foam Unique Foam Rotax Intake Rotax Intake Rotax Intake Rotax Intake Muffler Muffler Muffler Muffler Muffler Muffler Propeller Type Mainair Sports Mainair Sports Newton Mainair Sports Mainair Sports Mainair Sports Round Tip Round Tip Propeller Dia x Pitch 62” x 30” 62” x 30” 62” x 38” 62” x 37” 62” x 35” 62” x 40” Noise Type Cert No. 5M 12M 12m 12m 27m 28m AAN approving 19421 19421 19421 19421 19590 19590 configuration

TADS BM4 Issue 7 Page 2 of 13 CIVIL AVIATION AUTHORITY – SAFETY REGULATION GROUP

MICROLIGHT TYPE APPROVAL DATA SHEET (TADS)

NO: BM4 ISSUE: 7

Gemini Flash 503 Gemini Flash 503 Gemini Flash 462 Gemini Flash 462 Gemini Flash 462 Designation Engine Type Rotax 503 Rotax 503 Rotax 462 Upright Rotax 462 Upright Rotax 462 Upright Upright Upright Single Points Ign Single Points Ign Reduction Gear 2.58:1 2.58:1 2.58:1 2.58:1 2.58:1 Exhaust System Rotax Side Rotax Side Rotax Side Mount Rotax Side Mount Rotax Side Mount Mounted with After Mounted with After with After Muffler with After Muffler with After Muffler Muffler Muffler Intake System Rotax Intake Rotax Intake Rotax Intake Rotax Intake Rotax Intake Silencer Silencer Silencer Silencer Silencer Propeller Type Mainair Mainair Grd Mainair Round Tip Mainair Square Mainair Ground Adjustable Tip Adjustable Propeller Dia x Pitch 62” x 40” 3 Blade 62” 62” x 44” 62” x 46” 3 Blade 62” 107deg at 12” 107deg at 12” or 62” x 46” Noise Type Cert No. 26M 50M 35m 35m 35m AAN approving 19197 20375 19213 19213 20375 configuration

TADS BM4 Issue 7 Page 3 of 13 CIVIL AVIATION AUTHORITY – SAFETY REGULATION GROUP

MICROLIGHT TYPE APPROVAL DATA SHEET (TADS)

NO: BM4 ISSUE: 7

(7) MANDATORY LIMITATIONS:

(A) Max Take-Off Weight 370 Kg

(B) CG Limits N/A (C) CG datum N/A

(D) Cockpit Loadings Front Rear Total

Min 55kg 15 kg 70 kg

Max 90kg 90 kg 180 kg

(E) Never Exceed Speed 77 knots (89 mph)

(F) Manoeuvring Speed 38 knots (44 mph)

(G) Permitted Manoeuvres 30° Nose up / 30° nose down 45deg Max Bank Angle Non Aerobatic Normal acceleration limits, +4 / -0g

(H) Fuel Contents (Max Useable) 44 litres (22 litre optional) 65 (Mod 99 fitted 503 & 462 only)

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MICROLIGHT TYPE APPROVAL DATA SHEET (TADS)

NO: BM4 ISSUE: 7

(I) Power Plant See Table Engine Fuji 440 Rotax 447 Rotax 503 Rotax 462 Upright or Upright or Upright Upright Inverted Inverted Max RPM 6900 6800 6800 6800 MAX CHT 218 degC 250 degC 250 degC 150 degC MAX EGT 815 degC 650 degC 650 degC 650 degC Fuel Spec 83 MON or 90 RON minimum unleaded to BS(EN)228 or 97+ octane 4-star /MOGAS leaded fuel to BS 4040, or AVGAS 100LL. Engine Oil Spec Two Stroke Oil Two Stroke Oil Two Stroke Oil Two Stroke Oil ASTM/CEC ASTM/CEC ASTM/CEC ASTM/CEC Standards, API- Standards, API- Standards, API- Standards, API- TC TC TC TC Classification Classification Classification Classification Gearbox oil spec N/A API-GL5 or API-GL5 or API-GL5 or GL6, SAE 140 GL6, SAE 140 GL6, SAE 140 EP EP EP Fuel/Oil Mix 40/1 50/1 50/1 50/1 Coolant Temperature N/A N/A N/A 80 DegC Oil Pressure N/A N/A N/A N/A Oil Temperature N/A N/A N/A N/A Fuel Pressure N/A N/A N/A N/A

(8) INSTRUMENTS REQUIRED:

ASI Altimeter RPM CHT / Compass Coolant Fuel VSI Slip ball EGT temp Pressure Required Required N/A N/A N/A N/A N/A N/A N/A (to 90 mph min.)

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MICROLIGHT TYPE APPROVAL DATA SHEET (TADS)

NO: BM4 ISSUE: 7

(9) CONTROL DEFLECTIONS: N/A

Elevator UP: ± Tailplane trim UP: ± Elevator DOWN: ± Tailplane trim DOWN ± Ailerons* UP: ± Rudder LEFT: ± Ailerons* Down: ± Rudder RIGHT: ±

(10) PILOT'S NOTES, MAINTENANCE MANUALS REFERENCES:

10.1 Manuals approved for use with this aircraft.

(a) Flash Microlight Manual Doc Ref GF Manual (at appropriate issue)

10.2 The following placards are to be fitted:-

(a) Flight Limitations Placard (to be visible to pilot) See Annex D.

(b) Engine Limitations Placard (to be located near to engine instruments) See Annex D.

(c) Fuel Limitations Placard (to be located near to filler cap)

A placard is to be fitted showing fuel capacity ( litres), fuel type(s), fuel:oil ratio (if relevant) and if MTOW can be exceeded with full fuel and maximum cockpit weight, the fuel loads at MTOW for cockpit weights. An example is shown at Annex D.

(d) Switches See Annex D.

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MICROLIGHT TYPE APPROVAL DATA SHEET (TADS)

NO: BM4 ISSUE: 7

(11) MANDATORY MODIFICATIONS / SERVICE BULLETINS / AIRWORTHINESS DIRECTIVES ETC:

CAA MPD 1995-005 R1 Inspection of main vertical strut CAA MPD 1995-012 Flight limitations CAA MPD 1995-016 Front stub heavy landing overload damage CAA MPD 2001-004 Upper torso restraint

Annual Bettsometer test is to be carried out to 1050 grammes with wing sails fitted and tensioned to flight. Test must be to both upper and lower surfaces.

(12) MINIMUM PERFORMANCE AT MAX TAKE-OFF WEIGHT

Rate of Climb: 500 fpm at 47 (42mph) IAS.

Stall or Minimum Flying Speed: 24kts (25mph) IAS at MTOW / idle.

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MICROLIGHT TYPE APPROVAL DATA SHEET (TADS)

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Issue History

Issue No. Reason and signatory

1 27/12/84 Initial Issue J WRAITH 2 25/03/86 Rotax 447 and 503 options. Additional optional modifications. J WRAITH 3 25/09/87 Mainair ground adjustable propeller. Additional optional modifications. J WATKINS 4 __/12/91 To reflect the approval of an increased all up weight coincident with the approval of modification No. 21A (optional second fuel tank). To incorporate editoral changes required and introduce new format. To increase max rpm limit on Rotax 503 and 462 engine variants in accordance with current engine specification. K D RUSSELL 5 08/07/02 Update using new format. J BARRATT 6 06/07/05 New company name J BARRATT 7 18/11/09 To record Modification Number 187, which increases seat load limit to 110kg but still with a total cockpit load of 180g.

D S CORTIZO

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MICROLIGHT TYPE APPROVAL DATA SHEET (TADS)

NO: BM4 ISSUE: 7

Illustration of Aircraft - 3 View

TADS BM4 Issue 7 Page 9 of 13 CIVIL AVIATION AUTHORITY – SAFETY REGULATION GROUP

MICROLIGHT TYPE APPROVAL DATA SHEET (TADS)

NO: BM4 ISSUE: 7

ANNEX A – MANDATORY MODIFICATIONS

Modification 98 Shoulder Straps (MPD 2001-004 refers)

ANNEX B - APPROVED OPTIONAL MODIFICATIONS The installation of all optional modifications is to be inspected by a BMAA inspector and an entry made in the appropriate logbook(s). Note that other approved modifications may exist which are not listed here.

Mainair Description Modification Number

1 Single Lap Seat Belts 2 Extended Front Stub 3 Inverted 440 engine 4 Nylon Steering Bearings 5 Rotax 447 Engine Option 6 Wheel Spats 7 Rear Seat Steering 8 Electrical Wiring Box 9 Wing Fabric 10 Top Tank 11 Rotax (Upright) 503 engine installation 12 Rotax 462 engine installation 12a Rotax 462 Fuel Heating 12b Rotax 462 + 62” x 42” Tip Propeller 12c Rotax 462 + 62” x 44” Rd. Tip Propeller 12d Rotax 462 + 62” x 46” Rd. Tip Propeller 14 Fuji Propeller bolts (5/16”) 15 Additional sleeve and back up wire - Vertical Strut 16 Front Strut Back Up Wire 17 Front Suspension - Gas Spring Dampers 18 Transit Yoke 20 Rotax 447 Engine (Upright Installation) 21 Rear Fuel Tank (Upright Rotax Engines) 21a Additional Fuel Capacity 22 Alternative Ignition Switch Position 25 Spring Return Throttle Mixer on Cables 26 Steel Muffler Brackets 27 Fireproof filter between Pump and Carburettor TADS BM4 Issue 7 Page 10 of 13 CIVIL AVIATION AUTHORITY – SAFETY REGULATION GROUP

MICROLIGHT TYPE APPROVAL DATA SHEET (TADS)

NO: BM4 ISSUE: 7

28 Mark II Control Frame Fitting (Longer Socket) 29 Cranked Seat Hinge Plates (Dwg 99-99-14J) 32 3 blade propeller on Flash/Flash 2 (A) and Scorcher 38 Rear Dip Pipe Locator (Dwg 99-44-168) 39 Negative Load Wing Warning Sticker 00-02 40 Fibreglass Exhaust Shield 99-44-204 45 Boss Ballast Bag (Dwg 99-44-500) 50 Flash Wing Overrider Instructor Bars 53 Nose Cone Warning Lable 55 Radiator Top Mounting 69 Wiring For Point Ign (Rotax) 77 Trailing Link Front Susp & Brake 83 Mercury Mud Guard 86 Alloy Wheels 90 Clear Fuel Filter 99 65 Litre Fuel Tank 187 Increase of Seat Load Limit to 110kg

ANNEX C WEIGHING INFORMATION

1. CG Datum: N/A 2. Weighing attitude: N/A 3. Mainwheel moment arm: N/A 4. Nosewheel moment arm: N/A ____ (units) (direction) of datum 5. Fuel moment arm: N/A ____ (units) (direction) of datum 6. Crew moment arm: N/A ____ (units) (direction) of datum 7. Crew weights: Minimum 55 kg / maximum 90 kg (maximum reducible, not below 86 kg, if required). 8. Aft CG Limit: N/A ____ (units) (direction) of datum 9. Fwd CG Limit: N/A ____ (units) (direction) of datum

TADS BM4 Issue 7 Page 11 of 13 CIVIL AVIATION AUTHORITY – SAFETY REGULATION GROUP

MICROLIGHT TYPE APPROVAL DATA SHEET (TADS)

NO: BM4 ISSUE: 7

ANNEX D

EXAMPLE PLACARDS

(a) Flight & Engine Limitations Placard (to be visible to pilot) [Typical Examples]

GEMINI FLASH

MAX. ALL UP WEIGHT 370KG MIN. ALL UP WEIGHT 234KG EMPTY WEIGHT 145KG STALL SPEED 23KTS-28MPH NEVER EXCEED (V.N.E.) 77KTS-89MPH MIN LANDING APPROACH 36KTS-42MPH MAX CROSS WIND 8KTS-10MPH REC. ENGINE EGT 650 DEGC REC ENGINE CHT 150 DEGC REC. ENGINE MAX 6800RPM

WARNING THIS AIRCRAFT IS NON-AEROBATIC MAXIMUM NOSE UP 30DEG MAXIMUM NOSE DOWN 30DEG MAXIMUM BANK ANGLE 45DEG SPINNING ATTEMPTS PROHIBITED NO WHIPSTALLS LOOPS TAILSLIDES OR AEROBATIC MANOEUVRES

DO NOT EXCEED MAX LOAD

(b) Fuel Limitations Placard (to be visible to pilot)

Empty Wt Kg Date Fuel Load Max Cockpit (litres) Wt (kg) 65 55 45 35 25 15 5

TADS BM4 Issue 7 Page 12 of 13 CIVIL AVIATION AUTHORITY – SAFETY REGULATION GROUP

MICROLIGHT TYPE APPROVAL DATA SHEET (TADS)

NO: BM4 ISSUE: 7

(c) Fuel Capacity and Type (to be located near to filler cap)

FUEL - 22 LITRES FUEL - 65 LITRES EN228 UNLEADED or AVGAS 100LL EN228 UNLEADED or AVGAS 100LL INSPECT INTERNAL AND EXTERNAL INSPECT INTERNAL AND EXTERNAL FILTERS FREQUENTLY FILTERS FREQUENTLY

2 STROKE OIL MIX AT RATIO 50:1 2 STROKE OIL MIX AT RATIO 50:1

(d) Switches

All switches are to be marked with function and sense (up = on, down = off)

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Number: 2016-011-E Issue date: 23 November 2016

In accordance with Article 41(1) of The Air Navigation Order 2016, as amended, the following action required by this Mandatory Permit Directive (MPD) is mandatory for applicable aircraft registered in the United Kingdom operating on a UK CAA Permit to Fly.

Type Approval Holder’s Name: Type/Model Designation(s): P&M Aviation Ltd Various, see below

Title: Clevis Pin / Split Ring Installations – Inspection / Replacement

Manufacturer: P&M Aviation Ltd

Applicability: All Microlights where P & M Aviation Ltd is the Type Approval Holder:

TADS No. Aircraft Type TADS No. Aircraft Type

BM2 Gemini Sprint BM43 Mainair Mercury BM3 Tri-Flyer Sprint BM44 Pegasus Quasar 2 TC BM4 Gemini Flash BM45 Cyclone AX3//503 BM5 Panther XL-S BM46 Pegasus Quantum 15 (Rotax 2-stroke engines) BM9 Pegasus XL-R BM47 Mainair Blade BM10 Pegasus Flash BM50 Pegasus Quantum 15-912 BM17 Pegasus Flash 2 BM51 Mainair Blade 912 BM14 Gemini Flash 2 BM53 Cyclone AX2000 BM16 Scorcher BM54 Mainair Rapier BM17 Pegasus Flash 2 BM56 Pegasus Quantum 15-HKS BM23 Gemini Flash 2 Alpha BM60 Mainair Blade 912S BM25 Pegasus XL-Q BM65 Flight Design CT2K (rudder control) BM27 Chaser S BM66 Pegasus Quik BM28 Pegasus Photon BM70 Quik GT450 BM31 Chaser S 1000 BM72 Flight Design CTSW (rudder control) BM33 Chaser S 508 BM77 QuikR BM37 Chaser S 447 BM80 Quik GTR BM38 Pegasus Quasar BM81 PulsR BM42 Pegasus Quasar – TC BM83 Flight Design CTSL (rudder control)

Mandatory Permit Directive 2016-011 Page 1 of 2

Civil Aviation Authority Mandatory Permit Directive SARG

Reason: Following maintenance, a clevis pin came out of the RP-4 roll trim system pulley on a QuikR causing a left turn. The split ring securing the clevis pin had come out. It is not known if the ring was disturbed during the maintenance.

The split ring which came out was the same “spiral start” pattern as that which has caused trouble before (see Service Bulletin 139). This pattern of ring has no positive stop, so that simple rotation of the ring (e.g. caused by it getting caught on something) will cause it to disengage. Disengagement of the split ring and subsequent clevis pin departure could affect the control of the aircraft.

Effective Date: 24 November 2016

Compliance/Action: Compliance is required as follows, unless previously accomplished: 1. Before further flight, from the effective date of this MPD, inspect all clevis pin / split ring installations on the aircraft in accordance with paragraph 2 of P & M Aviation Ltd Service Bulletin 144. 2. If the inspection in paragraph 1 reveals any spiral start pattern split rings they must be replaced in accordance with paragraph 2 of P & M Aviation Ltd Service Bulletin 144 before further flight. 3. Record the inspection from paragraph 1 and any necessary rectification action from paragraph 2 in the aircraft technical log in accordance with paragraph 3 of P & M Aviation Ltd Service Bulletin 144. 4. Repeat the actions in paragraphs 1, 2 and 3 at each Permit to Fly revalidation.

ENSURE COMPLIANCE WITH THIS MPD IS RECORDED IN THE AIRCRAFT LOGBOOK

Reference P & M Aviation Ltd Service Bulletin Number 144, Issue 3, dated Publications: 27 October 2016.

Remarks: 1. This MPD was not posted for consultation because of the urgency of the requirement.

2. Enquiries regarding this Mandatory Permit Directive should be referred to: GA Unit, Civil Aviation Authority, Safety and Airspace Regulation Group, Aviation House, Gatwick Airport South, West Sussex, RH6 0YR.

Tel: +44 (0)1293 573988 E-mail: [email protected]

Mandatory Permit Directive 2016-011 Page 2 of 2 Civil Aviation Authority EMERGENCY MANDATORY PERMIT DIRECTIVE

Number: 2017-004-E Issue date: 15 May 2017

In accordance with Article 41(1) of The Air Navigation Order 2016, as amended, the following action required by this Mandatory Permit Directive (MPD) is mandatory for applicable aircraft registered in the United Kingdom operating on a UK CAA Permit to Fly.

Type Approval Holder’s Name: Type/Model Designation(s): P&M Aviation Ltd Various, see below

Title: Rigging Cables with Roll Swaged End Terminals – Inspection / Replacement

Manufacturer: P&M Aviation Ltd

Applicability: All Microlights of the following types where P & M Aviation Ltd are the Type Approval Holder:

TADS No. Aircraft Type

BM4 Gemini Flash BM10 Pegasus Flash BM14 Gemini Flash 2 BM16 Scorcher BM17 Pegasus Flash 2 BM23 Gemini Flash 2 Alpha BM43 Mainair Mercury BM47 Mainair Blade BM51 Mainair Blade 912 BM54 Mainair Rapier BM60 Mainair Blade 912S BM70 Quik GT450 BM77 QuikR BM80 Quik GTR PulsR BM81

Mandatory Permit Directive 2017-004-E Page 1 of 3

Civil Aviation Authority Mandatory Permit Directive Safety and Airspace Regulation Group

Reason: A P&M Quik GT450 in a flying school had a partial failure of a lower side rigging cable (Part No. YQD-045) when recovering from a spiral manoeuvre, within the limits of the flight envelope. These cables are arranged in pairs, to give a backup load path. The second cable carried the load and the aircraft landed safely. This is the only recorded lower side cable failure since 1984. The partial failure was at the edge of the roll swaged terminal end. The alternative cable terminations using Nicopress sleeves and thimbles allow more progressive flexing of the cable.

The incident Quik GT450 lower side rigging cables had been in use for 1050 hours and 9 years. The aircraft had been subject to an accident and rebuilt once in its life. It was also operated quite near the coast where it is probable that sea air chlorides could have affected the material. There were corrosion pits in the S316 stainless steel material which accelerate fatigue failures. CLSCC (Chloride Stress Corrosion Cracking) is known to affect stainless steel.

The cable fitting was at the bottom end of the cable, where solutions can wick down it and collect. The strand failures were caused by bending and tensile fatigue because of cracks propagating from scratches and corrosion pits on the surface.

All the remaining cables had broken strands at the edge of the roll swaged terminals. Some of these strands had been failed for some time, as shown by discolouration of the failure surfaces. The cable is 7 cores of 7 strands construction.

Failure of a lower rigging cable would potentially reduce the integrity of the wing and hazard the aircraft.

Effective Date: 15 May 2017

Mandatory Permit Directive 2017-004-E Page 2 of 3 Civil Aviation Authority Mandatory Permit Directive Safety and Airspace Regulation Group

Compliance/Action: Compliance is required as follows, unless previously accomplished:

1. Before further flight, for lower side, front and rear rigging cables with roll swaged terminal ends with more than 750 flying hours or 7 years of service, whichever comes first, visually inspect at the edge of the roll-swaged terminal(s) using a magnifying glass with a power of at least 3x. Inspect closely for damage i.e. broken strands, corrosion, mechanical damage or slippage. If any damage is found, replace the affected cable before further flight. If no damage is found, replace the cable within 25 flying hours. See paragraphs 1 and 2 of P & M Aviation Ltd Service Bulletin 147 including the warning in paragraph 2.

2. Within 25 flying hours, for lower side, front and rear rigging cables with roll swaged terminal ends with less than 750 flying hours and less than 7 years of service, visually inspect at the edge of the roll- swaged terminal(s) using a magnifying glass with a power of at least 3x. Inspect closely for damage i.e. broken strands, corrosion, mechanical damage or slippage. If any damage is found, replace the affected cable before further flight. If no damage is found, replace the cable at 750 flying hours or 7 years of service, whichever comes first. See paragraphs 1 and 2 of P & M Aviation Ltd Service Bulletin 147 including the warning in paragraph 2.

3. Removal and replacement of any airframe structural cable requires a duplicate inspection - see paragraph 3 of P & M Aviation Ltd Service Bulletin 147.

4. Record the inspection from paragraph 1 or paragraph 2 and any necessary rectification action in the aircraft technical log in accordance with paragraph 3 of P & M Aviation Ltd Service Bulletin 147.

5. Repeat the inspection in paragraph 2 at each Permit to Fly revalidation and replace damaged cables as necessary. Replace the cables at 750 flying hours or 7 years of service, whichever comes first.

ENSURE COMPLIANCE WITH THIS MPD IS RECORDED IN THE AIRCRAFT LOGBOOK

Reference P & M Aviation Ltd Service Bulletin Number 147 Issue 1 dated 10 May 2017 Publications:

Remarks: 1. This MPD was not posted for consultation because of the urgency of the requirement.

2. Enquiries regarding this Mandatory Permit Directive should be referred to: GA Unit, Civil Aviation Authority, Safety and Airspace Regulation Group, Aviation House, Gatwick Airport South, West Sussex, RH6 0YR.

Tel: +44 (0)1293 573988 E-mail: [email protected]

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