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Nynja Build manual 1.0
18.2.2
Fitting the Lexan
a) Cut out the Lexan sheet from the patterns.
Use a large pair of tin snips. The patterns are supplied as a guide, and
your individually constructed doors may vary slightly, so cut oversize
initially to be safe.
b) With the door in position offer up the Lexan and mark some reference points
to align with the door frame.
For now it should be positioned accurately against the hinge, and centred to
provide an even overlap all the way around its other three sides.
c) Before riveting mark and drill the holes on the doorframe.
Use a nominal rivet spacing of 60mm. Try to drill in the centre of the
tubes or it will pull the lexan out of shape. Lightly marking the centre by
drawing a long flexible metal straight edge across the frame can help.
d) Drill and rivet in place the lexan using 4mm aluminium rivets.
Remove the protective coating from the inside face of the Lexan, leave
it in place on the outside but remove it using your fingernail around
each point to clear the rivet heads.
It is advisable
to fix with cleco‟s/skin pin‟s first before rivetting
Work from the upper front corner, and rivet the front edge first. Follow
this by riveting the lower edge. Due to the curve in the central cross-
piece the rear edge will have to be worked around the curve, to avoid a
wavy edge.
It may be necessary to drill out some rivets and reposition the tension in
the Lexan slightly to get the best fit
(cleco‟s/ skinpin‟s used first will help
avoid this). Do not be tempted to put more curve in the central cross
piece to give greater shoulder room or you will turn this into an
impossible task! Finish by riveting the upper cross piece and then the
central cross piece.
When drilling angle the drill slightly away from the last rivet. When
squeezing the rivets bring the rivet upright. This then applies some light
tension to the Lexan and prevents the Lexan bulging between rivets.
Take care when drilling to ensure the tube is drilled centrally.
e) Fit the door and mark carefully the overlap for cutting to final position.
The front and lower edge should be cut to match the recess. The rear
can overlap the rear window, or another glassfibre strip can be used.
Summary of Contents for Nynja Build
Page 1: ...1 Nynja Build manual Version 1 0...
Page 2: ...2 Figure 1 tube numbering scheme...
Page 3: ...3 Figure 2 Basic frame Skyranger...
Page 4: ...4 Figure 3 uncovered Skyranger frame...
Page 5: ...5 Figure 4 Uncovered Nynja frame Figure 5 Nynja fuselage with rear fairings removed...
Page 6: ...6 Figure 6 Nynja fuselage with rear fairings removed rear view Figure 7 simply assemble thus...
Page 22: ...22 Figure 13 forward fuselage from front quarter Figure 14 Cabin upper rear corner...
Page 60: ...60 Figures 65 cable arrangement further overview...
Page 86: ...86 Figure 100 Nynja elevator joiner with integral control horn...
Page 113: ...113 Figure 135 front jury strut attachment Figure 136 rear jury strut attachment...
Page 183: ...183 Figure 231 heavy duty power wiring schematic Rotax 912...
Page 184: ...184 Figure 232 low current wiring schematic Rotax 912...
Page 185: ...185 Figure 233 instrument wiring schematic Rotax 912...
Page 200: ...200 Nynja Build manual 1 0 18 2 One Piece Door Figure 250 one piece door frame...
Page 256: ...256 Nynja Build manual 1 0...
Page 257: ...257 Nynja Build manual 1 0 27 2 Wire locking...
Page 258: ...258 Nynja Build manual 1 0...
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