Flylight Nynja Build, Manual

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Nynja Build manual 1.0
18.3.3 Fitting the Lexan
a) Mark out the Lexan sheets using the patterns supplied.
The Lexan is big enough but there is not much spare space. Lay out
the patterns and find the best arrangement to ensure they can all be cut
from the sheet.
Cut out the Lexan using a pair of large tin snips.
The patterns are supplied as a guide and your individually constructed
doors will vary slightly, so cut out oversize to be safe.
b) Remove the doors from the aeroplane for fitting the lexan. Fit the Lexan to the
lower doors first.
Use the forward and upper edges as your accurate edges and trim so
that these fit nicely. Allow a generous overlap on the lower and rear
edges, which can be trimmed later.
c) Before riveting mark the position of the holes to be drilled on the doorframe.
Use a nominal rivet spacing of 60mm adjusted where required to
provide an even spacing on each side. Remove the protective covering
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.
The front vertical tube is riveted in position with the lexan. Drill the
hinge and tube at this stage ready
Figure 267 front tube
d) Drill and rivet the Lexan into place.
Work from the upper front corner, outwards and downwards together.
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.