Aircraft Technical Manual
Jabiru Aircraft
Pty Ltd
J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants
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ISSUE
1
2
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5
Dated: 29th October 2014
Issued By: AS
Page: 274 of 298
3.
Grind excess resin from joints being careful not to grind into fibreglass layers. Take care not to
grind into the horn of any control surfaces.
4.
A clean wire brush is used to search out any crab holes or pinholes. Give the entire aircraft a
good scrub all over especially around corners etc.
5.
Wear a breathing respirator with painting cartridges right from initial sanding through to painting.
Hint: Body Filler sets quickly in high temperatures particularly when larger mixes are
necessary. Use cold packs under the Body Filler board to extend setting time.
6.
Follow instructions carefully and experiment with setting times.
7.
On large radius (e.g. sides of fuselage) an extra large homemade spatula (9” thin tin plate) is very
handy when applying Body Filler.
8.
When filling up to window edges, grind chamfer onto edge of window to give depth for bog
adhesion.
WARNING
THE GEL COAT IS MICRO THIN, SO SANDING IS ALWAYS A CAREFUL PROCEDURE. IF GEL
COAT IS INADVERTENTLY PENETRATED DO NOT CONTINUE SANDING INTO STRUCTURAL
GLASS.
9.
With the surface satisfactorily prepared white primer is required only on the discoloured areas
(i.e. Body Filled areas). Pin holes become evident after the primer is applied so use “spot putty”
to fill. Be careful and meticulous to find all pin holes because primer and top coat will not fill
holes.
10.
Your final product can only be as good as your preparation. Remember, paint does NOT cover a
multitude of sins.
11.
The factory uses a low-pressure pot gun for spraying at pressures from 60-100 psi.
12.
It is mandatory that exterior colour is WHITE only broken if desired, by pin stripes on the vertical
surfaces (i.e. Sides of fuselage) but not horizontal surfaces (i.e. top of wings or fuselage) as the
heat build up under the tape in hot sun is considerable.
13.
After filling all pinholes spray another coat of primer on the discoloured areas. An all over primer
coat is not required over the gel coat as gel coat is a sufficient undercoat.
14.
The final rub is with 320 grit all over and if satisfied with the surface preparation (remember paint
will simply change colour not hide lumps, bumps, scratches and holes) blow off the dust and give
an all over wipe with a tack cloth to pick up the final dust particles.
15.
Wash down the floor of the spray area to settle dust and proceed to spray as per your selected
technique.
16.
You are now ready to spray your final coat. GOOD LUCK!
WARNING
The Jabiru aircraft is only approved to be painted in basic White colour, so as to minimise the
effects of heat and ultra-violet light to the aircraft structure.
In addition, colour (including stripes etc) must not be applied to horizontal, upper surfaces.
