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Jabiru J450 Constructors Manual
Pre-Paint>Fuselage>Fit cowling
Tuesday, April 6, 2010
114 of 343
Final fit the cowling
Fit the top and bottom cowls to the
fuselage and insert the hinge pins
from the front door openings. Drill
one 5/16” hole through each side of
the propeller boss for a Camloc
fitting (shown circled at right).
Starting with the bottom cowl, remove one 6G stainless steel screw at a time and drill the hole
out to 3/16”, then drill the 3 holes in the top cowl to 5/16”.
Remove the cowls and fit
the captive nuts (a
complete captive nut
assembly shown at right)
to the 3/16” holes in the
bottom of the fuselage.
Use the captive nut itself as a jig to drill the rivet holes as shown at above right – thread the
screw part way through the captive nut from the back and fit the exposed end of the thread
into the hole in the fuselage, then drill the 2 x 3/32” rivet holes.
Repeat this process for each captive nut and then fit the captive nuts to the inside of the
fuselage, countersinking each rivet hole and riveting from the outside of the fuselage.
Use a similar technique for the 5 Camloc fasteners in the top
cowl (3 at the back, 2 around the propeller boss): hold the
captive part of the Camloc centred over the hole and drill the
3/32” rivet holes then fit the captive part inside the fuselage,
once again countersinking the rivet holes on the outside of the
fuselage. A complete Camloc assembly is shown at right:
Countersink the holes in the bottom cowl enough to allow the Tinneman washers to seat
snugly. Do not countersink the holes in the top cowl, just deburr them.
Fit the machined oil door
Locate the marked position on the right side of the top cowl.
Lay the oil door on the marking and mark around it, then
move the oil door forward 2mm and remark the front – this
slightly larger gap (circled at right) is to allow for the forward
movement of the hinge when the oil door is opened.
Assemble the door to the hinge and fit to the hinge surround.
Sand around the inside of the oil door opening and then test fit
the door assembly, taking care to keep the door centred
sideways and to the rear of the opening with the hinge to the
front. Tape the door to the cowl with 2 strips of cloth tape to
keep the correct position.
Mix a batch of 5-minute Araldite and flock, then lift the hinge
frame up, apply the Araldite/flock mix to the hinge frame and
seat the hinge frame to the cowl. Take particular care that no
Araldite/flock gets into any part of the hinge.