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Jabiru J450 Constructors Manual 

 

Pre-Paint>Fuselage>Interior>Fit aileron cable brackets 

 

 

Tuesday, April 6, 2010 

131 of 343 

Pre-Paint>Fuselage>Interior>Fit aileron cable brackets 

Objectives of this task: 

In this task the aileron cable brackets will be positioned and mounted to the seat backs. 

Positioning of the aileron cable brackets is absolutely critical and great care must be taken in 
this task. 

Materials required: 

 

Card # J5 „Aileron System‟ 

Epoxy Resin and Flock 

73AS 6-6 rivets from box 3 of the hardware pack 

220 x 270mm plywood or heavy cardboard for the alignment 
template 

Position and fix the aileron cable brackets 

completed aileron cable mounts as viewed from the rear facing forwards 

Preparation  

Start by making the positioning template from the drawing on the next page. Heavy cardboard 
is quite adequate for the template as long as care is taken to cut the lines and drill the holes 
accurately. 

It will be necessary to redrill the top rivet holes in the aileron cable brackets – scribe a line 
parallel to the top of the bracket and in line with the centre of the existing hole.  

Centre-punch and drill 2 new 3/16” holes as shown at right. 

Make sure that you leave 
enough clearance around each 
hole for a 3/16” washer. 

Clean around each hole and 
test a rivet in each hole – it 
should be a snug fit. 

Summary of Contents for J450

Page 1: ...Jabiru J450 Constructors Manual from kit serial number 659...

Page 2: ...gned prototyped and produced in house so we can support you like no other kit manufacturer can Our distributors are fully supported by us and are a ready source of spares and free advice You need not...

Page 3: ...in one group may be worked on independent of tasks in the other group but the individual sequences under each group really need to remain intact This Manual details the procedures that we have refined...

Page 4: ...selage Firewall forward Fit firewall 44 Pre Paint Fuselage Firewall forward Firewall fittings 48 Pre Paint Fuselage Firewall forward Assemble and fit nose gear 54 Pre Paint Fuselage Firewall forward F...

Page 5: ...nt Wings Mount flaps 171 Pre Paint Wings Fit wing tips 178 Pre Paint Wings Fit ailerons 180 Pre Paint Wings Fit pitot tube to strut 186 Pre Paint Wings Fit vibration damper to strut 188 Pre Paint Wing...

Page 6: ...ats 278 Post Paint Wings Install aileron cables 279 Post Paint Wings Fit stall warning 281 Post Paint Wings Prepare wings for fitting 283 Post Paint Wings Fit wings 287 Post Paint Wings Connect ailero...

Page 7: ...workbench can be particularly useful in this instance and also make a vertical bin in a cooler corner of the workshop to stand long items like elevator rudder and flaps in while building the relevant...

Page 8: ...int stripping gun used to adjust some non structural glass fibre airframe parts like doorframes door stop strips etc Electric soldering iron for general wiring as well as removing temporary screws Fil...

Page 9: ...attachment to keep dust to a minimum This is for grinding parts like the trailing edge of the wing above the flaps If you can get an adjustable speed one then so much the better Fit a disc sander bac...

Page 10: ...metre long length of 100mm RHS rectangular hollow section aluminium is excellent for checking the rear of the wing and aligning the horizontal stabiliser make sure that you buy a straight length with...

Page 11: ...Low grade short fibre reinforcement for resin Also used as a verb to flock something into place for example Gelcoat White polyester resin film used on exterior of supplied fibreglass parts to provide...

Page 12: ...ssociation of Australia SAAA PO Box 169 Clifton Hill VIC 3068 Phone 03 9482 4716 Fax 03 9482 3936 Recreational Aviation Australia RAA PO Box 1265 Fyshwick ACT 2609 Phone 02 6280 4700 Fax 02 6280 4775...

Page 13: ...pt of your kit At this stage it would be a good idea to store your instruments in a low humidity environment Store your propeller in a horizontal position Treat all the steel components with an antico...

Page 14: ...h with a knife and peel the peel cloth off as shown in the photo at right then lightly roughen the surface by sanding to provide a good key for the epoxy to bond to Peel cloth is typically red in colo...

Page 15: ...which is what we do in our factory Curing times The LC3600 is a room temperature 24 Celsius minimum curing epoxy so it requires no elevated temperature curing unless you are working in a particularly...

Page 16: ...after mixing and when the structure is fully cured Various tools are used for trimming edges but for thin or tacky lay ups a sharp utility knife may be used Thicker cured edges may require a jigsaw a...

Page 17: ...h is measured from underneath the head of the bolt to the beginning of the threads see the drawing at right The thread length is generally fixed in relation to the diameter of the bolt Bolt identifica...

Page 18: ...for most uses or a steel lock nut for hot areas such as in the engine bay It is important to understand the procedure for tightening Aircraft lock nuts each nut must be fitted with a flat washer unde...

Page 19: ...cable threads must be visible if you cannot see the cable threads through the safety hole then you must not fly the aircraft until adjustments have been made so that the cable threads are visible thro...

Page 20: ...nto the skin wash off with warm water and soap immediately Barrier cream can help the skin to avoid becoming sensitised Note if barrier cream is used take care to keep it away from any surfaces to be...

Page 21: ...place with masking tape and run it out to 2600mm and tape it in place and then carefully mark the position of each hole with a marker pen Recheck each mark and then drill each hole Note that the 22mm...

Page 22: ...int Fuselage Underbody penetrations Tuesday April 6 2010 22 of 343 Firewall datum Existing Transponder optional 22mm Fuel vent Fuel vents 2 at Header tank quick drain 1 1 8 415m m 750m m 2240mm 2470mm...

Page 23: ...be transferred through the peel cloth by scribing around the marks with a sharp knife cutting just deep enough that the cut can be seen once the peel cloth has been removed File and sand all cutouts t...

Page 24: ...Fit the trim horn Sand away any remaining gel coat and roughness from around the trim horn mounting area The trim horn is slightly offset from the fuselage centreline so it will be necessary to sand t...

Page 25: ...d pour into the bottom of the ventral fin then prop the fin up at a 45 angle while it cures Once the resin has cured drill a 12 5mm hole through at the marked location this will be your rear tie down...

Page 26: ...th bits and hole saws in various sizes jigsaw Orbital sander sanding blocks and 80 grit sandpaper Sand the fuselage Start by using your orbital sander to take any rough edges away the moulding process...

Page 27: ...ide enough to work through when the horizontal stabiliser is later mounted after which you will fill the hole in to make a smooth curved surface across the top rear of the empennage Vertical fin stub...

Page 28: ...t 65mm wide and 15mm high in front of the gauge opining Drill both ends to 15mm and use a jigsaw to cut between the holes File the top and bottom of the slot to a smooth and even finish Fuel line cond...

Page 29: ...as shown above Leave enough length in front of the bulkhead to fit the sheath over the conduit and fix it in place with lock wire later in the build Fit each plastic conduit in place with 5 minute Ar...

Page 30: ...m Use a jigsaw to cut with and finish with a half round file Cable access hole behind seats Drill a 30mm hole in the console to the rear of the front seats as shows at right This will be used to assis...

Page 31: ...of 3 Layer Plate over the opening and drill 3 32 pilot holes 1 on each corner and 1 midway on each long side then use countersunk 3 32 rivets to pop rivet captive nuts under each hole first enlarging...

Page 32: ...tube to prevent it becoming pinched then fit tyre and tube over the main hub and fit the outer rim to the main hub with the inner tube inflation valve facing out Bolt the outer rim to the main hub bu...

Page 33: ...Jabiru J450 Constructors Manual Pre Paint Fuselage Undercarriage Assemble main wheels Tuesday April 6 2010 33 of 343 This completes the Pre Paint Fuselage Undercarriage Assemble main wheels task...

Page 34: ...is on the side that faces the gear leg Align the bolt hole in the outboard end of the stub axle vertically and fix the plate in place 2 x AN5 16A bolts at the top and 2 x AN5 15A bolts at the bottom T...

Page 35: ...rusion and flare the rivet using a tapered punch then use a flat punch to mushroom the end of the rivet over The rivets should not be able to move when correctly fitted In the factory we use a simple...

Page 36: ...rake fluid to the O rings and fit one to each piston then apply a smear of brake fluid to the inside of the caliper and fit the pistons to the calipers press the piston gently into the caliper with th...

Page 37: ...Jabiru J450 Constructors Manual Pre Paint Fuselage Undercarriage Assemble main gear Tuesday April 6 2010 37 of 343...

Page 38: ...2 opposite flats of the steel lock nut and then pull the steel lock nut back into the U channel as shown arrowed at right to glue the nut into the U channel Take care not to glue the bolt into the nu...

Page 39: ...away from the disc until the wheel can turn freely but with the pad just touching the disc Repeat the process for the other caliper Now tighten the main bolts up until the outer pad just starts to bi...

Page 40: ...aterials required Card J7 Undercarriage Epoxy resin and flock 10mm 3 8 ID reinforced hose approximately 80mm long Prepare and pre fit the main gear legs Fit the centre bolt to the inboard end of each...

Page 41: ...eft hand photo on the previous page Roughen the area around each hole and the back of each reinforcing plate to provide a key for the flock The surface around each hole is not flat and no attempt shou...

Page 42: ...Jabiru J450 Constructors Manual Pre Paint Fuselage Undercarriage Fit main gear Tuesday April 6 2010 42 of 343...

Page 43: ...or the sides of the fuselage as appropriate The clamp bolt reinforcing plates have the holes drilled off centre the widest part of the plate should be closest to the higher part of the floor Brush so...

Page 44: ...ube in kit shown above right Firewall insulation sheet white roll in kit shown at right 38 x 73 AS 5 32 rivets and matching washers Mark and bend the firewall plate The technique that we use in our fa...

Page 45: ...ke the plate towards the rear of the aircraft while the upper bend should take the plate upwards parallel to the lower part of the plate Take care to make the bends in the correct sense the plate cann...

Page 46: ...d then lay one insulating sheet onto the plywood firewall to the midpoint of the firewall so that it is held by the sealant Lay the other sheet and butt up to the first sheet in the middle of the fire...

Page 47: ...you rivet Be particularly careful when drilling though the plywood firewall if you push too hard then the drill can chip a section of ply out when it breaks through the back of the plywood so drill u...

Page 48: ...ion the air box so that it sits flat on the firewall just above the upper bend then measure in 280mm from the left hand edge of the firewall to the left hand main side of the air box Check that the ai...

Page 49: ...de rivets are arrowed in red above Battery box and battery Run a 3 16 drill through the 2 pairs of holes on the right hand mid section of the firewall and bolt the tie down brackets into place with AN...

Page 50: ...nd actuating arm and then push the threaded end of the main body through the firewall Turn the main body so that the pressed in tube faces the left of the aircraft and fit a small screw into the notch...

Page 51: ...l fuel line fitting Press the flat plate of the brass bulkhead fuel fitting into the top of the aluminium sleeve this sleeve connects to the plastic fuel sheath on the inside of the firewall and bond...

Page 52: ...and the top of the terminals 30mm below the top of the firewall Fix the solenoid into place with 2 AN3 7A bolts washers and Nyloc nuts Fit the main electrical earth terminal maroon arrow above by dril...

Page 53: ...raldite and flock filling the area around the inside and outside of the join Use enough of the Araldite flock mixture to completely fill the area surrounding the tube on the inside of the cover as sho...

Page 54: ...le the nose leg by reference to the drawing 2 pages over Press the nylon bush through the tube at the bottom of the leg photo at right flock in place if needed and then fit the machined yoke with an A...

Page 55: ...nose leg housing Assemble the top and bottom plates to the spacer with the supplied cap screws clean the threads use a drop of Loctite 620 on each cap screw and tighten firmly Clean the nylon bushes...

Page 56: ...Jabiru J450 Constructors Manual Pre Paint Fuselage Firewall forward Assemble and fit nose gear Tuesday April 6 2010 56 of 343...

Page 57: ...Jabiru J450 Constructors Manual Pre Paint Fuselage Firewall forward Assemble and fit nose gear Tuesday April 6 2010 57 of 343...

Page 58: ...arefully level the nose gear housing Once it is level drill the other top hole and recheck for level then drill the bottom holes and bolt the nose gear housing in place You will need to flock the 2 in...

Page 59: ...the axle this will put a side load of the wheel bearings Partially inflate the inner tube with the valve out then liberally coat the tube with talcum powder fit it into the tyre and place the tyre on...

Page 60: ...J450 Constructors Manual Pre Paint Fuselage Firewall forward Assemble and fit nose gear Tuesday April 6 2010 60 of 343 This completes the Pre Paint Fuselage Firewall forward Assemble and fit nose gea...

Page 61: ...sets AN4 20A 31A bolts plus washers spacers rubber mounts From Card J10 Firewall the 4 x 4025094 backing plates photo below right From Card J23 Engine the washers and lock nuts in Engine mount hardwar...

Page 62: ...may be necessary to compress the mount rubbers in order to get the steel lock nuts on use a G clamp or similar and clamp across a socket on the head of the bolt and the side of the machined washer bes...

Page 63: ...Jabiru J450 Constructors Manual Pre Paint Fuselage Firewall forward Fit engine mount and engine Tuesday April 6 2010 63 of 343...

Page 64: ...s Now release the jack and recheck the angle of incidence If the engine is slightly down at the front you can fit up to a maximum of 3 penny washers under each bottom engine mount to adjust the angle...

Page 65: ...e performed by the kit builder with the engine mounted to the aircraft In the factory we do this task while the engine is fitted to a mobile engine stand so some of the photos will be slightly differe...

Page 66: ...ension Set your torque wrench to 30 ft lbs or 40 Nm and place it on top of the engine Apply a few drops of Loctite 620 to each screw hole place the propeller flange extension on the hub and fit the 6...

Page 67: ...ree length of the screw Fit a rubber grommet to each of the 4 large holes in each sump rail and fit each sump rail into place feed each countersunk screw though until the nut can be fitted between the...

Page 68: ...Jabiru J450 Constructors Manual Pre Paint Fuselage Firewall forward Fit oil cooler Tuesday April 6 2010 68 of 343...

Page 69: ...clean engine oil to the O rings on the adaptor and the oil filter refit the oil filter and tighten gently until resistance is felt as the seal first contacts the housing and then tighten exactly one f...

Page 70: ...he supplied hose clamp and cutting off the excess hose clamp screw Now roll the fireproof sleeve over the hose clamp and lock wire into place as shown top right using a double loop and twisting off Th...

Page 71: ...tting in the oil bottle without rubbing against the inside of the cowl and so that the outlet from the oil bottle can be routed over the lower engine mount as shown in the photo at right Mark the posi...

Page 72: ...nlet line from the engine oil filler will curve smoothly down to the top fitting in the oil bottle without rubbing against the inside of the cowl and so that the outlet at the bottom can be routed int...

Page 73: ...be the lowest point when the tray is fitted and flock the drain fitting into place with 5 minute Araldite and flock Put a piece of tape over the inside of the tray and over the fitting and leave to cu...

Page 74: ...debris before fitting Note that the fuel pump inlet is on the side of the pump and the outlet is on the top of the pump as pictured at right Use the flow arrows in the 2 photos on this page to help yo...

Page 75: ...oth from the bag labelled Extra Cloth 5 minute Araldite and flock Assemble the ducts Use a length of masking tape on the join line at the bottom of each duct inlet to hold the join firm and prevent Ar...

Page 76: ...nd 1 rear rocker cover cap screws circled top test fit the duct and mark the locations for the cutouts around the oil lines arrowed above File out a notch for each oil line until the duct clears them...

Page 77: ...ch of the 3 rocker cover holes circled in the photo at the top of the previous page to and temporarily mount both ducts using the cap screws Mark a point on the inside of the duct directly above each...

Page 78: ...tube to the duct and hold it in position with masking tape Mix a small batch of 5 minute Araldite and flock and fix the tube to the duct Leave to cure then remove the duct and apply flock around the t...

Page 79: ...gsaw Photos are of a J200 the same process applies to all Materials required Epoxy resin and flock x adhesive backed foam strip not included in kit Pre fit the windscreen Start by carefully sanding aw...

Page 80: ...ly in place while the flock cures Start by drilling at each corner then drill halfway between each corner and then drill halfway between those holes until you have the holes as shown above and on the...

Page 81: ...nd to see that the flock has keyed to the windscreen the sanded surface of the windscreen edge will appear to go clear with no bubbles when the flock is in full contact with it It may be necessary to...

Page 82: ...he console All electrical cabling and the fuel line exit the console at the top front of the lower console just before the rudder pedals This slot was enlarged in the Prepare fuselage task The trim ca...

Page 83: ...y tail strobe wiring can be left trailing out the rear of the fuselage at this point they will later be routed up and into the vertical fin The 2 fuel pump wires can be pulled up through the hole in t...

Page 84: ...e Feed the rudder cable tagged end first into the slot on the right hand side of the fin stub then down though the front hole in the empennage as shown at top right and forward into the lower longitud...

Page 85: ...d in one continuous action from start to finish This task will take most of a day in our factory with trained staff we allow a morning to final fit and reinforce the fin so plan on at least that amoun...

Page 86: ...the vertical fin beside the fuselage on trestles set at the same height as the fin mounting stub Lay the strake across the mounting stub Locate the drawstrings inside the fin that will be used for th...

Page 87: ...th and even so that there is one continuous line along the entire length of the strake if there is any discontinuity it will look extremely disappointing when paint is applied so take care to get it e...

Page 88: ...al fin lift the fin into position and lower it down while holding the sides apart Take care not to let the fin just slide down into place because it will push all the flock out of the join and keep th...

Page 89: ...s fibre cloth from the bag labelled Outer Reo Tail Fin as shown above taking care to brush each layer in with absolutely no air bubbles Depending on the temperature you may need to mix a fresh batch o...

Page 90: ...the horizontal stabiliser Open the bag labelled Outer Reo Tail Fin and take out the 6 T shaped pieces of glass fibre cloth the top of the T is intended to be fitted inside the fin reinforcing channel...

Page 91: ...le saw to open the inspection hole and a drill and jigsaw to recut the rudder cable slot File out any rough edges Use a small wire hook to pull the rudder cable out of the slot Fit the VHF Antenna Ens...

Page 92: ...and fit heat shrink tubing over the terminal joins as shown in the sketch below Screw the inner cable to the TOP section and the braided coax sheath to the LOWER section Tuck any excess cable back int...

Page 93: ...static probe assembly back into the hole at the front top of the vertical fin so that the static probe assembly is parallel with the top of the vertical fin and centred laterally in the fin Secure th...

Page 94: ...rds Lay the horizontal stabiliser and the elevator on the work surface in the finished position with a 1mm gap use 2 equally spaced mixing sticks between them You will need to place a wedge under the...

Page 95: ...Jabiru J450 Constructors Manual Pre Paint Fuselage Empennage Fit elevator Tuesday April 6 2010 95 of 343...

Page 96: ...countersunk rivets Now remove the Clecoes from the outside holes one at a time countersink each hole and fit a countersunk rivet until each hinge has 8 countersunk rivets Take care to keep flock away...

Page 97: ...to the end cap stub then fit the end cap to the elevator and fix in place with the self tapping screws Smooth away any excess flock with a mixing stick recheck the alignment and leave overnight to cu...

Page 98: ...ed Horizontal Stabiliser Steps 1 Level the aircraft 2 Fit the stabiliser 3 Glass the tailcone 4 Glass the stabiliser Level the aircraft The aircraft should be fixed in a wings level attitude prior to...

Page 99: ...iser to the rear of the fuselage using the stabiliser centreline as a lateral location guide against the fuselage centreline Push the stabiliser fully forward into the rear of the fuselage and check t...

Page 100: ...with the self tapping screws do a final check of the alignment and leave overnight to cure Next day remove the self tapping screws that were used to temporarily fix the stabiliser in place If they ar...

Page 101: ...e tailcone and brush it on then down over the foam blocks cut to clear the elevator stop and brush under the tailcone taking care to avoid any bubbles or gaps The second layer of glass cloth is placed...

Page 102: ...ting at a point 50mm back from the leading edge of the stabiliser and covering the stabiliser to fuselage join brush it onto and under the stabiliser Place the second layer on top of the stabiliser an...

Page 103: ...the fin and rudder and the top of the fin and the rudder horn It may be necessary to sand part of the forward section of the rudder horn and or the back of the fin ahead of the rudder horn away taking...

Page 104: ...t taped in place Make sure that the alignment is still correct then drill the top hole of the top hinge and fix in place with a rivet and then drill a hole in the bottom hinge and fix that in place wi...

Page 105: ...Jabiru J450 Constructors Manual Pre Paint Fuselage Empennage Fit rudder Tuesday April 6 2010 105 of 343...

Page 106: ...xing stick and leave overnight to cure Next day use a rat tail file to make a slot into the fin at each hinge pin mark fit the hinge pin and the hinge pin retainer mark the retainer screw hole and dri...

Page 107: ...eds to be enough room above the top hole and below the bottom hole to fit the head of the bolt in place Make any vertical adjustments that may be required then drill to 3 16 Test fit the cable clamp f...

Page 108: ...the propeller boss area then mark a 105mm circle and use a jigsaw to cut the hole out In the factory we use a circular jig as shown in the second photo but the hole can easily be scribed with a compas...

Page 109: ...ith the back edge of the fuselage tape while in the photo above right the cut is being made in line with the front edge of the cowl tape Sand any rough edges away with a long sanding block and refit t...

Page 110: ...5 x 3 32 holes on each side each 10mm in from the edge of the cowling and each at 60mm away from each bend plus one screw near the bottom of the cowl the lines in the photo above show the positions Te...

Page 111: ...to prevent possible accidents Fit both cowls together fitting the locating section at the front of both cowls first and then butt the side joins together Tape the cowls together with cloth tape on bot...

Page 112: ...e removing the Clecoes Working on one hole at a time drill a 3 32 hole and use a 120 countersink bit to carefully countersink the outside of each rivet hole just enough to allow a countersunk rivet to...

Page 113: ...owl join as shown above right which will be very near to the waterline and drill a hole towards the hole that you have just drilled Use a file to round the ends of the guide tubes slightly Continue to...

Page 114: ...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 ri...

Page 115: ...angles to the hinge line and mark around the outside of the unit and then make a second line inside the first about the size of the actual opening Cut the opening and fit the scoop to the inside of t...

Page 116: ...ctually 2 tubes one inside the other make sure that both tubes are still together when this task is completed and the shaft is reassembled Position the bearing blocks Place the drive shaft through the...

Page 117: ...inside The photo above shows the bearing blocks circled flocked into place with the drive shaft keeping them in alignment the photo has been taken from the front of the aircraft facing towards the re...

Page 118: ...ll bead of Loctite 577 on the thread attach the brass compression fitting to the master cylinder and tighten firmly Put a piece of masking tape over the hole to keep foreign objects out Drill the uppe...

Page 119: ...Jabiru J450 Constructors Manual Pre Paint Fuselage Interior Console Pre fit handbrake Tuesday April 6 2010 119 of 343...

Page 120: ...to allow free movement of the handbrake lever locking cam The lever assembly can now be fitted to the brake lever mount It may be necessary to file the cut out on top of the console in order to achie...

Page 121: ...clamp to the seat base At the completion of this task the trim levers will be removed and put aside until the final fitting following painting and installation of the upholstery This task is broken d...

Page 122: ...ly fit the trim levers including the friction washers and tighten the castellated nut onto the pivot bolt by hand until the trim levers are held securely onto the pivot shaft Move the trim levers fore...

Page 123: ...m of the template on the pivot shaft and the top level with the top of the forward console Mark the locations for the trim lever stops on the left hand side of the console only and lightly sand the ar...

Page 124: ...it the cable clamp to the outer cable and make sure that the cable clamp grips the locating groove on the outer cable circled at right Position the trim cable clamp against the console in such a way a...

Page 125: ...e and through to the rear of the fuselage inside the longitudinal rib Drill the existing 3 16 holes through and place both bolts through the mounting holes from the inside of the console through the c...

Page 126: ...Jabiru J450 Constructors Manual Pre Paint Fuselage Interior Console Fit control stick Tuesday April 6 2010 126 of 343...

Page 127: ...h the bellcrank and the shaft as shown below right Do not force the bolt through the holes ensure that the holes are aligned exactly before fitting the bolt Now the control shaft is held in the consol...

Page 128: ...k and reset the endplay very carefully and leave to cure taking care not to get any flock onto the control shaft Smooth off any surplus resin with a small amount of resin on a clean mixing stick When...

Page 129: ...Fit the rudder pedals into place as shown above with the mount blocks supporting the pedal assembly Check each lower block to see if it is touching both the floor mounts and the rudder pedal assembly...

Page 130: ...of the mount block in place and replace the centre bolt Place all three bolts in the centre mount block and do them up by hand until the bolts reach the bottom of the captive nuts this will ensure th...

Page 131: ...for the alignment template Position and fix the aileron cable brackets completed aileron cable mounts as viewed from the rear facing forwards Preparation Start by making the positioning template from...

Page 132: ...Jabiru J450 Constructors Manual Pre Paint Fuselage Interior Fit aileron cable brackets Tuesday April 6 2010 132 of 343 Aileron cable bracket positioning template...

Page 133: ...the control yoke with 2 bolts placed through the yoke and into the template as shown circled at the bottom of the photo at right Level the top of the template in line with the top of the seat backs Wo...

Page 134: ...rom the rear of the seats hold each bracket against the seat back so that the outside and bottom of the bracket is in line with the marks on the front of the seat back you will be able to see the mark...

Page 135: ...aced Working from the front of the seat place all of the rivets through the holes in the seat backs Add flock to the resin and apply an even layer of flock approximately 2 3mm thick to the back of eac...

Page 136: ...he header tank fitting operation and oriented as shown on drawing 4A408AOD 1 this drawing is shown full size on the next page of this task Cut four positioning brackets from fibreglass angle and glue...

Page 137: ...Jabiru J450 Constructors Manual Pre Paint Fuselage Interior Fuel system Tuesday April 6 2010 137 of 343...

Page 138: ...ter body and another zip tie to secure the wrapped filter to the locating bracket as shown at right Araldite a clip on the top of the lower longitudinal rib to secure the fuel line from the fuel filte...

Page 139: ...on the fuel tap as shown at right Fit the fuel line and tap assembly cover the ends of both fuel lines to prevent foreign objects from entering by using masking tape over the ends and then insert the...

Page 140: ...eader tank and stored the lines for later fitting Check that all the flow arrows on the fuel filter the electric fuel pump and the fuel tap are pointing in the correct direction which is away from the...

Page 141: ...seat Both bottom anchor brackets are attached to the main beam that runs behind the seats Start by marking a horizontal line 100mm up from the base of the main beam on each side of each seat and then...

Page 142: ...hoto at right Hold the bracket in position and drill a 3 16 hole at the top of the bracket and slip a bolt through then line up the bottom of the bracket and drill the second hole The top bracket will...

Page 143: ...Each bottom bracket should be mounted 25mm in from the fuselage skin and fixed in place with AN3 bolts through the brackets and fuselage with penny washers and Nyloc nuts behind and tightened firmly...

Page 144: ...ner then add the screws each side of the longitudinal rib then fit the remaining screws until the bottom is secured all round Mark the fuselage around the edge of the seat bottom and remove the bottom...

Page 145: ...equired Make sure that each side at the top is an equal distance from the rear bulkhead mark the fuselage as a reference see the photo on the previous page It may be necessary to shape the outside top...

Page 146: ...the door jambs are fitted and mark the inside of the door around the edge of the opening Remove the door and use a sanding disc to trim the door to the mark Hold the door in the opening and carefully...

Page 147: ...he factory we use a simple plastic block that is 28mm from front to back which is the width of the jamb plus the compressed door seals with a screw as a handle as shown in the photo at right With the...

Page 148: ...he latch pin to the barrel from the bottom with the rubber sleeve and circlip fitted from the top as shown above Test the latch for free but firm movement Fit the top handle 50mm behind the top latch...

Page 149: ...ch the door and mark the slot onto the back of the door use a builder s pencil or any similar thin marker and mark through the slot Mark and cut the slot into the door jamb and then refit the door jam...

Page 150: ...sin and flock wax x adhesive backed foam strip 8G self tapping screws in heavy duty coax cable clamps Pre fit the window Start by carefully sanding away all of the gel coat from the joggle then fit a...

Page 151: ...ping screws and cable clamps and start fitting them around the door frame as shown at right working from the corners first and then the middle screws and so on The clamps will pull the window into the...

Page 152: ...the camber of the main wheels This procedure outlines how to check the wheel alignment and make the necessary adjustments to correct the issue It s a fairly basic technique but we ve had success with...

Page 153: ...toe out The wheels will naturally want to rotate outwards when the aircraft is at gross weight so it is recommended to have a slight amount of toe in to allow for this If adjustments are required wash...

Page 154: ...test fitted and the gear leg opening shaped to suit Mark back 55mm from the axle bolt hole and drill a 1 1 8 hole for access to the valve as shown above left Slip the spat down over the wheel until t...

Page 155: ...halves together as shown at right Countersink the screw holes in the front section and fit captive nuts shown above to the rear joggle use countersunk 3 32 rivets to hold the captive nuts in place Sc...

Page 156: ...ve up as weight is added to the aircraft then hold the spat in that position and mark the location of the holes for the machine screws on each side of the yoke A completed nose wheel spat is shown bel...

Page 157: ...step of the operation is broken out as one of a series of tasks that are ordered in the sequence that we would normally perform them The homebuilder could and should follow the same sequence but with...

Page 158: ...t length of the wing tank To do this take the supplied breather tube and shape the end to a point as shown below Feed the breather tube into the tank from the top front wing root fitting and carefully...

Page 159: ...wing surface only and not into the fuel tank Hold the drill at right angles to the wing surface and very gently drill until you can see darkness at the bottom of the cut as indicated in the yellow cir...

Page 160: ...nside to keep flock from entering Mix a batch of resin and coat the outside of the filler body and the top of the wing tank area where it will be mounted Add flock to the resin and carefully fill the...

Page 161: ...y brush it into place with no wrinkles or bubbles Leave overnight to cure Next day remove the peel cloth and seal the opening with a square of plastic or heavy card secured with masking tape to keep t...

Page 162: ...he blanking plug and fit to the top rear fitting Assemble the fittings onto the breather tube as shown and then insert the breather tube into the front top fitting and work it fully into the wing tank...

Page 163: ...y until the entire length of plain earth wire is inside the tank Fit the speed nut onto the P clip fit the P clip around the breather tube and then fit the 6g self tapping screw through the 4mm ring t...

Page 164: ...oul the fuel cap when it is fitted The braided length of the earth cable is the fuel cap retaining cable and it should now be connected to the bottom of the post on the fuel cap with a machine screw w...

Page 165: ...gsaw near the wing attachment lug you will need to make sure that the shoe of the jigsaw is completely level when cutting near the wing attachment lug as shown above Use a hacksaw in a holder to remov...

Page 166: ...reference circled in the photos above Now remove the ruler from the hole and lay it on the wing with the reference mark lined up and mark where the end of the ruler lies which is where the outboard s...

Page 167: ...Jabiru J450 Constructors Manual Pre Paint Wings Cut aileron cable openings Tuesday April 6 2010 167 of 343...

Page 168: ...le slot be accurately positioned in relation to the wing rib because the aileron cable will be clamped to the wing rib and it must align with the aileron drive arm The aileron drive arm and thus the a...

Page 169: ...e wing root and mark a line then measure forwards 65mm from the front of the rear wing lug and mark another line Where these lines cross is where the quick drain sump will be fitted Now we can drill t...

Page 170: ...r Leave overnight to cure The flock will be partly covered by the glass fibre cloth lay up for the flaps and any roughness in the finish will be rectified in the Painting Pre paint preparation task Cl...

Page 171: ...s task This is probably the single most important task in the Manual Materials required Card J16 Electric Flaps Glass fibre cloth bag labelled Hollow Wing Epoxy resin and flock Prepare the wing Turn t...

Page 172: ...ateral flap position Now the flap is positioned laterally The intention is to position the flap so that the distance from the outside of the wing mounting lugs to the outside of the flap drive arm is...

Page 173: ...mark the trailing edge of the wing where the flap touches and then carefully grind the trailing edge away until the flap sits snugly into the wing recess Shaping should be done with a long sanding blo...

Page 174: ...make any changes without causing considerable damage Remove the peel cloth from the outside and the inside of the flap brackets Lightly sand the inside and outside of each bracket Lightly sand the en...

Page 175: ...ed Mix a separate small firm batch of flock and fill the inside of the angled end of the flap brackets as shown above right Place each bracket holding the bracket clear of the wing insert the bolt thr...

Page 176: ...g Repeat this process for each of the 3 layers Note that the first layer should be slightly wetter than the following 2 layers The photos above show the second layer being applied Brush a layer of pee...

Page 177: ...h bolt Deflect each flap to as close to 39 5 as you can and hold the flap in that position at each end with cloth tape Now measure the slot size at each flap post as shown in the drawing at right the...

Page 178: ...tip The wing tip should fit up hard against the joggle step Tape in place and turn the wing right side up The rear of the wingtip has a step that sits into an aligning joggle at the top rear of the w...

Page 179: ...with the strobe packing Decide exactly where you want the strobe to fit and in what position and then shape the underside of the strobe mount so that it will fit in the desired location and fix it in...

Page 180: ...on the wing and use a ruler or straightedge to line the aileron drive arm up with the aileron cable slot that was cut previously in the Pre Paint Wings Cut aileron cable inspection opening task The d...

Page 181: ...from the area Protect the outboard end of the flap from any excess resin or flock by covering it in brown packing tape For each wing mix a 280g batch of resin and divide into a 240g batch and a 40g ba...

Page 182: ...bricks Wipe away any excess flock along the bottom of the curved rib then brush on 3 layers of glass fibre cloth around the gap at the wing tip end of the pre mould strip as circled in the photo at a...

Page 183: ...ron in place and clip the trailing edge of the aileron the flap and the wing tip winglet The front edge of the aileron should be sitting on top of the pre mould strip Check that the trailing edges are...

Page 184: ...ge and the locations where they will be fitted then mix a small batch of resin and coat each area Add flock to the remaining resin and apply a 2mm layer of flock to each hinge and flock into place usi...

Page 185: ...right Each gusset will need to be sanded to a good fit then flock one gusset in place at each side of each hinge refer to the photo below for an example of gusset placement Position each gusset carefu...

Page 186: ...ront of the strut Feed the supplied ID plastic tubing into the hole and down the strut until it can be seen at the bottom then fit the top end of the tube over the pitot fitting and superglue and lock...

Page 187: ...Jabiru J450 Constructors Manual Pre Paint Wings Fit pitot tube to strut Tuesday April 6 2010 187 of 343 This completes the Pre Paint Wings Fit pitot tube to strut task...

Page 188: ...the drawing on the next page 2mm in from the rear edge of the strut 460mm up from the bottom of the strut and hold it in place with tape or by hand Drill a 1 16 hole through one end of the damper and...

Page 189: ...Jabiru J450 Constructors Manual Pre Paint Wings Fit vibration damper to strut Tuesday April 6 2010 189 of 343 This completes the Pre Paint Wings Fit vibration damper to strut task...

Page 190: ...is very important that the AN4 14A wing attach bolts fit snugly through the holes in the attach bushes on the wing and the aluminium wing attach lugs on the fuselage Test fit a bolt in each hole and i...

Page 191: ...age and guide the wing attach lugs into the aluminium wing attach brackets on the fuselage The fit will be tight and it may take some careful positioning of the wing to get them to fit the outboard en...

Page 192: ...oard end of the flap The inboard end of each flap is manufactured slightly over length to allow for variations in flap hanger placement and it will now require trimming to allow it to clear the fusela...

Page 193: ...e sure that the fairing is lined up fore and aft Mark around the back half of the fairing and tape it into place then drill 6 evenly spaced holes through the mounting lip of the fairing and through th...

Page 194: ...eck all round each half of the fairing and adjust as required for the best fit When the fit is correct all round drill 5 32 holes around each fairing and the fuselage in the pattern shown in the photo...

Page 195: ...n white Filler and paint In general we use automotive grade paint preparation products and automotive grade 2 pack epoxy paint The specific brands that we use here in Australia may not be available wh...

Page 196: ...ts will be prepared and painted separately and then reassembled after the paint has cured We suggest that you bag all the hardware bolts nuts washers clips etc for each component separately and clearl...

Page 197: ...ill see the shape of your windscreen and windows every time that you fly so make them even and pleasing to the eye The photo above right shows a side window fully masked note the blue Fine Line tape d...

Page 198: ...ch of Q Cell and polyester resin to a creamy consistency and keep it in a sealed tin this mix will last about 5 days Stir the Q Cell mix thoroughly before each use and then scoop out one hand sized am...

Page 199: ...ld use an industrial fan as an extractor fan to draw clean air over the work surface It bears repeating here that the topcoat must be white under no circumstances must any other colour be used and any...

Page 200: ...up the instrument panel all of which is done out of the aircraft on the workbench The assembly sequence then is to fit all of the upholstery apart from the seat covers firewall console floor sides ro...

Page 201: ...ach bearing block and move the bottom half of each bearing block out until the cross shaft has no side to side movement Make sure that the cross shaft is evenly spaced in from each side of the panel t...

Page 202: ...shown arrowed at right Mark a line on each side of the panel housing along the centreline of each throttle shaft Remove the instrument panel and set aside Mark and drill the 3 16 and 1 2 holes as sho...

Page 203: ...ts Countersink the rivet holes just enough to make a countersunk 3 32 rivet sit flush and rivet the captive nuts in place and then enlarge the 5 32 holes in the panel to 3 16 to provide clearance for...

Page 204: ...anel so that the panel can be placed face down without any risk of scratches to the front face of the panel or the faces of the instruments All electrical connectors should be close at hand and your h...

Page 205: ...ly filing a 6mm wide 45 recess on the back of the panel at each side of each circuit breaker hole as shown above this allows the circuit breaker attachment clips to seat firmly into the holes Work car...

Page 206: ...gneto to earth while the UP position will remove the earth and make the magnetos live Accordingly the magneto switches will have the groove facing upwards The 3 way flap switch should be fitted with t...

Page 207: ...ower side of the bottom contacts on the 5 and 10 amp circuit breakers only using the M3 silver screws and Nyloc nuts as shown above Tighten firmly only these screws and nuts are very small so take car...

Page 208: ...nual Discard any O rings from around the instruments these will not be required The Microair VHF radio and Transponder can be removed from their boxes at this time Each unit is wrapped in a silver ele...

Page 209: ...anodized captive nuts are first inserted into the rear of the screw holes in the instrument and then held in place with a finger while the screw is fitted from the front through the panel and the ins...

Page 210: ...the position of the mounting holes on the panel with a sharp drill Remove the instrument drill the holes through and fix the mounting bracket into place with M4 screws and Nyloc nuts and then fit the...

Page 211: ...for tagging each electrical connector or wire in the following manner Red positive Black negative earth White signal Cut about 20 of each colour to start with and cut more as needed Put a strip of ma...

Page 212: ...blue connector Do not crimp more than 2 wires into a single connector or you run the risk of having some of the wires pull out of the connector so stay with 2 wires maximum Quite a lot of wires will g...

Page 213: ...the Post Paint Fuselage Install electrical wiring task Each connector is assigned a group of wires that go to a similar physical location The connector pairs should be marked from A B C D or E as sho...

Page 214: ...Right MAG 4 Oil temperature 8 Oil pressure Connector B Electrical QK6 16 gauge wire 1 Starter 4 Regulator to main busbar 2 Starter pilot light 5 EFIS negative 3 Charge pilot light 6 Fuel pressure Conn...

Page 215: ...l a 6mm hole through the panel and mount the socket Use zip ties to hold the digital harnesses to the wiring loom Tube up to the pressure instruments Fit the nylon fittings to the rear of the pressure...

Page 216: ...Jabiru J450 Constructors Manual Post Paint Fuselage Electrical wiring diagrams Tuesday April 6 2010 216 of 343 Post Paint Fuselage Electrical wiring diagrams...

Page 217: ...Jabiru J450 Constructors Manual Post Paint Fuselage Electrical wiring diagrams Tuesday April 6 2010 217 of 343...

Page 218: ...Jabiru J450 Constructors Manual Post Paint Fuselage Electrical wiring diagrams Tuesday April 6 2010 218 of 343...

Page 219: ...Jabiru J450 Constructors Manual Post Paint Fuselage Electrical wiring diagrams Tuesday April 6 2010 219 of 343...

Page 220: ...Jabiru J450 Constructors Manual Post Paint Fuselage Electrical wiring diagrams Tuesday April 6 2010 220 of 343...

Page 221: ...Jabiru J450 Constructors Manual Post Paint Fuselage Electrical wiring diagrams Tuesday April 6 2010 221 of 343 This completes the Post Paint Fuselage Electrical wiring diagrams task...

Page 222: ...e while the edged panels will be the finishing panels where the edges will be seen Take your time and test fit each panel it is much easier to do this now without adhesive Consider labelling the locat...

Page 223: ...all surrounds These areas are covered by several small pieces that each cover a rib or brace Note the fuel tank wiring should be fitted inside the front pillars before covering them Refer to the Insta...

Page 224: ...t applicable to J160 J170 10 Rear sidewalls not applicable to J160 J170 11 Door panels 12 Door pockets attached with snap fasteners and Velcro 13 Instrument panel housing 14 Cable covers and all other...

Page 225: ...pin assignment for the multi pin connectors Preparation Before heading out to the aircraft there are a couple of things that need to be prepared The 2 tachometer tacho sender unit wires will need to b...

Page 226: ...ders to the rear of the engine and zip tied to the pushrod tubes Strip 4mm of insulation from each wire and crimp a red female spade connector and a black heat shrink tag to each You will need to cut...

Page 227: ...rn and tighten the lock nut finger tight Now rotate the engine one half of a turn until the other timing tag is under the sender unit and screw the sender down until it just touches that tag which sho...

Page 228: ...res should be twisted This will help to minimize inducing noise into the wiring harness from the alternator From here the wiring bundle can be routed up to the top right engine mount and then back alo...

Page 229: ...gauge lighter wire shown above as purple The colour coding of the pins in the diagram above indicates the colour of the wires coming from the regulator to the connector Route the 10 gauge positive wir...

Page 230: ...motor Earth the starter motor by fitting the long heavy orange cable under the top bolt that holds the front of the starter motor housing in place this provides maximum current to the starter unit Loo...

Page 231: ...obe unit to the top of the fin and connect the wiring Wingtip strobe units will be connected after the wings have been fitted to the fuselage Seal the cable collars Once all wiring has been routed thr...

Page 232: ...and fit a 4mm countersunk screw with a Tinnerman washer from under the fuselage then place all 4 ring terminals over the screw and secure them with an M4 Nyloc nut and washer Tighten firmly This will...

Page 233: ...tre as shown above left Leave the wires hanging down about 300mm and make sure that the wires from each side are clearly labeled Left and Right use masking tape to label them There is no polarity requ...

Page 234: ...ors for a male connector body The connector bodies that will be used are the matching halves of the connectors that were used in the Assemble instrument panel task these were store at the completion o...

Page 235: ...d into the left underside of the control stick taking the Pilot group up the left hand side and the Co Pilot group up the right hand side For a single stick feed the Pilot group up and into the stick...

Page 236: ...arness plug to the encoder unit tighten the plug retaining screws by hand and leave the other end free for later connection to the transponder unit when the instrument panel is fitted Mount the transp...

Page 237: ...ontrol Stick task Clean any debris from the front and rear bushes and apply a small amount of lubricant to the bushes Fit the control shaft into the console from the front wipe away any lubricant from...

Page 238: ...Jabiru J450 Constructors Manual Post Paint Fuselage Interior Fit console controls Tuesday April 6 2010 238 of 343...

Page 239: ...rommet over the brake hose at the front of the console blow the hose clear and fit it to the brass fitting on the master cylinder Tighten the fitting firmly Leave the brake hose about 50mm below the f...

Page 240: ...Jabiru J450 Constructors Manual Post Paint Fuselage Interior Fit console controls Tuesday April 6 2010 240 of 343...

Page 241: ...out of the hole under fuselage where the brake line exits Leave enough length so that the top of the tubing is just below the bottom of the windscreen and so that the bottom of the tubing reaches acro...

Page 242: ...into place in the lower blocks Seat the pedal assemblies in the blocks and fit the upper blocks and clamp plates and secure with an AN4 25A centre bolt to each block to hold it in place Check for min...

Page 243: ...with the arm facing the left Fit the steering yoke to the top of the noseleg and then fit the leg extension bush down into the top of the noseleg Refer to the drawing below and the photos on the next...

Page 244: ...right hand side of the steering yoke and the shorter pushrod fits to the left hand side of the steering yoke Fit the pushrods though the holes in the firewall and then connect them to the steering yo...

Page 245: ...then fit the rod end to the outside of the rudder pedal arm with an AN4 14A bolt through the pedal arm then an AN960 416L flat washer and then the rod end followed by an AN960 516 flat washer and Nylo...

Page 246: ...the outer cable so that it runs in a smooth a line as possible from the cable entry cut out in the console to the rudder pedal tab and then mark and drill the 2 x 3 16 holes through the clamp and con...

Page 247: ...making sure that the bracket is vertical Use 3 x 7 32 TLR rivets per side as shown above Use pliers to bend the hooked ends of the springs so that the springs cannot easily or accidentally be removed...

Page 248: ...Jabiru J450 Constructors Manual Post Paint Fuselage Interior Controls Fit rudder pedals Tuesday April 6 2010 248 of 343 This completes the Post Paint Fuselage Interior Controls Fit rudder pedals task...

Page 249: ...he shaft before the shaft exits the cabin through the right side flap shaft mount Ensure that the flap drive arm will be 180 away from the outer flap drive arms as shown above in red Refit the inner f...

Page 250: ...ut to safety and then swing the motor assembly forwards and up until the mounting bracket sits against the whalebone as shown above The alignment requires that the motor assembly be horizontal and the...

Page 251: ...he 3 spacers and the 2 retaining nuts circled in green above Position the flap indicator on the right hand windscreen pillar so that the cable follows the line of the door opening and remains clear of...

Page 252: ...fit the instrument panel housing to the aircraft This task will require 2 people Materials required Card 4 Panel mount throttle Prepare the panel housing Instrument panel housings come in 2 sizes Stan...

Page 253: ...ewall fitting check that all the rudder pedal bolts are tightened correctly and generally clean the area out Fit the panel This will take 2 people one to hold the panel and one to position the panel F...

Page 254: ...e forwards and check that the pilot hole is precisely in front of the output lever and correct if necessary You can now work from the front of the firewall and expand the pilot hole until the throttle...

Page 255: ...cable to length The Choke and the optional Cabin Heat cables will then need to have allowance made for the threaded end section which is then crimped onto the cut end use the crimping tool shown at ri...

Page 256: ...ge is just touching the front stop on the carburettor Tighten all 4 lock nuts firmly for the moment fine adjustments will be made later Put 1 lock nut on the threaded end of the choke cable and fit it...

Page 257: ...y in the air valve drive arm is fully forward as shown above Tighten the clamp bolts firmly Cabin heat Put 1 lock nut on the threaded end of the Cabin Heat cable and fit it up through the hole in the...

Page 258: ...onnector should have been clearly marked A B C D or E join each connector pair by pushing them together firmly until the safety clip clicks into place Connect the VHF antenna cable and transponder cab...

Page 259: ...bric and fix into place with contact adhesive The join line should be at the top rear of the shaft Headset brackets Position the headset brackets on the top longitudinal rib and fix in place with 2 TL...

Page 260: ...ound curtain Attach the sound curtain to the rear bulkhead with about 8 evenly spaced Velcro strips Rear seat cover Fit the rear seat cover to the seat base and press the Velcro retaining strips into...

Page 261: ...hat this cover is fitted after the wings have been fitted and the aileron cables have been connected and adjusted It is included in this Upholstery 2 task for convenience Slip the cover over the rear...

Page 262: ...tainer screw with TorqueSeal Connect the rudder cable Withdraw the rudder cable from the slot at the base of the vertical fin and pull it out until the locating groove in the outer cable is level with...

Page 263: ...ffset centre mark as shown in the photos above When this has been done tighten up both of the lock nuts firmly and mark each one with TorqueSeal The rudder is now adjusted Fit the elevator Hold the el...

Page 264: ...deflection templates to check the up and down travel of the elevator Hold the control stick all the way forward have someone help you and check the amount of down deflection and adjust the cable lengt...

Page 265: ...orn with an AN4 14A bolt Fit the rod end of the trim spring unit to the bottom hole in the elevator drive arm extension with an AN3 07A bolt Push the trim lever on the console fully forward hold the t...

Page 266: ...biru J450 Constructors Manual Post Paint Fuselage Fit rudder elevator and elevator trim Tuesday April 6 2010 266 of 343 This completes the Post Paint Fuselage Fit rudder elevator and elevator trim tas...

Page 267: ...l should seal against the black seal Refit the doors Fit the hinges to the door pivot arms using the screws and nuts that were used in the Pre Paint Fuselage Pre fit doors task and tighten the nuts to...

Page 268: ...so that the door can be opened to no more than 90 to the fuselage and the webbing can be wrapped around the inside the front of the door jamb Cut the webbing to length and secure to the back of the do...

Page 269: ...ary to lengthen the slot slightly if the key cannot be removed in the locked position Clean the windows Now you can clean the windows start with a small amount of methylated spirits on a clean cloth a...

Page 270: ...h up until it touches the muffler and tighten the Allen head cap screws Fit the muffler Remove the red sealing caps from the ends of the exhaust pipes and fit the pipes into the inlet holes in the fro...

Page 271: ...ecure with a hose clamp then cut a short length of scat hose to fit between that fitting and the air box outlet and fit it into place The scat hose should be routed in a smooth curve between the 2 fit...

Page 272: ...e inlet Cut the tube to length so that it will not rub on the inside of the lower cowling and fit to the oil bottle with a hose clamp Cut a short length of oil tube as shown at right so that it can be...

Page 273: ...t in the front left of the lower cowling to the bottom of the heat exchanger unit Fit the lower engine cowling into place Route the hose along the cowling and secure with zip ties through flocked on h...

Page 274: ...oth sides of each spinner mounting plate flat in the flange propeller mounting area Turn the engine so that one set of flywheel magnets are at the top circled above left This will ensure that the prop...

Page 275: ...peller and check that each tip is just touching the pointer If there is any variation then the technique to be used is as follows Coarse adjustment if the difference between blades is greater than 1 t...

Page 276: ...n each hole to keep the spinner and the mounting plate in alignment Work your way around all 6 holes in this manner Repeat the process for the 6 holes in the front mounting plate The spinner should re...

Page 277: ...g leads Each cylinder pair can only be fitted to the correct cylinder Push each spark plug cap until it clicks fully home onto the spark plug end Refit the ram air cooling ducts fit and tighten the ta...

Page 278: ...f each spat Nose wheel spat Support the front of the aircraft so that the nose wheel is off the ground and remove the front axle and wheel Fit the front of the spat over the yoke and refit the front w...

Page 279: ...aileron cable inspection opening Loosen the drawstring and check that it can be moved freely then pull a short length out of the wing root circled above and tie it firmly through the rod end Wrap clot...

Page 280: ...rib then the cable and then the saddle bracket with the aligning indentation fitting into the slot on the outer cable and the assembly is held in place with Nyloc nuts Check that the cable is correct...

Page 281: ...1195mm from the wing root of the left hand wing and mark the location Use cloth tape to protect the paint on the leading edge of the wing during this step Using the drawing on the next page locate the...

Page 282: ...Jabiru J450 Constructors Manual Post Paint Wings Fit stall warning Tuesday April 6 2010 282 of 343 This completes the Post Paint Wings Fit stall warning task...

Page 283: ...place and slide the hinge pins though each hinge starting from the side of the hinge where the pin retaining slot was filed in the Pre Paint Wings Fit ailerons task Fit the pin retainers and hold them...

Page 284: ...e disassembled by pulling the black nylon float drive out of the aluminium gauge body and the magnet can be twisted slightly by hand See the photos below for detail of the gauge unit The gauge can the...

Page 285: ...when the lines are bent to the rear while the breather line faces rearwards already Fit each fuel line to the tank fitting and secure with a hose clamp Slide a 100mm length of spring over each fuel l...

Page 286: ...p of the cap Use a file to cut 4 notches each 1mm deep into the top of the vent tube Remove all burrs Fit the notched end of the vent tube to the vent cap the vent tube should be a snug fit into the v...

Page 287: ...t and an AN960 516 washer MS20365 528 nut Rest the outboard end of the strut against a saw stool as shown at right Lay the AN4 14A wing attach bolts and some AN960 416 washers on top of the fuselage w...

Page 288: ...he wing attach lugs Fit the strut When both wing attach bolts are in place lift the strut up to the underside of the wing and fit the strut to the wing with an AN175 15A bolt inserted from the front a...

Page 289: ...hand bracket Fit the groove in the outer cable into the shaped hole and push the cable forward so that the cable seats into the bracket then fit the retaining wedge pin in behind the cable push the we...

Page 290: ...ump the control stick slightly while testing cable lengths and it may be necessary to repeat the process several times until both ailerons are set to neutral and the cable lengths are both correct Ens...

Page 291: ...ength to the stop bolts Repeat the process for the other aileron and tighten the stop bolt locknuts Final check Recheck each step Check that the outer cables are firmly fixed into the brackets by the...

Page 292: ...d the earth wire though the sheath and then through the rear bulkhead conduit Lock wire the sheath in place over the front and rear conduits as shown at right The fuel lines will be hanging down behin...

Page 293: ...ehind the rear bulkhead Crimp a suitable terminal to the bottom of each wire and fit to the common earth connection the same earth connection that connects the earth from the fuel pump and the quick d...

Page 294: ...t washers then the rod end and an AN960 515 1 4 flat washer and a Nyloc nut as shown in the photo at right Tighten the nut to safety The flap push rods should now be centred in the slot in the leading...

Page 295: ...th the hole in the flap drive arm then fit the rod end into the clevis in the flap drive arm as shown below right with an AN3 10A bolt with a 3 16 washer under the head of the bolt and another 3 16 fl...

Page 296: ...ring and screw in place in the same manner Fit the rear top fairing as shown Repeat the process for the other wing Refer to the photos at right for details of placement and screw spacing Wing tank ear...

Page 297: ...trap connector and tuck the pitot line up into the main gear recess Fit the right hand section first tuck the blue water trap connector into the fairing and then fit the fairing into place and hold it...

Page 298: ...eted this checklist runs to 15 pages and to complete it correctly will take you several days And finally the Test Flight which will require a disciplined approach and which should be conducted by a su...

Page 299: ...l dust and dirt with a damp cloth Check that the engine oil is full to the bottom of the hatched marking on the dipstick Turn the fuel tap on the console to the OFF position lever facing up Fill the h...

Page 300: ...of the front axle the red line above to the Datum line these are distances A and B add them both together and divide by 2 to get the average distance this will compensate if the front wheel is not set...

Page 301: ...distances forward of the Datum are considered negative in the calculation that we are about to do in this step Calculate the Moment of each wheel starting with the nose wheel multiply the Weight by th...

Page 302: ...an intended loading could exceed for example the forward limit then you would need to consider adding some ballast to the rear of the aircraft If any rear ballast is required the preferred method is...

Page 303: ...nder the front of the fuselage to lift the nose wheel off the ground and then adjust the rudder cable length so that the rudder sits on the centre mark with the rudder pedals centred and all level Use...

Page 304: ...that all rod end jam nuts are tight and mark each with TorqueSeal Check the aileron deflections Place the aileron deflection template on top of the wing and set the aileron to the full UP travel defl...

Page 305: ...til the down deflection is correct Now have your helper hold full back stick and check the amount of up deflection it should be very close to correct if the down deflection is OK however you may need...

Page 306: ...y level along the door sills Pack under the wheels if and as required to level the aircraft If the surface is exactly level you can measure the distance from each wingtip to the ground as a final chec...

Page 307: ...o the empty tank and complete replacement of the leaking fuel line Note that fracturing of the fuel lines after clamping is a rare occurrence that is only likely to happen if the fuel lines are very o...

Page 308: ...ralia either the Recreational Aircraft Association RAA for recreational registration or the Civil Aviation Safety Authority CASA for general aviation registration controls the allocation of aviation r...

Page 309: ...Check tip tracking is accurate to 2mm adjust if required 3 TorqueSeal the propeller nuts 4 Visually check propeller for serviceability Spinner 1 Spinner screws secure 2 Check that the spinner and spi...

Page 310: ...ment of rubber front lip with the top cowl 6 Air ducts not touching the underside of the top cowl or oil door hinge 7 Cooling tubes directed onto coils Engine Oil 1 Oil level correct capacity 2200 2 3...

Page 311: ...correct with outer 5 Operational Cabin Heat Cable 1 Lock nuts secure both ends 2 Butterfly sealing in ON and OFF positions 3 Over centre spring fitted properly and working 4 SCAT hoses routing nothin...

Page 312: ...re 12 Centring springs do not become coil bound full deflection Electrical 1 Battery tie down secure 2 Battery terminals secure 3 Battery earth secure on firewall 4 Starter solenoid locknuts and wires...

Page 313: ...cap is free d check fuel breather tube is secure to body fuel filler e fuel breather check has been conducted Note you must be able to hear air in all outlets independently by i Removing filler cap in...

Page 314: ...Anchor secure and correct position in clamp 2 Rod end secure in pedal with washer outside 3 Safety hole is within limits on rod ends 4 Jam nuts on rod ends secured 5 Rod end free play at full deflecti...

Page 315: ...er secure 5 Input lever x 2 secure 6 Throttle lock hole in pilot s input lever 7 Bearing blocks x 2 secure 8 Throttle stops correct and secure Main control shaft 1 Control stick pivot secure 2 Yoke se...

Page 316: ...end secure 5 Safety hole is within limits on rod ends 6 Jam nuts on rod ends secured 7 Aileron stoppers secure x 2 cannot over centre aileron bellcrank Seat belts LEFT RIGHT 1 Check bolts are through...

Page 317: ...e altimeter should start to show an increase in altitude The vertical speed indicator should start to show a positive rate of climb and the airspeed indicator may show a small positive indication When...

Page 318: ...ansponder not calibrated if applicable 5 Switches labelled label above switch OFF below switch 6 Aircraft built to LSA standards decal beside main placard 7 Warning placard above windscreen Weight ent...

Page 319: ...s secure with pivot bolts in safety 2 Pushrod rod ends secure and not binding in any position 3 Safety hole in rod ends is within limits 4 Jam nuts on rod ends secure 5 Pushrods not fouling on cover s...

Page 320: ...2 ASI operation see below 3 Cover present 4 Pressure Test with no leaks see below Slip 1 metre of surgical tubing over the pitot tube Have one person watch the airspeed indicator while the other pers...

Page 321: ...secure 2 Stub axle secure 3 Hubs secure 4 Stub axle extension is secure 5 Calliper secure 6 Discs secure 7 Ease of rotation 8 Tyre pressure 45 psi 9 Tyre Pressure decal in place 10 Brake line not rubb...

Page 322: ...re and correct position in clamp 6 Drive plate secure 7 Rod end free play at full deflections 8 End plug not touching end cap full deflection down 9 Elevator min 2mm clear of stabiliser channel 10 Ele...

Page 323: ...centre mark b Right _________mm from the offset centre mark 3 2mm clearance to the stops on fuselage at full deflection 4 Hinge pin and pin retainers secure 5 Rod end secure 6 Safety in rod end within...

Page 324: ...ropriate forms to record the results of each stage The correct sequence for rectifying any out of rig conditions will be explained along the way Reference documentation The Australian Civil Aviation S...

Page 325: ...adly and an accident happens and know the local emergency telephone numbers A support crew of 2 suitably experienced people will be required to support the flight testing sequences and assist the test...

Page 326: ...ude 200ft after takeoff Recover from stalls in level flight and in banked turns Recover from a spin Recover from unusual attitudes including a spiral dive Carry out a flapless landing Carry out a glid...

Page 327: ...slowly and steadily to 50 60 C and the Cylinder Head Temperature CHT should rise to 85 105 C The Exhaust Gas Temperature EGT gauge if fitted should read between 425 485 C Once the engine has warmed EO...

Page 328: ...back to idle Engine shutdown Allow the engine to return to idle the idle should be smooth at 900 rpm Turn both magneto switches OFF and the engine should stop smoothly Turn the Master switch OFF Remo...

Page 329: ...East West adjustments Position the aircraft at a known North heading using a compass rose or a reference compass 1 With the aircraft oriented North the engine running and all radios switched on adjus...

Page 330: ...itres per side at this point if not then drain or add fuel as required Engine Start and Run up Start the engine normally taxi to the run up area and perform an engine run up Check temperatures and pre...

Page 331: ...tests that must be made 1 If the aircraft flies straight with the ball in the centre but with the rudder pedals displaced then the pushrods that connect the rudder pedals to the steering yoke need ad...

Page 332: ...nted out and used to record information while in flight Print one form per test flight and retain each as a permanent record Does the aircraft fly straight and level with the ball centred Are the rudd...

Page 333: ...task The wing that drops is stalling slightly ahead of the other wing and it will need to have its angle of incidence reduced by a small amount You will need to fit the eccentric bushes to the wing t...

Page 334: ...result in failure of the wing attach lugs Refit the wing root fairings Retest the aircraft and if required make any small roll corrections by adjusting each flap individually 4 Adjusting the Flaps Us...

Page 335: ...e performed in the configurations listed on page 1 of the Flight Testing form Sequence 3 Each stall is started from 60 KIAS and the aircraft is decelerated at a constant rate of 1 knot per second unti...

Page 336: ...er if fitted the GPS if fitted all flight and engine instrumentation and any other fitted equipment such as strobe and Nav lighting or UHF comm Ground handling during and after landing When landing ch...

Page 337: ...record Abbreviations Here is a listing of common abbreviations that are used throughout these forms AGL Above Ground Level AH Artificial Horizon ALT Altimeter CHT Cylinder Head Temperature EFIS Electr...

Page 338: ...CHT EGT VOLT Engine instrumentation EFIS AH Make Serial number GPS EMS Cross out one Make Serial number Owner Phone Kit Address Mobile Fax Aircraft Identification J Model Engine Serial number ASI Regi...

Page 339: ...start OAT WIND All in the green range All in the green range All in the green range Engine parameters Engine parameters Engine parameters Sequence 1 Ground run EOP EOT CHT EGT Run up 2000 rpm Left MA...

Page 340: ...T EGT Pilot Engine RPM 2900 3050 rpm Date Pilot only no PAX 20 litres of fuel per side Loading Engine hours start P ALT 1013 2 hPa 1 2 3 4 Sequence 2 Rigging Does the aircraft fly straight and level w...

Page 341: ...stant rate of 1 knot per second until the aircraft is fully stalled and the IAS at the point of stall is recorded below NO Flap Straight Ahead 40 50 30 Bank to LEFT 30 Bank to RIGHT HALF Flap Straight...

Page 342: ...page 2 of 3 Control rigging OAT Start P ALT 1013 2 hPa Trim test AFT 50 65 KIAS FWD 90 140 KIAS Cruise power clean AFT 50 65 KIAS FWD 90 140 KIAS AFT 50 65 KIAS FWD 90 140 KIAS Cruise power clean AFT...

Page 343: ...g characteristics satisfactory Stability satisfactory Control rigging satisfactory Notes Instrumentation operation throughout satisfactory Equipment Ground handling Post flight review VHF Comm 1 opera...

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