
Jabiru J450 Constructors Manual
Pre-Paint>Fuselage>Pre-fit doors
Tuesday, April 6, 2010
148 of 343
Fit the top latch
There is a curved section at the top
front of each door for the top latch.
Measure in 25mm from inside the
door skin and drill a pilot hole and
then a ¾” hole down through the
door frame. Refer to photo at right:
Close the door and fit the latch
barrel up through the hole until it is
about 2 or 3mm clear of the door
jamb and mark that position, then
open the door and flock the barrel
into position with 5-minute Araldite and flock.
Make sure that the open end of the barrel faces upwards as shown in the photo above.
Smooth the flock to a uniform radius around the top and bottom of the barrel and leave to
cure.
With the door closed, hold the top front of the door flush with the fuselage and drill a 3/8”
hole up through the latch-pin hole in the barrel and right through the door jamb and opening.
This hole will pass through part of the jamb.
Open the door and fit the 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 – mark and drill the screw holes through both
surfaces then drill the top holes to ½” for access to the screws.
Final fit the door
Shut the door using both latches and check right around the door to see if there are any areas
that need final adjustment, for example if the door does not fit easily inside the opening, and
sand to fit as required.
Fit the fairing to the top hinge
Test fit the fairing to the upper top and cut to suit the hinge
arm and the fuselage joggle then fix in place with 5-minute
Araldite and flock.
Test that the door can open and close freely and adjust the
clearance of the hinge arm slot if required.
Fit the fairing to the bottom hinge
Centre the fairing on the bottom hinge and tape it in place
then test that the door can open and close freely and make
adjustments to the hinge arm slot as required then fix into
place with 3 x 6G self-tapping screws.
Retest the hinge arm for clearance and adjust if required.
Top handle -
front screw
access hole
50mm
25mm