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Jabiru J450 Constructors Manual
Post-Paint>Fuselage>Interior>Fit console controls
Tuesday, April 6, 2010
239 of 343
Brake system
Cut a short length of sheet aluminium the width of the brake lever slot and about 40mm in
length. Bend the aluminium strip in half, apply a smear of Araldite inside the bend and crimp
it to the front of the brake lever slot – this is the bearing surface for the brake lever cam.
The brake lever should still be assembled from the
Pre-Paint>Fuselage>Interior>Console>
Pre-Fit Handbrake
task: fit the brake lever mount bracket to the front inside of the console
and secure with 2 x ¼” by ½” UNC Allen head cap bolts and flat washers. Fit the lever into
the bracket with an AN4-11 bolt and castle nut, with a thin flat washer on each side of the
lever, tighten the castle nut firmly and lock it in place with a split pin.
Hint
: a magnet will help you place the flat washers.
Refer to the drawing on the next page for detail.
Fit the master cylinder to the front of the console
with 2 x ¼” by ¾” UNC Allen head cap bolts and
fit the clevis to the bottom of the lever with an
AN5-11 bolt and castle nut, tighten the castle nut
firmly and lock in place with a split pin.
Drill a ½” hole near the top left of the front face of
the console and feed the brake hose into the console
then down and out of the hole behind the top of the
main undercarriage legs. Fit a rubber grommet 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 fuselage and trim off.
Fit a brass “T” connection to the hose, then run a
length of brake hose down each main undercarriage
leg to a position level with the top of the wheel rim,
trim to length and fit a brass “T” connection to the
hose. Zip tie the brake hose half way down the leg.
Run a short length of brake hose from the “T”
connector to each brake assembly as shown in the
photo at right. The short length of PVC tubing over
the brake hose is to protect against chafing from the
wheel spat. Zip tie the brake hose to the leg.
Check that all of the brake hose fittings are tight.
Fill the reservoir on the master cylinder with the recommended brake fluid, loosen the bleed
valves on the wheel cylinder units (circled in yellow above) and slowly pump clean brake
fluid through the brake lines.
Pay careful attention to the brake fluid level in the master cylinder reservoir during this
procedure and keep the fluid level topped up, otherwise you run the risk of drawing air back
into the lines, which would mean starting all over again.
When brake fluid reaches the wheel cylinders close off each bleed valve and then pressure
bleed each wheel cylinder in turn until no more air remains in the brake lines and the brake
lever feels firm and not at all spongy when pressure is applied.
When you are satisfied with the brake pressure, top up the fluid and replace the reservoir cap.