Jabiru J450 Constructors Manual
Post-Paint>Fuselage>Interior>Fit instrument panel housing
Tuesday, April 6, 2010
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Fit the rubber grommets and the machined aluminium washers to the rear lip of the panel –
use a machined washer to mark the centre of each hole then drill each hole to 22mm and fit a
grommet into each hole. Drill each machined washer out to 7/32” and fit into each grommet.
Cut away the fabric under the
Carb Heat,
Choke and Cabin Heat
nameplate and flock
the nameplate into place with 5-Minute
Araldite and flock – hold it in place with
spring clamps as shown at right while the
flock cures.
Make sure that the nameplate is positioned
well down towards, and level with, the
bottom of the panel as shown at right.
Drill out the 3 cable holes to suit the cable outer fittings.
This is a good time to fit the wet compass to the top of the panel: much easier now than when
the panel has been fitted. Measure the exact centre of the panel and position the compass so
that it is square to the front face of the panel and mount with screws and Nyloc nuts.
Tidy under the panel
Once the panel housing is fitted access under the panel will be restricted so take some time
now to tidy up under the panel – lock-wire the fuel line sheath to the firewall 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. Fit a 3/16” drill
bit into your drill and have it handy inside the aircraft. The panel is held in place with AN3-
12A bolts and steel lock nuts, with the lock nuts located inside the engine compartment.
Hold the panel in place, which is centred in the fuselage and as high up the firewall as it can
go. Move any wiring away from the area of the mounting holes and have the second person
measure the distance in from the door jambs to the side of the panel and then move the panel
until it is exactly in the centre of the aircraft.
When it is correctly located, drill the top
centre hole through from the inside (shown at
right) and fit a washer and steel lock nut.
Check the aircraft for level and then check
the panel for level and drill the top left bolt,
then the top right and then each of the
remaining bolts.
Have the second person watch as each hole is
drilled and make sure that the drill bit does
not come into contact anything in the engine
compartment – wiring, battery, etc.
The drill bit will be visible as a point on the firewall before it breaks through and the person
watching must be vigilant to prevent any possible damage. It may only be necessary to move
a wire or something before drilling further.
Tighten all of the steel lock nuts to safety.