Jabiru J450 Constructors Manual
Pre-Paint>Fuselage>Prepare the fuselage
Tuesday, April 6, 2010
31 of 343
Cut the fuel header tank opening
Mark and cut an opening in the rear cabin step to access the area beneath, which is where the
fuel header tank, fuel pump and fuel filter will be fitted.
To make the opening, mark a 180mm by 350mm rectangle in the rear cabin step 70mm
forward of the rear bulkhead as shown above, then cut the rectangle out using a jigsaw or
hacksaw and remove it. Sand the edges smooth.
Centre the supplied 400mm x 220mm piece 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 the screw holes to be slightly
larger than the screws.
Drill a 20mm hole in the top of the lower longitudinal
rib directly under the front edge of the opening that
you have just made, then carefully chamfer the top
and bottom edges of the hole – this is where the fuel
line will run from the electric fuel pump forwards to
the fuel tap as shown on the photo on the right, and
there must be
no
roughness whatsoever in the hole
that could later abrade the fuel line.
This completes the
Pre-Paint>Fuselage>Prepare the fuselage
task.
180mm
70mm
350mm