Aircraft Technical Manual
Jabiru Aircraft
Pty Ltd
J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants
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ISSUE
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Dated: 29th October 2014
Issued By: AS
Page: 74 of 298
Acetone to remove any oils. Do not touch boding surface with bare hand after wiping with
Acetone.
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Prepare the fuselage for bonding: lightly sand the bonding faces using 180-grit sandpaper. After
sanding, wipe bonding faces with a rag moistened with Acetone to remove any oils. Do not touch
boding surface with bare hand after wiping with Acetone. Finally, roughen surface again with
180-grit sandpaper & blow off dust using clean, dry air.
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Mix Jabiru Epoxy resin & hardener according to the manufacturer instructions.
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Lightly paint both the fuselage and aluminium lug bonding surfaces with resin.
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Mix cotton fibre flock with the resin to a “gluey” consistency; this mix must be stiff enough to hold
its shape when applied vertically.
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Apply the resin/flock mix to the fuselage and bolt the lugs in place. Ensure 100% coverage of the
lug.
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Ensure the lugs are seating correctly. Fit a bolt through the outboard hole to align the two lugs.
Do not over-tighten: lugs must be parallel.
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Apply a resin/flock bead around the edge of the lugs as shown in Figure 35.
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Wipe off excess flock, clean up and allow to cure.
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When the resin has cured re-fit the upholstery.
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Re-assemble the aircraft and test to ensure the free-play has been removed. Ensure a new bolt
is used on the attachment which has been serviced.
Figure 35
– Bond Details (all J-Series)
If the holes in the stainless steel bushes inserted into the fibreglass wing structure have worn so that
standard or close tolerance bolts have excess movement then they must be replaced as detailed
below:
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Remove the wing from the aircraft or mount it on stands as detailed above.
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If the bush to be replaced is an eccentric type (where the hole for the bolt is not in the centre of
the bush) make a note of the orientation of the original part.
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Use a large soldering iron or similar to heat the bush to around 70°C. This softens the resin
bonding the bush in place and makes removal easier.
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As this bush will not be re-used a large drill bit or rat-tailed file can be used as a screwdriver to
remove the bush from the fibreglass.
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Clean the thread cut into the wing lug fibreglass using a 5/8” UNC or 7/8” UNC tap as
appropriate. Take care to align the tap teeth with the old thread & ensure tap is not cross-
threaded
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Note that there are several different styles and sizes of bush
– when ordering ensure the correct
part is specified.
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Take a bolt at least 1 size smaller than the centre hole in the bush
– i.e. for a ¼” bush use a 3/16”
bolt. Fit the bolt to the bush and affix a washer & nut. Tighten so that the small bolt is clamping
the bush.
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Clean the replacement bush / bolt assembly in an acetone bath. Blow dry using clean air before
installation.
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Mix Jabiru Epoxy resin & hardener according to the manufacturer instructions.
