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Nynja Build Manual 1.4d

Contents

Introduction ............................................................................................................. 10

1.1

How to Build Your Aircraft .................................................................................................... 10

1.2 The BMAA Homebuilt Aircraft System ....................................................................................... 12

1.3 General Assembly Notes ........................................................................................................... 14

1.4 Finish .......................................................................................................................................... 18

1.5 Weight ........................................................................................................................................ 20

Forward Fuselage ............................................................................................ 21

2.1

Tube Numbering .................................................................................................................. 21

2.2 Fuselage frame assembly overview ........................................................................................... 23

2.3 Lower Cabin Triangle .................................................................................................................. 25

2.4 Upper Cabin Triangle ................................................................................................................. 30

2.5

Rear Cabin Frame ................................................................................................................ 33

2.6

Rear cabin frame bracing. .................................................................................................... 34

2.7

Engine Supports ................................................................................................................... 37

2.8

Floor ..................................................................................................................................... 46

2.9

Rudder Pedals ..................................................................................................................... 48

2.10

Control Stick Assembly ........................................................................................................ 49

2.11

Finishing the Forward Fuselage ........................................................................................... 52

Rear Fuselage .................................................................................................. 54

3.1

Tail End ................................................................................................................................ 54

3.2 Bracing Frame ............................................................................................................................. 56

3.3

Front End.............................................................................................................................. 57

3.4 Fuselage bracing cables ............................................................................................................. 58

3.5

Tailplane Front Mounting ..................................................................................................... 63

3.6 Fuel Tank Support and Flap Handle ........................................................................................... 64

Not Tightening the Bolts and cables! ................................................................................................ 66

Undercarriage .................................................................................................. 67

4.1

Wheels ................................................................................................................................. 67

4.2

Main Undercarriage .............................................................................................................. 69

4.3 Nose Gear ................................................................................................................................... 73

4.4

Brakes .................................................................................................................................. 77

5. Tail Surfaces ....................................................................................................... 80

5.1

Tensioning the Rear Fuselage ............................................................................................. 80

5.2

Elevator Trim Tab ................................................................................................................. 81

5.3 Tailplane ...................................................................................................................................... 83

5.4

Rudder .................................................................................................................................. 87

5.5

Control Cables ..................................................................................................................... 90

Fitting the Rear Fuselage Fairings ............................................................... 100

6.1

Preparing the rear fuselage fairings ................................................................................... 100

6.2

Fitting the rear fuselage fairings ......................................................................................... 101

Engine Installation Rotax 912UL/912ULS .................................................... 105

Wings .............................................................................................................. 110

8.1

Wing Frame ........................................................................................................................ 110

8.2

Aileron Horn Assembly ....................................................................................................... 119

8.3

Attaching the Wings to the Fuselage ................................................................................. 121

8.4

Aileron Control Cables ....................................................................................................... 122

8.5

Flaps ................................................................................................................................... 126

8.6

Covering the Wings ............................................................................................................ 128

8.7

Inserting the Battens .......................................................................................................... 135

Windscreen Frame and Throttles ................................................................. 138

9.1

Windscreen Frame ............................................................................................................. 138

9.2

Throttles ............................................................................................................................. 143

Содержание Nynja

Страница 1: ...1 Nynja Build Manual 1 4d Nynja Build manual Version 1 4d...

Страница 2: ...2 Nynja Build Manual 1 4d Figure 1 tube numbering scheme...

Страница 3: ...3 Nynja Build Manual 1 4d Figure 2 Basic frame Skyranger...

Страница 4: ...4 Nynja Build Manual 1 4d Figure 3 uncovered Skyranger frame...

Страница 5: ...5 Nynja Build Manual 1 4d Figure 4 Uncovered Nynja frame Figure 5 Nynja fuselage with rear fairings removed...

Страница 6: ...6 Nynja Build Manual 1 4d Figure 6 Nynja fuselage with rear fairings removed rear view Figure 7 simply assemble thus...

Страница 7: ...bles 58 3 5 Tailplane Front Mounting 63 3 6 Fuel Tank Support and Flap Handle 64 Not Tightening the Bolts and cables 66 4 Undercarriage 67 4 1 Wheels 67 4 2 Main Undercarriage 69 4 3 Nose Gear 73 4 4...

Страница 8: ...172 12 7 Fuel tank connections 173 12 8 Fuel filler 175 13 Instrument panel 176 14 Throttle and Choke cables 180 15 Instruments 184 15 1 Pitot Static System 184 16 Electrical System 186 16 1 Soft star...

Страница 9: ...ofile Support Blocks 252 26 Fitting the heater option 254 27 Fitting the storage side pockets 256 28 Preparing for Flight 257 28 1 Airframe 257 28 2 Aerofoil Jury struts 257 28 3 General checks 259 28...

Страница 10: ...is essential It is remarkable how often the instructions are over looked or misread remembering that you are going to fly in your finished aircraft Instructions however are never as good as they coul...

Страница 11: ...ive it some thought before calling Email is preferred and more convenient than the telephone as it makes it simple to communicate answers to other builders and allows time for a better more researched...

Страница 12: ...Get his signature on the form at the time just in case He can be a very useful source of knowledge and advice and should be your mentor during the build Also a second pair of eyes and an experienced...

Страница 13: ...the paperwork and your inspector to allow you to do so However this short delay can be used very productively to familiarise yourself with the instructions and the components and prepare them for use...

Страница 14: ...so don t throw any boxes or packaging away until you have ascertained for certain that you have all the parts we have stories of unloading skips to retrieve parts that have gone with the rubbish We a...

Страница 15: ...less than 6mm Flat file Engineers Rule Tape measure 6mm reamer desirable Wire locking pliers desirable Cleco s or Skin pins for 4mm holes Dremel Multi tool or equivalent small cutting sanding tool Sof...

Страница 16: ...Nuts and washers Standard nuts and washers in the main kit are metric zinc plated steel An acceptable alternative is to use A2 stainless nuts and washers These can be purchased from a fastener suppli...

Страница 17: ...uded at the end of this manual Stainless steel parts A number of tubes have flattened steel end fittings which may require slight tweaks to align them as required This should be done carefully in a vi...

Страница 18: ...something too short If you find a part which you think is wrong in terms of size etc be very sure that this is so before cutting or drilling etc to correct the problem For instance over long bolts may...

Страница 19: ...nd around fittings Glassfibre fairing parts are supplied in a white finish This can be polished with T cut or similar to a high sheen Alternatively they can be painted but avoid using dark colours on...

Страница 20: ...rcraft Below is an approximate guide to the weight of specific options Wheel spat kit 4 0Kg Nynja wingtip fairings 2 0Kg Skyranger wing tip fairings alternative to above 1 5Kg Carb heat 912 engines 0...

Страница 21: ...better wing nuts can be used in the initial construction to be replaced with Nylocs when the time comes to tighten the nuts up However note that it is often beneficial to have the nuts loose anyway t...

Страница 22: ...22 Nynja Build Manual 1 4d Figure 13 forward fuselage from front quarter Figure 14 Cabin upper rear corner...

Страница 23: ...Manual 1 4d 2 2 Fuselage frame assembly overview Lower triangle assembly Attaching TU14 Upper triangle assembly Attaching upper triangle to TU14 Attaching rear cabin uprights TU6 Attaching Upper trian...

Страница 24: ...Manual 1 4d Cabin diagonals TU27 attached Twin TU19 tubes in position Front seat support TU15 and braces Forward engine mount assembly fitted Assembling tailcone Tailcone fitted to cabin Figures 15 as...

Страница 25: ...ting the sides of the lower cabin triangle to the main undercarriage cross beam a Assemble the aluminium linking plates 9 onto the pair of lower cabin triangle tubes tu12 including the seat support br...

Страница 26: ...main undercarriage cross beam tu9 using the fourth set of holes inwards from the ends of tu9 The front ends of the lower cabin triangle tubes tu12 should have the cut outs on the inside visible in Fig...

Страница 27: ...U brackets are slightly different from those used elsewhere in the kit with the holes on the side parts further from the end 16mm from the end to the hole centre The front vertical tu14 has a row of...

Страница 28: ...28 Nynja Build Manual 1 4d Figure 21 forward end of lower cabin triangle Note Stud shown may also be supplied as a bolt and should be fitted head up...

Страница 29: ...of a spacer sleeve in the tubes The studs should be long end downwards to mount the bottom of the firewall and the front of the fuselage covering later Discard the curved metal washer if fitted as th...

Страница 30: ...trailing edges of the wing These linking plates are drilled at one end with an 8mm hole and at the other with two 6mm holes The row of small holes should point forwards whilst the bolts point rearward...

Страница 31: ...e that the tubes themselves are not the same The cut outs at the front of the upper cabin triangle tubes tu10 should face outwards Figure 24 rear of upper cabin triangle tube tu10 2 4 2 Assembling the...

Страница 32: ...ld Manual 1 4d 8 SKR 94 SB 24 WASHER 8 30 CASTLENUT 8 31 SAFETY PIN 8 SKR 94 SB 24 WASHER 8 30 CASTLENUT 8 31 SAFETY PIN Figure 25 forward end of upper cabin triangle Figure 26 forward end of upper ca...

Страница 33: ...ards using an aluminium saddle washer under each against the rear cabin uprights SKR6 The rear cabin uprights SKR6 have inner sleeves at their upper end and are handed in that the holes that connect t...

Страница 34: ...ily secure with an 8mm diameter bolt c Secure the bolts through the rear cabin uprights SKR6 and the upper cabin triangle tubes SKR10 including the proper spacers etc This is easier now the upper cabi...

Страница 35: ...e spacer tube is also shown on Figure 30 as well as the small bracket piece The Nynja should be supplied with round peg support as per picture below Figure 29 seat support peg d Stiffen the cabin back...

Страница 36: ...nce Attach the lower ends to the rear of the main undercarriage cross beam SKR9 The final attachment be quite tight to get on and an additional person or a ratchet strap may be necessary to provide te...

Страница 37: ...k spreader pieces with fuel proof paint Fuel proof paint is available from model aircraft shops an enjoyable but potentially expensive visit c Assemble the wooden fuel tank load spreading pieces on th...

Страница 38: ...38 Nynja Build Manual 1 4d Figure34 Rotax 912 mounting bracket note position of TU310 is reversed for Nynja as shown correctly below Fig 35 Nynja engine mount assembly Remove this washer...

Страница 39: ...aged with firewall Fig37 liaison of TU19 s TU14 and SKR8 a Locate the two central cabin tubes SKR19 onto the front vertical SKR14 including the steel engine mounting bracket 98 between them Loosely bo...

Страница 40: ...ed c Attach the two central cabin tubes SKR19 onto the main undercarriage cross beam SKR9 Remove the pulley set from the assembly and put to one side for now This makes fitting the TU19 s to the under...

Страница 41: ...tight without ovaling the tubes This should result in thread protruding from the Nylocs If no thread is showing the washers shown under the nuts may be omitted washers under bolt heads should have bee...

Страница 42: ...engine mount plates 298BK SKR310 upper triangulation tubes SKR24 s and lower triangulation tubes SKR23 Note arrangement of plastic washers only fit them where shown Figure 41 upper engine mount trian...

Страница 43: ...t holding SKR310 slack enough to rotate it out of the way when fitting the engine Figure 43 lower triangulation tubes TU23 and lower engine mounts g Loosely fix the two stainless steel lower triangula...

Страница 44: ...those on the mount itself before tightening the bolts holding the top and bottom ends of the triangulation tubes Leave the bolt holding SKR310 loose enough to turn it i Check engine mount plates spac...

Страница 45: ...e SKR310 fixed into position with a 6mm bolt The SKR310 upper edge should be approximately 0 5mm from the upper edge of the engine mounting plate Check that the distance between the plates has not cha...

Страница 46: ...upper side It may be surfaced with vinyl or carpet or left as is Cut a hole in the floor for the battery box The hole is located on the centreline approximately 1cm back from the rudder pedal mountin...

Страница 47: ...pair of saddle washers per bolt between the two tubes Note the tapered ends of the tube taper towards the front Figure 50 TU15 assembly d The forward ends of the steel under seat diagonal tubes SKR42...

Страница 48: ...attached by the bolts which hold the central bracing pieces which are fitted later g Install the battery box and secure it with four bolts with penny washers h Fit the webbing strap passing right arou...

Страница 49: ...or is fitted put pieces of prop tape on the lower cabin triangle tubes SKR12 beneath the rudder pedals to protect the tubes from abrasion from the pedals when under load f Cut off any protruding ends...

Страница 50: ...ing Castle nut and split pin b When all is in final position this should be done up tight enough to remove excess play but without discernible friction c Fit the stick to the stick pivot fork with thi...

Страница 51: ...d be abraded lightly until a smooth action is achieved h The torque tube can now be fitted onto the front pivot attached to the aileron horn and the rear pivot can be bolted to the central cabin tubes...

Страница 52: ...er tighten the bolts The tubes should not be visibly distorted Remember the bolts are not relying on their tightness to stay done up they only need to be tight enough to avoid the parts rattling again...

Страница 53: ...53 Nynja Build Manual 1 4d Figure 55 central bracing pieces Note the bolts should be the other way around as shown in photo fig 56 Figure 56 central bracing pieces...

Страница 54: ...t washer on the lower bolt Some difficulty may be encountered with access to the various nuts in this area A useful trick to hold a nut to the end of a spanner is a piece of sticky tape placed over th...

Страница 55: ...g the upper pair of tubes on it whilst they are attached to the bracing frame and the rudder post is attached to the lower pair of tubes Figure 58 rear end of upper rear fuselage tubes Figure 59 rear...

Страница 56: ...les approximately mid way down the tubes b Check the orientation of this frame against the drawing below as examples have been delivered assembled the wrong way around Figure 60 rear fuselage bracing...

Страница 57: ...ear fuselage tubes Note upper tubes have brackets orientated at 90 degrees from that shown and cables are arranged differently on Nynja See Figure s 62 c Mount the front ends of the upper tubes onto t...

Страница 58: ...ht Cable B 2mm 1578 Both straight Cable C 3 6mm 1262 Both straight Cable D 3 6mm 1647 Forward bent rear straight Cable E 3 6mm 1472 Both bent Cable F 3 6mm 1645 Both bent Lengths taken from tang hole...

Страница 59: ...ld Manual 1 4d C cable tang under A cable tang E cable tang over D cable tang C cable tang under F cable tang Figure 64 fuselage cable ends detail Note both pairs of rear cables cross at rearmost atta...

Страница 60: ...60 Nynja Build Manual 1 4d Figures 65 cable arrangement further overview...

Страница 61: ...gure 67 cable arrangement lower port side of central frame Forwards Forwards A cable E cable D cable F cable C cable B cable 1mm plastic washers above and below tang 3mm plastic washer between tangs a...

Страница 62: ...cables if necessary The aim is to eliminate all slack at this stage as much as possible and it still be possible to attach them Final tensioning of these E and F cables is achieved by tightening the r...

Страница 63: ...r mounts There should be a thin plastic washer or saddle washer at the rear and a small saddle washer at the front If the bolt head at the front of the tailplane contacts the front mount an additional...

Страница 64: ...igure 69 fuel tank support flap handle mount a Fit the fuel tank support SKR20 to the lower rear fuselage tubes SKR4 with the U bracket located towards the port side of the fuselage and facing upwards...

Страница 65: ...ap handle pivot Do not space the detent lever away from the handle use only one thin plastic washer or a single saddle washer between them It is permissible to bend the lever slightly into a Z shape t...

Страница 66: ...Manual 1 4d Figure 73 Flap handle Not Tightening the Bolts and cables Do not finally tighten the bolts or cables around the rear fuselage at this stage this will be detailed later after the landing ge...

Страница 67: ...gh the hole in the wheel half Figure 75 tyre and inner tube c Place the other wheel halve onto the first wheel half so that the tyre and inner tube are positioned between the two wheel halves d Take a...

Страница 68: ...their washers both wheel halves and into the threaded holes on the hub f Tighten the bolts and inflate the tyre to 26psi If the tyre does not slip easily into position a little squirt of neat washing...

Страница 69: ...e This will result in a handed pair of callipers b If not already done drill an 8mm diameter hole in each undercarriage leg 18mm above the upper rear stub axle mounting holes as shown in Figure 78 Mar...

Страница 70: ...bolts supplied in the spat kit Excess bolt threads can be trimmed off The bracket may need relieving with a file if there is interference with the stub axle weld b Fit the brake mounting piece to the...

Страница 71: ...n gear inner spat mount c Fit the undercarriage legs to the main undercarriage cross beam SKR9 Make sure that the legs are on the correct sides to place the brake callipers towards the rear Figure 81...

Страница 72: ...hread bound It may be necessary to add another washer under the nut to achieve this balance Bolts should be fitted head down as shown Note the bolt that attached the SKR144 is longer than the rear bol...

Страница 73: ...he lower guide c Put a large steel washer then 7 rubber washers then another large steel washer onto the nose leg before sliding it up through the upper mount Washers and axle parts may be packed sepa...

Страница 74: ...nose leg d Above the upper mount there should be another two large steel washers with one two or three rubber washers between them as required secured by a bolt though the nose leg If a nice fit witho...

Страница 75: ...and below the forks Check that the tyre does not rub against the side of the forks The fit can be adjusted by filing the holes in the spacer tubes so that the wheel can be moved sideways Once in a pe...

Страница 76: ...plied in the bag with the grommets under each bolt head Do not tighten the bolts so much that you completely squash the rubber grommets d Temporarily fit the pushrods to the rudder pedals using the mi...

Страница 77: ...e then assemble with a little grease b Slide the callipers over the brake discs Figure 89 The callipers must be handed to sit behind the undercarriage legs by swapping the bolt which holds the callipe...

Страница 78: ...the brake lever fouls the instrument panel when this is fitted it will be necessary to put a small stop in front of the lever to limit its forward movement This may be a small bolt chopped off and scr...

Страница 79: ...irm brakes it will be necessary to push enough fluid upwards in one go to fill the calliper and the brake lines and flood fluid out of the master cylinder use plenty of rags and a catch tray to preven...

Страница 80: ...f the D cable to make the twists replace and re tension turnbuckles d Final tension of C cables should be around 5Kg for a 10mm displacement when cable is pulled at right angles downwards and mid cabl...

Страница 81: ...to prevent any chance of the hinge pin falling out as it wears over time e If not already done rivet the elevator trim tab hinge to the trim tab f Rivet the trim tab to the lower side of the trailing...

Страница 82: ...the inboard end of the tab with the flanges for bolting to the tab towards the outboard end They should be positioned in the vicinity of the inboard end of the straight section of the tab trailing edg...

Страница 83: ...bilisers to the forward and rear mounts on the rear fuselage c Fig 97 The nut securing the front of the tailplane halves may be tight against the structure of the tailplane If so hold it flat against...

Страница 84: ...t the inner eyebolts on the horizontal stabilizer have a saddle washer and one 3mm plastic spacer behind them to match the spacing of the outer eyebolts where the bracing cable tangs attach There are...

Страница 85: ...e elevator joiner are perpendicular 90 degrees to the elevator halves so that the joiner is properly centred then using the joiner as a jig drill through the tube in the following sequence g Drill the...

Страница 86: ...86 Nynja Build Manual 1 4d Figure 100 Nynja elevator joiner with integral control horn Ensure joiner sits so holes are drilled perpendicular to elevator centerline 90deg...

Страница 87: ...the rear 4mm hole is just in front of the rear tube and just below the horizontal bracing tube This will be on the trailing edge of the rudder c Burn a hole both sides of the fabric to accept the 4mm...

Страница 88: ...erial from the central part of the horn where it presses against the rudder leading edge tube to allow it to be positioned slightly further forwards i Rivet the horn in position with 4mm diameter stee...

Страница 89: ...ching the stainless steel elevator joiner tube when it is deflected from side to side 25 or so and the elevators are moved up and down 25 or so If it is touching you will need to put an additional ste...

Страница 90: ...one cable has the turnbuckle at the rear end and the other has it in the middle both forward ends have tangs with a single mounting hole Note that the cables will have to be disconnected later when t...

Страница 91: ...e 106 Rudder cable schematic 5 5 2 Pulleys Figure 107 Nynja central pulley block arrangement loking rearwards Rudder cables Elevator cable to lower left side of stick Elevator cable to upper right sid...

Страница 92: ...rn and lower attachment hole on the stick Check that A single metal washer should be in position on both sides of each pulley to provide a small amount of clearance from the side plate not more than 1...

Страница 93: ...deflects upward when you pull the stick back toward the rear of the aircraft e Tension the turnbuckles by hand keeping the elevator central when the stick is at 90 to the cabin central tubes tu19 not...

Страница 94: ...e the flap handle will push the cables downwards when you deflect the flaps j Attach the rudder cables to the rudder horn crossing them on the way back in the rear fuselage so that the starboard cable...

Страница 95: ...ots Fine adjustments can be made by twisting up the cables in the same manner as was used for tensioning the rear fuselage The positions of the rudder pedals fore and aft can be adjusted together at t...

Страница 96: ...tted over rudder cable tang b The other end should be fitted to the bolts supporting the rear stick pivot Figure 113 with the cables crossing the cable fitted to port side pair of pedals should fit on...

Страница 97: ...old the correct position Do not do this up too tight as it will distort the cable f If you have access to a Nicopress swaging tool crimp the ferrule remove the wire clamp and trim the excess cable Use...

Страница 98: ...als If it is too close for comfort a piece of prop tape can be placed on the tube to act as a fairlead If it touches the starboard central cabin brace piece this may be shimmed out with plastic washer...

Страница 99: ...another where they cross but this is acceptable The cables are supplied with lengths of heatshrink tubing on them Place these where they will best protect the cables from the structure and vice versa...

Страница 100: ...care should be taken to protect them from being scratched and to support them appropriately when working on them off the aeroplane Flexing them too far can result in surface cracking b The fairings a...

Страница 101: ...rs of the fairings with 80 grit or similar sandpaper b It is very important the following sequence for fitting is followed otherwise the fairings can be damaged Fit the starboard right fairing first F...

Страница 102: ...t positioning The halves should line up together and the front side edges should align with the rear cabin vertical TU6 tube so that the moulded joggle step is paralell and the middle of the joggled e...

Страница 103: ...n is applied A rivet will be put in this hole later after all other fixings are done Figure 121 positioning hole f The staps can now be tensioned until all the top and bottom seams align When a final...

Страница 104: ...5 white 4mm aluminium rivets h Then fix the top and bottom fairing seams using the white 4x10mm plastic screws and 4mm nyloc nuts Use a 4x16mm stainless steel screw and nyoc nut for the front most fi...

Страница 105: ...Remove the carburettors and air filters by loosening the screw clamping the carburettors into the rubber mounts and sliding them out Cover the exposed holes with tape or similar When reinstalling the...

Страница 106: ...ing in g Trial fit the bolt including the rubber mount and washers to make sure you have trimmed enough off Ensure an easy fit to eliminate any risk of cross threading the bolt Figure 125 upper port m...

Страница 107: ...two washers with a short 60mm bolt d Fix the lower starboard rubber engine mount between the two washers with a short 60mm bolt e Fix the lower port rubber engine mount between the two washers with a...

Страница 108: ...of the lower engine mount rubber This then provides support against bending loads due to torque being applied to the top engine mount bolt Fig 128 Overview and views of the upper and lower attachment...

Страница 109: ...do this 1 Remove the water pump housing Heat the area where the outlet pipe screw in with a plumber s gas blowlamp in order to soften the Loctite used to secure the outlet elbow into the threads When...

Страница 110: ...emble the fittings onto the tubes as per the following drawings in this section Tighten the fittings except for the aileron eyebolts the outer 3 eyebolts as per the rest of this section Important Do n...

Страница 111: ...111 Nynja Build Manual 1 4d c Join the leading and trailing edge tubes with the oval tube SKR37 3 maybe marked SKR54 at the tip Figs 142 143 144 Figure 131 Front of tip Figure 132 rear of tip...

Страница 112: ...nce from the jury struts when they are fitted at the very end of this manual They must not be fitted sooner as their length depends upon the exact alignment and tension of the airframe Figure 134 forw...

Страница 113: ...113 Nynja Build Manual 1 4d Figure 135 front jury strut attachment Figure 136 rear jury strut attachment...

Страница 114: ...on Don t forget to attach the bracing cables at the lift strut ends the one with the turnbuckle to the trailing edge using the end without the turnbuckle and the one without the turnbuckle to the lead...

Страница 115: ...ttachment And UK MOD pulleys The bolts holding the pulleys and the tu37 should point upwards to avoid pressing against the coverings Alternatively they may point downwards but then nutcaps must be use...

Страница 116: ...4d Note the lift strut plates front and rear have changed slightly and are now in common with the LS version spec and have an extra hole and link plate they should be assembled as below Figure 140 re...

Страница 117: ...cable If the sleeving on the cables is not in the correct location it may be slid along the cable by heating it first with a heatgun If this does not work protect the tube where the cables cross with...

Страница 118: ...d Figure 141 front and rear of tensioning tube Figure 142 tensioning tube fittings front in left photo note bolt through compression tube rear in right photo File edge of this saddle washer 2 3mm to c...

Страница 119: ...cover the hole c Lightly bolt into position the upper and lower angles Use the 6mm bolt with 45mm shank length The long brace goes underneath with horizontal edge facing the inboard end of the aileron...

Страница 120: ...brace from the opposite aileron against the upper surface as a guide to melt the upper slot This slot should be 50mm long measured from the centre of the leading edge spar Figure 145 slot for the ail...

Страница 121: ...shown in Figure 146 are not required Figure 146 lift strut attachments d With two people attach the wing to the fuselage One person should hold the tip up while the other person puts the pins through...

Страница 122: ...s worth doing on all the hinges even if no friction is present at this stage as when the coverings are fitted they tend to build some stress into the wing and cause the ailerons to bind slightly which...

Страница 123: ...f these are fitted then the cables attach to the driving horn using the shackles as supplied and as shown in drawing figure 147 above and the following down to j can be disregarded If using the full l...

Страница 124: ...he turnbuckle and feed the other ends from the fuselage outwards towards the ailerons l Attach the ends to the lower control horns on the ailerons m Tighten the bolts securing the aileron pulleys in t...

Страница 125: ...the centre turnbuckle simply takes up the slack Final adjustments to neutral position and control surface movement will be done when the aircraft is complete s Check the right and left joy stick move...

Страница 126: ...lap handle The slightly longer flap pushrod and the longer spacer tube goes on the starboard side of the rear end of the flap handle e Attach the push rods from the flap handle to the plates on the fl...

Страница 127: ...127 Nynja Build Manual 1 4d Figure 153 flap handle looking rearwards and flap rods note Nynja flap rods have slight bend in upper ends not shown in this drawing...

Страница 128: ...he fuselage Remove the lift struts from the wings followed by the fuselage then remove the wings from the fuselage and lay them down flat in a very clean place Do not place the wings on concrete as it...

Страница 129: ...he coverings to keep your hands and any tools etc you may handle clean at all times i Remove the turnbuckle from the drag cable Make sure that the cable with the turnbuckle is over the top of the fixe...

Страница 130: ...s and flaps as well as the strut attachments exit through their respective holes in the fabric o Stand the wing up with the trailing edge on the clean surface and the leading edge up p Attach a small...

Страница 131: ...tube is pushed into place It may be necessary to apply a sharp tap or to use a blunt screwdriver to push the cam straight There is no need to bolt the cam in place Ensure that the two large holes on t...

Страница 132: ...oles at the trailing edge of their pockets look closely they are there not through the holes further forwards Push the battens in as far as they will go and slip them into the wing root side of the po...

Страница 133: ...g the threaded rod To turn a threaded rod put two nuts on the end and tighten against each other Turn the rod with a spanner on the outermost nut whilst holding the nut behind the tensioning tube with...

Страница 134: ...the fabric tight in the same manner as before Look for the wrinkles just near the leading edge root section of the wing Tension the fabric with the rope until you see these wrinkles pull out This wil...

Страница 135: ...ng Stopping in the middle can cause the batten pocket to rip when you try to continue Wear a glove on your pushing hand Figure 161 inserting a batten Use your other hand to prevent the batten twisting...

Страница 136: ...he camber Fig 163 normal and flattened battens The above picture shows camber reduced for the tip batten compared to its starting shape Camber has been reduced along its length The forward section is...

Страница 137: ...f desired the two methods can be combined reduce camber and pre insert b Once each wing batten is in place use a screwdriver to push fully home slip the fabric flap over the end of the batten then sli...

Страница 138: ...washer should then be used a Attach the bottom of the cabin uprights SKR34 to the outer edges of the rudder pedal mounting bar as shown above Note that the bolt fixing the lower bracket to the upright...

Страница 139: ...the curve of the large innermost wing battens to get a good fit between the Lexan windscreen and the wing Use a long straight edge for this It may be necessary to tweak the stainless steel curved pie...

Страница 140: ...ts to secure the stainless steel curved pieces we recommend 4x10mm steel rivets spaced as shown below with the aim to secure and prevent any fore aft movement of the TU34 upright tube which may close...

Страница 141: ...using the measurement method as shown in fig 168 below If it checks out without adjustment it should be ok to proceed If it needs adjustment then wings will have to be fitted as gap from uprights to...

Страница 142: ...tubes h Remove the wings and heat shrink the rings into position i Secure the SKR34 tubes at the same positions they held whilst the wing was fitted These can be held in place simply by a tube such a...

Страница 143: ...de lever Figure 176 dual throttle parts Note Nynja has slightly different plates than those shown as SKR 736 in drawing see photos above Note Assembly on pivot has a nylon washer either side of the mo...

Страница 144: ...levers onto the plates Check correct position of cabin upright spacing Torque tube is supplied over long so offer it up mark and cut to length c Rivet the port lever pivot into the torque tube using...

Страница 145: ...s attach to an arm that will be hidden in the instrument console Figure 179 throttle cable arm h This arm has a threaded insert in its base The throttle torque tube must be drilled to fix this arm Mar...

Страница 146: ...into position to the cabin uprights tu34 using 4mm steel rivets m Adjust the throttle friction by tightening the lock nuts on the port side torque tube spindle The starboard side should be done up jus...

Страница 147: ...e to the underneath rear edge where it joins the rear fuselage shells and the cabin uprights see figures below Figure 181 rear edge Figure 182 forward positioning c Note in figure 177 above the joggle...

Страница 148: ...nel followed by a steel penny washer before the nut on each of the forward fixing points g Drill and fix the rear under floor edge with Clecos Skinpins starting from the middle and with spacing around...

Страница 149: ...is removed before final riveting Fig 186 final fixing j Fix the front to the door pillar tubes SKR34 using three 4mm aluminium rivets each side Countersink the rivets using a 10mm drill bit to counter...

Страница 150: ...access to drill behind the engine might be difficult b Firewall should fit in position as shown below Firewall should sit behind the reference bolt shown and top edge should be 95mm above its centre A...

Страница 151: ...just one top and one bottom each side for now the rest will be fitted when the exact position of the cowling screws are determined to ensure even spacing Drill a 3mm hole Then take a 10mm drill bit a...

Страница 152: ...scuttle may be encessary to acheive a symettrical measurement and may not be exactly 500mm h Firewall halves can be rivetted in position now short 4mm bolts can alternatively be used if desired and t...

Страница 153: ...tboard from the position where the cowling changes angle as shown below and 10mm up from the upper cowling edge Cleco Skinpin together then mark the other holes starting with the rear one which should...

Страница 154: ...one on the outside 30mm from the angle chage as shown below The others shoudl be evenly spaced from the centre approx 140 150mm apart The lower cowling has three fixings each side Start with the uppe...

Страница 155: ...hich will be required during the next steps d Cowlings need to be aligned with the spinner note that cowlings are made for spinners of around 20 23cm diameter alignment with larger or smaller ones may...

Страница 156: ...ompletely happy drill through the scuttle to fix it to the door pillar tubes Use a 4mm drill and fix with Clecos Skinpins as you go Check alignment hasnt shifted before drilling each hole Mark and tri...

Страница 157: ...cuttle edges into position easier Figure 200 fixing lower edges of Scuttle moulding i Remove cowlings at this stage and finish fixing side and top firewall edges to scuttle Use the 3mm countersunk riv...

Страница 158: ...aust pipes into the muffler and secure with springs A touch of Copaslip high temperature grease should be applied to the ball joint ends of the exhaust pipes Use string to pull the springs on not plie...

Страница 159: ...ear starboard pipes will not seal properly This will result in an exhaust blow or tick When happy with the fit tighten the mounting bolts and the clamping bolt Do a final check with a good firm wiggle...

Страница 160: ...to stiffen the firewall The Uk firewall spec is thicker than the prototype so these are not necessary but are supplied in the kit your choice Figure 205 Oil tank mounting b The oil cooler piggybacks b...

Страница 161: ...ixed on the lower brackets in turn fixed to the water radiator now offer up the upper bracket Check the upper spacing remains at 2 3mm from water radiator matrix bend bottom brackets to achieve this i...

Страница 162: ...Remove the cowling now and Install the hose from the sump connection beneath the engine passing beneath the lower cylinder head water pipes but above the exhaust pipes to connect with the inlet on the...

Страница 163: ...Figure 211 Hose routings from oil cooler outlets Figure 212 Routing of oil hose from Sump connection to inlet of oil tank It should be cabletied up to the small water pipes under the engine in the po...

Страница 164: ...ater hoses between the expansion tank and the elbows on the port side cylinder heads d Remove the elbows from the port side cylinder heads and swap them over between the front and rear cylinder heads...

Страница 165: ...e hoses The hoses may have to be repositioned slightly to effect maximum rotation of the expansion tank g Fit the rubber elbow on the port water pipe assembly to the expansion tank passing between the...

Страница 166: ...clearance Figure 218 port water hose k The water overflow tank should be mounted on the port side of the firewall by bending the securing strap around the indent in the tank and securing it to the fi...

Страница 167: ...hose clips are supplied in the kit The crimp type crimps are less bulky and have no sharp edges Use these on connections that will not have to be undone for routine maintenance tasks For those connect...

Страница 168: ...ot on the pump e The fuel supply pipe from the tank connects to the inlet of the fuel pump the larger diameter pipe spigot on the pump Note that although the fuel pump inlet and outlet tubes are of di...

Страница 169: ...ties spaced every 150mm or so It is soft pipe designed for bending so it can be contoured where necessary simply by hand To prevent chafing cut some short 20mm lengths of the Tygon fuel tubing the tra...

Страница 170: ...e in the top outer most holes in the tanks for the breather connections Metal elbows should be used for all the other fittings Push the rubber part in first and then the insert Use some lubrication li...

Страница 171: ...dressed out with abrasive paper so hole edges are nice and smooth Fig 230 Then remove all debris from inside the tank Use the fitting guide wire supplied in the kit Straighten it out and thread it th...

Страница 172: ...e tanks fit on the one that the flap handle attaches to to protect the rear corner of the tanks from abrasion Use a piece of fuel tubing or similar split and slipped on then held in position with cabl...

Страница 173: ...balance pipe the lowest if two are fitted Fit the pipe with a T piece to connect the fuel drain which must discharge clear of the aircraft Figure 229 The fuel drain tap is fitted through the fuselage...

Страница 174: ...its fitting in the top of the starboard tank e Both breather fittings should have individual lengths of tubing attached routing forwards then downwards along the SKR27 tubes passing through the fusel...

Страница 175: ...angle for the filler to be positioned c The fitting can now be secured to the fuselage by drilling and using 4mm nuts and bolts d The flexible hose can now be cut to size and fitted secured with two...

Страница 176: ...nd dashboard supports shown below Figure 236 dashboard supports and instrument panel framing angles b Start with fixing the angle part A to the firewall flush with its top and centrally positioned as...

Страница 177: ...for the thickness of the clipnut the edge is flush with the edge of the instrument panel so everything will do up later nice and snug with no gaps or distortion A nice alternive it to fit 4mm rivnuts...

Страница 178: ...ront using the 4mm bolt and nut through A and B and again with a 4mm nut and bolt mid point of B Figure 240 triangular dash top panel g Offer up the dash binnacle mouldings Trim to fit snugly but allo...

Страница 179: ...d top so that it is not distorted when the screws are tightened Figures 241 dash binnacle mouldings i The binnacle mouldings overhang the instrument panel Trim this to taste It is edged with a trim st...

Страница 180: ...pair passes inside and clear of it and the choke cable pair passes outside and clear of it Don t forget to drill the holes in the firewall for the cables before riveting the plate Figure 243 Cable gu...

Страница 181: ...through the outers to the carburettors d The throttle arm incorporates a spring to help balance the pull of the springs on the carburettor It fits as shown in Fig 225 below Figures 246 throttle balan...

Страница 182: ...below Figure 247 choke cable route to starboard carburettor in white Figure 248 route of choke cable to port carburettor in white f The choke inner cable is a simple loop of cable covered with plastic...

Страница 183: ...on the carb mouth Make sure the filter is secure The cut edges of the ring may need trimming to allow the jubilee clip to fully clamp the filters and rings to the carb h Possible interference with bo...

Страница 184: ...h a junior hacksaw then finish the hole to the line with an abrasive flap wheel in a power drill Sandpaper wrapped around a tapered wine bottle neck is also a good way to finally ease the holes to siz...

Страница 185: ...b The connecting tube should be routed down the inside of the lift strut to a push fit joiner tube at the fuselage to lift strut bolt c The fuselage piece of tube should enter the cockpit and pass un...

Страница 186: ...186 Nynja Build Manual 1 4d 16 Electrical System Figure 253 overall wiring schematic Rotax 912 and standard analogue instruments ensure all colours are visible when printed out...

Страница 187: ...187 Nynja Build Manual 1 4d Figure 254 heavy duty power wiring schematic Rotax 912...

Страница 188: ...188 Nynja Build Manual 1 4d Figure 255 low current wiring schematic Rotax 912...

Страница 189: ...189 Nynja Build Manual 1 4d Figure 256 instrument wiring schematic Rotax 912...

Страница 190: ...lugs See below the explanatory wiring diagram from the Rotax manual Figure 257 Easy start wiring diagram It is basically two leads that come off the solenoid spade connector and insert in the plugs as...

Страница 191: ...able from Maplins electrical and car accessory shops etc Secure the wiring with cable ties P clips or similar ensuring that it remains clear of all moving and vibrating parts and is protected from cha...

Страница 192: ...is concerned as the magnetos are grounded to prevent operation On the 912 the master switch is a double pole single throw DPST type to allow it to turn off the power from both the battery and the regu...

Страница 193: ...r and a start button warning light k Additional systems such as GPS radio etc should be individually protected by fuses of the appropriate size 16 4 Battery a All high current cables should be kept as...

Страница 194: ...enoid and regulator on SKR98 plate g Ensure that the regulator is properly earthed If fitting regulator and solenoid to the firewall beware that the aluminium firewall is not a good earth it may work...

Страница 195: ...wings in place to ensure perfect fit a Apply the supplied strips of thin self adhesive foam strip to the top of the curved tubes TU34 supporting the top part of the windscreen This will reduce noise a...

Страница 196: ...in situ 900mm 1160m m 260mm 830mm Use pattern in preceding page to cut this shape Trim these lines in situ to match door pillar Small angle cut to taste 6mm hole 1040mm to match tops of wing root bat...

Страница 197: ...h sandpaper over a sanding block For more intricate curves a Dremel cutting toll can be used followed by using the sanding drum attachment To trim excess from edges a Surform tool has been found to be...

Страница 198: ...emove and cut so that the edges sit just past the peak of the wing covering root batten by 5mm or so Figure 266 lexan edge matched to wing covering root batten peak g Before rivetting the lexan in pos...

Страница 199: ...rly and check that the shape of the cowling remains as it should be otherwise you may build a strange shape into the windscreen and the cowling The drawn centreline is a useful reference and should en...

Страница 200: ...ck don t do this until you are ready for a final fixing it may be rather permanent we have managed to unscrew them but they might need cutting off l If using the two piece doors drill and rivet the si...

Страница 201: ...cowling piece the lexan and through the batten Fig 268 screen centre batten o With the left over Lexan cut a triangular piece to fit in the corners of the windscreen and tube SKR34 Secure in place wit...

Страница 202: ...ium We also used an H section moulding DIY shop item painted black to join left and right halves Fig 270 windscreen rear edge rear window interface UK demonstrator 2 Now used on the manufacturers demo...

Страница 203: ...flaps connected to make a card template which can be taped into position and hole cut and finessed to match travel of flap rod when flaps are extended Mark the position of the template and then with l...

Страница 204: ...o the cabin rear upright TU 6 Trim the edge of the lexan to be flush with forward edge of tube Use the trim beading over the exposed edge The rivet line should be covered with a strip of 3mm self adhe...

Страница 205: ...ding to the wing undersurface However they weight around a total 1kg installed 500g each In the UK demonstrator to save weight we did not use these We extended the angle used on the door tops to meet...

Страница 206: ...upper surface to cut marks to fit as shown in fig 249 above It sits against the TU34 upper tube and rivets to it with 4mm aluminium rivets Before final trimming and riveting Fit the wings and positio...

Страница 207: ...207 Nynja Build manual 1 4d 18 2 One Piece Door Figure 282 one piece door frame...

Страница 208: ...rill the centre of the angle in these positions 4mm diameter in TU34 and 5mm in TU6 c Offer it up again mark and drill the TU34 and TU6 to match and temporarily fix into position d When using the one...

Страница 209: ...just below the hinge line Drill the hinge and door tubes with 4mm holes and secure with cleco s skinpin s h Fit the central curved tube The curve should go towards the rear of the door like a backward...

Страница 210: ...ch point to clear the rivet heads It is advisable to fix with cleco s skin pin s first before rivetting Work from the upper front corner and rivet the front edge first Follow this by riveting the lowe...

Страница 211: ...can be filed a little to achieve a slight indent to prevent the lever from inadvertently rotating to the open position or an aluminium piece can be riveted on to protect the fibreglass from wear c Po...

Страница 212: ...surface with two screws cut these to length with spreader plates made from two rectangles of scrap Lexan 30mm X 150 15mm radius at each end either side of the wing fabric This job will require two pe...

Страница 213: ...er that the doors open outwards and forwards so the hinge bulge needs to be on the outside Hinge should be fitted so top edge is 25mm below the top edge of the glassfibre cowling This should then matc...

Страница 214: ...ven fit inside the opening spaced 10 15mm make up some spacers this size and tape them around strategically around the opening so you can rest the tube in position and achieve this Figure 292 tube spa...

Страница 215: ...o cut the tube to fit Figure 295 rear gusset plate and rear end of lower door g Drill the front end of the tube and hinge and secure with a cleco skinpin Make sure the tube is in exactly the correct p...

Страница 216: ...ome adjustment by carefully bending the tubes may be required Leave the clecos in position holding the tubes to the hinge for now They are not riveted to the hinge until the lexan is fitted 18 3 2 Upp...

Страница 217: ...door outside and inside Lower pictures show front of port door outside and inside Angle is white plastic in pictures kit supply is 20x20 aluminium angle e Fix the hinges to the angle Use 4mm aluminium...

Страница 218: ...y with the fit and with the frame taped into position Drill through the hinge and the tube ends and fix with clecos h Cut a top rail tube to fit inside the tubes and fix into position Use 2 x 3mm coun...

Страница 219: ...can be trimmed later c Before riveting mark the position of the holes to be drilled on the doorframe Use a nominal rivet spacing of 60mm adjusted where required to provide an even spacing on each sid...

Страница 220: ...f Refit the lower door Using a chart pen or similar accurately mark the lexan for trimming It should fit evenly just inside the joggle on the glassfibre door sill and overlap the rear window by 25mm a...

Страница 221: ...e through the hole in the doorframe c On the inside fit a thin plastic washer followed by the plain nut hooped shape handle and Nyloc nut d Tighten the nuts against one another to lock the parts into...

Страница 222: ...two 4mm steel rivets and snug down firmly so that it fits tightly with no movement Determine the best position for the latch ensuring maximum engagement when closed Mark the position and drill and ri...

Страница 223: ...en keeper i Now check final fit of the lower door when closed and latched then fit the front gusset plates We didnt fit these parts earlier becuase it is difficult to gurantee a nice fit between the l...

Страница 224: ...1 Trimmer cable a Pass the trimmer cable outer through the hole in the fairing at the starboard tailplane forward attachment and feed down the fuselage Figure 308 trim tab cable b Fit the trim tab cab...

Страница 225: ...ct the heat away from them and check they don t get hot Figure 310 aft end of trimmer cable e Melt a hole in the upper surface of the elevator fabric for the inner cable 230mm forwards of the trailing...

Страница 226: ...op at the end of the trimmer cable to the top trim tab control horn with a bolt and plastic top hat spacer The cable goes on the inboard side of the horn Figure 313 cable attachment on trim tab horn i...

Страница 227: ...these washers c Adjust the trim lever friction with the first nut and lock it with the second nut Movement should be smooth but tight enough to prevent the lever slipping due to the trim tab loads Th...

Страница 228: ...314 spring fitting and control stop f Attach the inner cable to the lever The cable wraps around the top hat bush and is secured using two solderless nipples The holes in these need to be drilled out...

Страница 229: ...uld be level with the lower surface of the elevator Coarse adjustment can be made by feeding the inner cable though the solderless nipples and fine adjustment by winding the adjuster on the forward ou...

Страница 230: ...the way for initial console fitting b If using the centre stick cut an opening in the centre console around the stick position as shown in Figure 317 below Figure 317 stick opening c Put it loosely i...

Страница 231: ...ure 318 console trimming It will also need trimming around the front upper corners as shown below Figure 319 front corner trimming e Use thin Aluminium angle fixed to the floor with self taping screws...

Страница 232: ...at the rear edge should be cut up the side of the recess Drill and fix the top hat bushes that form the retaining points for the controls stick gaiter using the dimensions shown below These fit with 4...

Страница 233: ...ber beading strip applied with a dabs of superglue When console is finally fixed the top of the trim lever can be fitted with a knob made from a skiffy cap fitted each side Figure 322 trim lever finis...

Страница 234: ...holes in the front of the side tubes to set the seat position Figure 323 seat base b Rest the glassfibre part of the seats on the base and drill and fix them Front is fixed passing the SKR 0 27eyebolt...

Страница 235: ...crossmember may be fitted as shown below Figure 326 optional second cross member e Attach the two strips of Velcro to match the Velcro in the inside of the seat covers and then put on the seat covers...

Страница 236: ...ft the front of the seat or can be fitted under the TU15 if a lower position is desired At the rear the inboard rest peg on the TU27has two positions The oter rest is an L bracket It attaches directly...

Страница 237: ...lts should be looped around the main undercarriage cross beam Take a double wrap around the beam to prevent the strap slipping under side loads Figure 331 lap strap looped around undercarriage beam c...

Страница 238: ...e instrument panel link drilling and finishing with a flap wheel Cutting a little oversize and finishing the hole with rubber edging super glued into place gives a good effect Spat should be positione...

Страница 239: ...craft down whilst you slide the nose leg out The spat was not fitted earlier to protect it from all the parts which you dropped whilst fitting the engine d Drill the spat and the nose leg for a 4mm di...

Страница 240: ...d drilled at one end this is the end the aluminium angles fit Attach with the M5x20 bolt supplied The retaining tube should be drilled to suit where it attaches to the axle so that the wheel is retain...

Страница 241: ...ither use a 5mm rivut as shown or drill and tap to an M5 thread Figure 337 The spat should be offered up to the nose wheel to mark the position of the hole for the nose leg if not already marked and o...

Страница 242: ...bolts and 30mm spacer between fork and spat sides Under the head of the bolt should be M5washer skiffy cap base 1 5mm plastic washer Figure 339 The nose leg will have to be dropped out of the aircraft...

Страница 243: ...er Figure 341 The inner attachment bracket should have been fitted earlier as was detailed in the main build manual If retrofitting spats fit them now Use the new slightly longer M6 bolts supplied The...

Страница 244: ...d 1 5mm plastic washer Figure 343 The outer attachment bolt is an M6x50 and a 20mm plastic spacer bobbin Under the head of the bolt should be M6 washer 1 5mm plastic washer Figure 344 The spats as sup...

Страница 245: ...al sanding and fettling may be necessary on the gear leg cut out section and inner attachment holes to get angles aligned between left and right spats and to avoid abrasion on the gear legs and the br...

Страница 246: ...fairing at the rear where it slips over the fin leading edge tube This will help ensure a smooth non abrasive surface where the two meet Additionally apply some clear protective tape over the fin in...

Страница 247: ...ith two rivets on the fin leading edge centreline one 20mm from the lower edge of the fairing and the other 140mm Make the holes in the glassfibre slightly oversize to avoid splitting the gel seam whe...

Страница 248: ...outermost on the top is not drilled too close to the wing root batten where the nut might foul it For best effect against the tinted screen viewed from the inside we painted the inside of the fairings...

Страница 249: ...plastic panhead screw at the front and taped on their edges to hold at rear In position they hide the tailplane front mounting bolt It is a good idea to cut a hole on the underside of the fairing so t...

Страница 250: ...ip fairings a These attach with 5 rivets on the top and 5 below Use the white 4mm aluminium rivets These should fix the wingtip fairing to the TU37a tip tube Take care not to drill through the U brack...

Страница 251: ...fairing 35mm from its edge After verifying where to drill and checking clearance from aileron drill the wingtip fairing first Then offer it up and drill through the holes into the tip tube Figure 355...

Страница 252: ...aintain the wings profile at speed Figure 356 wing profile support blocks a Cut the 10mm wide foam strip supplied into 155mm lengths Cut 2 for the very end battens 110mm b Using some 80 grit sandpaper...

Страница 253: ...overing underside insert the blocks into position The best technique appears to be to slot against the lower batten first and push then push the block downwards and under the upper batten into place S...

Страница 254: ...et into the cockpit On the cockpit side a length of scat hose takes the warm air to a diffuser T Figure 358 Heater control valve a Cut a 50mm diameter hole in the firewall to accept the heater control...

Страница 255: ...Fig 330 d Fix the heater control cable into the instrument panel and connect it up to the valve using the cable clamp clip in the kit suitably positioned There is no hard and fast correct position for...

Страница 256: ...e and another just below the windscreen fixing nuts The velcro meeds a nice smooth surface to stick to It wont stick well to the glassfibre If you have left enough overlap stick it to the lexan below...

Страница 257: ...remains slack whilst the other is tight it may be that the covering is not properly seated on the leading edge requiring removal of the wing covering and refitting as per the instructions 28 2 Aerofo...

Страница 258: ...luminium spacer over the bolt Washers should be used both under the head of the bolt and under the nut Figure 362 Aerofoil jury strut overview Fig 363 Rear and front lower fittings Note orientation lo...

Страница 259: ...ll electrical connections are properly made with no risk of short circuiting d Check that all fuel oil and water pipe clips and other connections are properly tightened and sealed 28 4 Baggage Bag a R...

Страница 260: ...ect the lower straps to the rear securing straps using the click in buckle Note that the lower fixing do not go around the rear cabin uprights TU6 The baggage bag should be free to move upwards and ba...

Страница 261: ...f adjustment is needed defection can be reduced by increasing the diameter of the stops at the torque tube horn using tape around the tube to pad out the stops If more movement is needed the control h...

Страница 262: ...n Figure 368 cable guide i Check the neutral position and operation of the elevator The elevator should be horizontal with the lower half of the stick at 90 to the central cabin tubes not vertical Ele...

Страница 263: ...prop is set on its recommended starting pitch then the RPM gauge may not be indicating accurately and may need calibrating with an optical tachometer your inspector or local engine service facility sh...

Страница 264: ...outers at the carburettor Carburettors should also be balanced at this time specialist engine balance tools exist for this you can buy them yourself a good investment if you intend to maintain the en...

Страница 265: ...s calculated by dividing 3600 seconds by the number of seconds taken for 1 litre This is required to be greater than 25 of the full power fuel consumption typically 20 30 litres per hour depending on...

Страница 266: ...Ensure that all paperwork is complete In particular the AW029 needs to be signed by the BMAA Chief Technical Officer and then finally by your inspector Check that the airfield you intend to fly from...

Страница 267: ...end the extra one lying at the bottom of your pile of leftover parts Lockwire lockwire pliers and side cutter pliers General tools Screwdrivers spanners etc Propeller pitch setting tool Fuel in cans...

Страница 268: ...268 Nynja Build manual 1 4d 27 Additional Information 27 1 Example BMAA Homebuilt Registration Form...

Страница 269: ...269 Nynja Build manual 1 4d...

Страница 270: ...270 Nynja Build manual 1 4d 27 2 Wire locking...

Страница 271: ...271 Nynja Build manual 1 4d...

Страница 272: ...272 Nynja Build manual 1 4d...

Страница 273: ...273 Nynja Build manual 1 4d...

Страница 274: ...race 52 central cabin tubes tu19 39 compression tubes tu38 131 control stick 49 Copaslip 158 covering 128 door catch 211 221 door frame 208 earth bolt 192 earth cable 194 electrical system schematics...

Страница 275: ...s position 95 rudder post 54 rudder stops 51 96 seat front support tube tu15 47 seatbelts 237 seats 234 self adhesive foam strip 195 Skyranger Hotline 11 solenoid 194 spacer tube tu102 75 spats 70 73...

Страница 276: ...e 67 UP for ON 192 upper cabin triangle tubes tu10 31 upper rear cabin cross piece tu7 30 31 vertical fin 80 water overflow tank 166 water pipe 164 water pump inlet 105 wheels 67 windscreen 138 195 wi...

Страница 277: ...o issue 1 1 tidy up of Figs 53 73 79 85 106 215to prevent possible confusion Text changes for brake advice Fuel breather balance pipe possible incorrect assembly of central frame fuselage cable tangs...

Страница 278: ...Commonalisation of VLA lift strut attach plates renumbering of figs and replacement update of many photos correction to mission of reference to firewall foam addition of screen drawing Reclassificati...

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