1-Jabiru J170 Constructors Manual WEB

Jabiru
J170
Construction
Manual
From Kit number 273
Jabiru J170 Constructors Manual

Introduction
2 of 377
Monday, January 12, 2015

Introduction
Introduction
Welcome to the Jabiru family, and a family it is.
Jabiru is a small aircraft and aero-engine manufacturer located in Bundaberg, Queensland,
Australia. The city has a population of 60,000 and until recently its most renowned export has been
the famous (or infamous) Bundaberg Rum. The Jabiru factory is located on the airport at the
Western edge of town where a staff of 55 craftsmen turns out these fine aircraft and engines.
We are not just another kit manufacturer; we also build certified aircraft, engines and propellers and
have a quality assurance program fully approved by the Australian Civil Aviation Safety Authority
(CASA); as far as we know we are the only company doing so.
All of our products are original and have been designed, prototyped and produced in house, so we
can support you like no other kit manufacturer can.
Our distributors are fully supported by us and are a ready source of spares and free advice.
You need not have a degree in electrical engineering, an intimate knowledge of hydraulics or a
garage full of tools to complete this aircraft. There are no complex or complicated systems on this
aircraft. The gear stays down, the prop pitch is fixed and a simple switch operates the flaps. The
brakes are hydraulic and the simplicity will delight you.
Your Jabiru kit is designed to be simple to complete and finish, and will provide you with many
years of enjoyable flying.
Once completed you will find the aircraft extremely economical with operating costs more
associated with a car than an aeroplane, and the ease of maintenance will increase your flying time.
If you're ever in our area call in for a coffee, we'll show you what we're up to and how we make our
aircraft and engines.
Rodney Stiff Managing Director

Safe Aviating and Happy Landings.
General>Constructors manual
Welcome to the Constructors Manual!
In this Manual you will find all the instructions that you will need to build your very own Jabiru,
one step or task at a time. Each task in this Manual stands alone, with the intention that each task
will be completed before you move on to the next task. There are many good reasons for this
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List of Effective Pages / Issue Status
approach: you can easily keep track of where you are in the build; it forms a checklist to ensure that
nothing gets overlooked; and in many cases a task will be dependant on the completion of a
previous task and if the sequence shown in the Table of Contents is followed there will be no issues
of this kind.
The Table of Contents of this Manual is also the Build Sequence.
We suggest that you print the Table of Contents out and keep it on the wall in your workshop. As
each task is completed mark it off - in this manner you can accurately track your progress while
ensuring that nothing gets overlooked.
The manual has been arranged into 2 major Sections plus General and Painting sections:
Pre-Paint
Post-Paint
Which have been further Grouped by:
Fuselage
Wings
Each Group is then broken down into a series of Tasks and Steps as required.
In the main the only sets of tasks that can be done without relation to each other are those under the
Group headings: Fuselage and Wings. Tasks in one group may be worked on independently of tasks
in the other group, but the individual sequences under each group really need to remain intact.
This Manual details the procedures that we have refined over many years of certified factory builds,
all combined with the experience of many kit builders to produce a document that combines the best
of both worlds: efficient, proven factory techniques throughout, but arranged into a build sequence
that meets the needs of kit builders.
For example: the first objective for most kit builders is to get the fuselage up onto its wheels and
mobile as quickly as possible so that the fuselage can be moved around the workshop/out of the
way of the wifes car/outside for cleaning/etc. By way of contrast, in the factory the fuselage
remains in a floor-mounted jig for the majority of the Pre-Paint tasks, which is not usually practical
for kit builders.
Each task contains photographs of the work in progress in our factory, often in a step-by-step
manner in the case of the more complex tasks. While the Manual is formatted in A4 size you may
wish to print some pages in A3 size (if you have a suitable printer) for a clearer view should that be
required. Each task starts on a new page so you can print out single tasks.
As you work through this manual, and we suggest that you read it right through from start to finish
before you start your build, if something is not completely clear please call your dealer or e-mail us
for clarification: it may be that we can better explain something for the benefit of future kit builders
at the same time as helping you.
This manual is revised as a whole. All pages retain the revision status of the overall document.
Altered text is shown in red.
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Table 1 List of Approved Revisions
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Initial Issue
Typographic errors fixed.

Introduction ................................................................................................................................................... 3
General>Constructors manual ....................................................................................................................... 3
List of Effective Pages / Issue Status ............................................................................................................ 4
General>Tools and equipment ...................................................................................................................... 9
General>Glossary........................................................................................................................................ 14
General>Registration and certification ....................................................................................................... 15
General>Reference documentation ............................................................................................................. 15
General>Unpacking and support................................................................................................................. 16
General>Composite standard procedures.................................................................................................... 17
General>Aircraft grade bolts and lock nuts ................................................................................................ 20
General>Rod ends ....................................................................................................................................... 22
General>Health and safety .......................................................................................................................... 23
Pre-Paint>Fuselage>Fit ventral fin and trim horn....................................................................................... 24
Pre-Paint>Fuselage>Prepare the fuselage ................................................................................................... 27
Pre-Paint>Fuselage>Undercarriage>Assemble main wheels ..................................................................... 32
Pre-Paint>Fuselage>Undercarriage>Assemble main gear.......................................................................... 35
Pre-Paint>Fuselage>Undercarriage>Fit main gear ..................................................................................... 41
Pre-Paint>Fuselage>Firewall forward>Fit firewall .................................................................................... 45
Pre-Paint>Fuselage>Firewall>Firewall fittings .......................................................................................... 49
Pre-Paint>Fuselage>Firewall forward>Assemble and fit nose gear ........................................................... 55
Pre-Paint>Fuselage>Firewall forward>Fit engine mount and engine ........................................................ 64
Pre-Paint>Fuselage>Firewall forward>Fit propeller flange extension ....................................................... 68
Pre-Paint>Fuselage>Firewall forward>Fit oil cooler ................................................................................. 69
Pre-Paint>Fuselage>Firewall forward>Fuel pump fittings ......................................................................... 74
Pre-Paint>Fuselage>Firewall forward>Fit ram air cooling ducts ............................................................... 77
Pre-Paint>Fuselage>Fit windscreen............................................................................................................ 81
Pre-Paint>Fuselage>Fit control cables and lines ........................................................................................ 84
Pre-Paint>Fuselage>Empennage>Fit vertical tail fin ................................................................................. 87
Pre-Paint>Fuselage>Empennage>Fit elevator ............................................................................................ 95
Pre-Paint>Fuselage>Empennage>Fit horizontal stabiliser ....................................................................... 100
Pre-Paint>Fuselage>Empennage>Fit rudder ............................................................................................ 104
Pre-Paint>Fuselage>Fit cowling ............................................................................................................... 109
Pre-Paint>Fuselage>Fit flap drive shaft bearing blocks ........................................................................... 117
Pre-Paint>Fuselage>Interior>Console>Pre-fit handbrake ........................................................................ 119
Pre-Paint>Fuselage>Interior>Console>Pre-fit trim control...................................................................... 122
Pre-Paint>Fuselage>Interior>Console>Fit control stick .......................................................................... 126
Pre-Paint>Fuselage>Interior>Fit rudder pedal mount blocks ................................................................... 130
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Pre-Paint>Fuselage>Interior>Controls>Fit aileron cable brackets ........................................................... 132
Pre-Paint>Fuselage>Interior>Fuel system ................................................................................................ 137
Pre-Paint>Fuselage>Interior>Fit seatbelt anchors .................................................................................... 143
Pre-Paint>Fuselage>Pre-fit doors ............................................................................................................. 145
Pre-Paint>Fuselage>Fit windows ............................................................................................................. 149
Pre-Paint>Fuselage>Wheel alignment ...................................................................................................... 151
Pre-Paint>Fuselage>Pre-fit wheel spats ................................................................................................... 153
Pre-Paint>Wings>General ........................................................................................................................ 156
Pre-Paint>Wings>Fit fuel tank filler body ................................................................................................ 157
Pre-Paint>Wings>Prepare wing root ........................................................................................................ 161
Pre-Paint>Wings>Cut aileron cable openings .......................................................................................... 165
Pre-Paint>Wings>Fit quick drain sumps .................................................................................................. 169
Pre-Paint>Wings>Mount flaps.................................................................................................................. 171
Pre-Paint>Wings>Fit wing tips ................................................................................................................. 178
Pre-Paint>Wings>Fit Z-spar ailerons ....................................................................................................... 181
Pre-Paint>Wings>Fit pitot tube to strut .................................................................................................... 188
Pre-Paint>Wings>Fit vibration damper to strut ........................................................................................ 190
Pre-Paint>Wings>Test fit wings ............................................................................................................... 193
Paint>General............................................................................................................................................ 198
Paint>Masking .......................................................................................................................................... 201
Paint>Surface preparation ......................................................................................................................... 202
Paint>Topcoat ........................................................................................................................................... 204
Post-Paint>General ................................................................................................................................... 205
Post-Paint>Fuselage>Fit panel mounted throttle ...................................................................................... 206
Post-Paint>Fuselage>Assemble instrument panel .................................................................................... 209
Post-Paint>Fuselage>Electrical wiring diagrams ..................................................................................... 227
Post-Paint>Fuselage>Interior>Fit upholstery 1 ........................................................................................ 233
Post-Paint>Fuselage>Install electrical wiring........................................................................................... 236
Post-Paint>Fuselage>Interior>Fit console controls .................................................................................. 249
Post-Paint>Fuselage>Interior>Controls>Fit rudder pedals ...................................................................... 255
Post-Paint>Fuselage>Interior>Fit flap drive motor .................................................................................. 262
Post-Paint>Fuselage>Interior>Fit instrument panel housing .................................................................... 266
Post-Paint> Fuselage>Interior>Engine control cabling ............................................................................ 270
Post-Paint>Fuselage>Interior>Fit the instrument panel ........................................................................... 273
Post-Paint>Fuselage>Interior>Fit upholstery 2 ........................................................................................ 274
Post-Paint>Fuselage>Fit rudder, elevator and elevator trim ..................................................................... 278
Post-Paint>Fuselage>Fit doors ................................................................................................................. 287
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Post-Paint>Fuselage>Firewall forward>Final assembly .......................................................................... 290
Post-Paint>Fuselage>Engine>Fit Jabiru wood propeller and spinner ...................................................... 294
Post-Paint>Fuselage>Engine>Fit Jabiru composite propeller and spinner ............................................... 298
Post-Paint>Fuselage>Fit wheel spats ........................................................................................................ 302
Post-Paint>Wings>Install aileron cables .................................................................................................. 303
Post-Paint>Wings>Fit stall warning ......................................................................................................... 305
Post-Paint>Wings>Prepare wings for fitting ............................................................................................ 308
Post-Paint>Wings>Fit wings .................................................................................................................... 315
Post-Paint>Wings>Connect ailerons ........................................................................................................ 317
Post-Paint>Wings>Connect wing tanks .................................................................................................... 320
Post-Paint>Wings>Fit flaps ...................................................................................................................... 321
Post-Paint>Wings>Fit fairings .................................................................................................................. 323
Testing>General ........................................................................................................................................ 325
Testing>Weight and balance ..................................................................................................................... 326
Testing>Rigging check ............................................................................................................................. 331
Testing>Calibrate fuel gauges................................................................................................................... 335
Testing>Registration markings ................................................................................................................. 337
Testing>Final inspection checklist ............................................................................................................ 339
Testing>Flight testing ............................................................................................................................... 356
Testing>Forms .......................................................................................................................................... 371
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General>Tools and equipment

Before getting started we recommend that you acquire the following tools and equipment: these
tools are not included in the kit and must be supplied by you.
Required tools
The following tools and equipment will be required as a bare minimum to complete this kit:
Allen keys: imperial set.
Aluminium angle: 3 or 4 straight lengths of 20x20x3 angle approximately 2m in length.
Clecoes: Clecoe pliers and at least 20 Clecoes.
Digital Kitchen Scales: (up to 5kg measured in 10
gram increments) for mixing resins by weight, using
mixing pots provided. Accurate measurements of
small mixes can be made. Slip the scales into a clear
plastic bag to keep them clean the scale can still be
through the bag.
the
read
Disposable gloves: for handling of epoxy and resin.

a large box from the supermarket or hardware supply store.
Buy
Drill bits: 1/8" to " normal shank, 5/32" and 3/16" extended shank.
Electric drill: 3/8 chuck, preferably cordless with a variable speed trigger.
Electric hot air (paint stripping) gun: used to 'adjust' some non - structural glass fibre airframe
parts, like doorframes, door stop strips, etc.
Electric soldering iron: for general wiring as well as removing temporary screws.
Files: medium flat, medium and small rat-tail, medium half-round.
Hacksaw blades in holders for cutting in restricted spaces.
Hole saws: 1" to 2" or metric equivalents.
Masks: disposable paper face masks and/or a half-face respirator with suitable filter elements.
Nylon spring clamps: these come in mixed size bags from
hardware stores and you will use them in a multitude of ways. Get 2
or 3 bags plus 3 or 4 big individual clamps.
Ring-open ended spanners: 3/8", 7/16", 1/2" and 7mm
Padding: felt or old blankets for various uses.
Pop rivet gun: hand operated or pneumatic.
Sandpaper: various grades between 80 and 240 grit. Detailed in the Painting task.
Screwdrivers: Phillips: small & #2, medium flat blade.
Socket set: " drive: at the very least 3/8", 7/16" and 1/2" sockets.
Torque wrench: for engine/prop fitting, etc. Check the torque settings in the Technical
Manual that shipped with your kit to ensure you get one with the right range.
Trestles: at least 2 required, preferably 4 at about 800-900mm high with carpet covered tops.
Wet and dry bulb thermometer or calibrated hygrometer for the wall of your workshop.
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Optional tools and equipment

The following tools are not essential, but they will certainly make the job more pleasant:
Air Compressor & Air Gun. You can probably do without this if you plan to contract out your
filling and painting job, but if you intend to prime/fill/paint then you'll definitely need to use the air
gun to clean out crevices and pinholes in the gel coat. If you intend to do all of your own painting
then get a good quality spray gun and a compressor capable of at least 15cfm. You will need to
include a good quality water trap too anywhere that compressors and air tools are sold will be able
to advise you on brands and specifications.
Cordless Screwdriver with various bits (get some spare Phillips #2 bits: those self-tappers are
really hard!)
Dremel Moto-Tool (or similar, cordless and multi speed if possible) used for grinding and drilling
glass fibre in hard-to-get places. Permagrit make some very useful bits for these: the cut off disc
and cylindrical grinding tools can be particularly handy.
Electric or Pneumatic Angle Grinder (4 - 5"), preferably with a vacuum cleaner attachment to
keep dust to a minimum. This is for grinding parts like the trailing edge of the wing above the flaps.
If you can get an adjustable speed one then so much the better. Fit a disc sander backing pad and
use discs between 80 and 240 grit.
Electric or Pneumatic Jig Saw for cutting holes such as the aileron/flap fitting holes in the wing
and other holes in wing/fuselage/empennage.
Electric or Pneumatic Orbital Sander for surfacing filler, preferably with a vacuum cleaner
attachment to keep dust to a minimum.
Industrial Vacuum Cleaner with 'crevice tools' A domestic vacuum may not be up to the task,
and as industrial units are readily available we suggest the purchase of a suitable machine. You will
be surprised how difficult it is to get glass fibre dust out from behind the seats with just a brush! Get
any fittings necessary to connect to your sanders and grinders. We use several of these units in our
factories and the amount of glass fibre dust lying around at any time is minimal. A very worthwhile
investment.
Lock Wire Pliers to put that professional twist on all of your lock wire.
Lock latch
Lock handle
Lock the jaws onto both

ends of your lockwire
To
use: lock the jaws onto both ends of your lockwire using the silver lock handle, then simply pull the
twist handle at the back of the pliers and presto, perfect lockwire!
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and pull back on the twist handle
Pedestal Fans to blow fresh air across work surfaces. We use plenty of these in our factory.
Permagrit-type Shaped Abrasive Tools for shaping/sanding glass fibre parts (try to get a set of
various shapes). Or make your own Sanding Blocks as described further down the page.
Pneumatic tools are great if you have a compressor that can drive them drills, jigsaws, various
sanding tools are widely available. We use plenty of these in our factory too.
Scales for weighing the aircraft: must be capable of weighing up to 150kg. Regular bathroom scales
are fine for this task. A single scale can be used, but these scales are quite reasonably priced (less
than $50 each in Australia currently) and the task is much easier with 3 scales.
Setsquare the long builders type with each side at least 500mm in length.
Silicone Sealer, General Purpose or Roof and Gutter sealer, must suitable for use on metal.
Spade Drill Bits as used in woodwork (pictured at right).
Used to recess the threaded inserts in the ventral fin and the
lower strut fairings.
Straightedge in 2 lengths: a 1 metre builders level type is
good for aligning the flaps to wings and checking the control surface deflections, while a 3 metre
long length of 100mm RHS (rectangular hollow section) aluminium is excellent for checking the
rear of the wing and aligning the horizontal stabiliser: make sure that you buy a straight length with
no dents.
Sanding Blocks - stapling 80 grit emery tape around the ends of a length of straight timber about
600mm long (shown below left) is very useful for achieving straight edges on items such as trailing
edges, flaps, etc. Taping emery tape to a short length of tubing (shown below right) can be useful
for things like the final sizing of the fuel filler body holes in the wing/tank and so on. You will use
plenty of sanding blocks as you progress through your build, and with a little bit of imagination you
can make them in almost any size and shape that you need.
TorqueSeal brand name security sealing lacquer used to show that nuts have been tightened to
safety or to the recommended torque setting and require no further work. Try aircraft parts or
engineering suppliers for this product. Comes in several colours.
Loctite compounds
This brand name compound is considered essential in the construction of your Jabiru.
Purchase the following grades:
Type Use Appearance
242
Thread locker medium strength
262
Thread locker high strength
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Blue liquid
Red liquid

518
Sealant, form-in-place gasket
Red gel
577
Thread sealer medium strength
Yellow paste
620
Thread retainer high strength
Green liquid
7063
Cleaner (can use Acetone in place)
Clear solvent, aerosol applicator
Direction references
In all cases throughout this manual when any reference is made to direction (left, right, front,
forward, rear, aft) it is made relative to the pilots point of view, where the pilot is assumed to be
sitting in the pilots seat facing towards the front of the aircraft.
Lateral means something that it is oriented from side to side in relation to the aircraft.
Longitudinal or Fore and aft means something that it is oriented from the front to the back of
the aircraft.
Preparation
We suggest that you get as much preparation done as possible before starting your build.
Start with your workshop: give it a good clean out and consider upgrading the lighting and power
with plenty of strip lights and extra sockets for power tools. Paint the walls and ceiling a light
colour to provide as light a work area as possible. This will also help if you plan to prepare the
aircraft for painting preparation (filling/primer) and also the topcoat if you feel you are capable of
doing so.
In preparation for storing the vacuum-sealed Build Cards that pack many of the small parts into
convenient groups we suggest that you construct a large wallboard that you can place the Build
Cards on, preferably in numerical order (each Card is numbered) you will find that this is much
easier and more pleasant than sorting through a box or pile of Build Cards!
For items such as fairings and instrumentation prepare as much protected shelf space as you can
find (some shelving under a workbench can be particularly useful in this instance) and also make a
vertical bin in a cooler corner of the workshop to stand long items like elevator, rudder and flaps in
while building the relevant parts of the aircraft. Reserve an out-of-the-way area for windows and
other fragile parts.
In our factory we use large mobile bench/racks that contain all of the parts for an aircraft and that
rack stays with that aircraft all the way through production.
If you're going to do any painting, try to keep equipment and parts off the floor as much as possible
so that you can sweep/vacuum/hose the place out thoroughly in order to minimise dust before you
start any painting.
Get all of the tools and equipment on the list that starts on the next page.
Read this manual from start to finish to familiarise yourself with the work to come.
Consider getting extra insurance cover for your kit during the build to cover any risks
(fire/damage/theft, etc). Most aircraft insurers will quote for this and many builders consider that
the cost is worth it for the peace of mind that it brings.
Cold climate considerations

If you are building in a colder climate/during winter, some extra heating and insulation in your
workshop will help, as well as keeping the humidity levels up to acceptable levels for epoxy work.
Clearly, all workshops are different and your build inspector will advise.
12 of 377

Get a large roll of bubble wrap packaging sheet (1.5m x 15m) from your local garden centre or
packaging company (usually cheaper). In low temperature environments you will use this to create
an insulated tunnel by draping it over the work you've bonded/flocked and, with the careful
application of warm air from a fan heater, you'll easily achieve the 24C (or so) you need for a good
epoxy cure.
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General>Glossary
General>Glossary
Here is a glossary of common composite terms that are used throughout this manual:
Term
Description
5-Minute Araldite
Quick setting brand name epoxy glue.
AT133 (not supplied)
Fibreglass cloth with wide unidirectional strands, which provides

great strength for weight. It is used in the fabrication of the spar and
undercarriage legs.
AT244
This is a standard bi-directional cloth that is used extensively for

plates and other flat surfaces.
AT303
This is a twill weaved cloth that can be moulded into curves and is
therefore used for wing and fuselage skins, cowls, etc.
AT312
A 2 wide glass tape.
AT313
This 3 wide glass tape is used to joint other glass structures.

The edges of glass tape do not fray like glass cloth.
Body Filler (bog)
Lightweight automotive filler used in paint preparation.
Clecoes
Patented reusable fasteners used to align parts prior to flocking and

fixing with pop-rivets. Store in Acetone to keep them clean.
Coremat
Lightweight core material used to make sandwich panels.
Flock
Low-grade short fibre reinforcement for resin. Also used as a verb: to

flock something into place for example.
Gelcoat
White polyester resin film used on exterior of supplied fibreglass parts

to provide a smooth finish.
Glass
Fibreglass cloth. Also describes the process of wetting fibreglass cloth

into a mould or onto parts: to glass something into place.
Joggle
Recessed step where 2 surfaces are to be flush joined.

An example is the joggle around the windscreen and windows.
Lay-Up
Resin wetted fibreglass cloth laid into a mould or onto parts.
LC 3600 Epoxy
Epoxy system used on all structural parts.
LC 3600 Hardener
part of LC 3600 epoxy.
LC 3600 Resin
part of LC 3600 epoxy.
Peel Cloth
To provide a surface that requires minimal preparation before

bonding, polyester cloth is included as the top layer of a glass lay-up.
The cloth is simply peeled off and the surface beneath is ready for
bonding, hence the name.
Polyester Resin
Resin system that uses a catalyst to cure. Does not provide good
structural properties like epoxies, and for this reason is not used on
any structural parts in your Jabiru.
Q-Cells (not supplied)
Inorganic micro-spheres mixed with resin and used as a lightweight

filler, usually used in paint preparation.
Resin
Generic term used to refer to the LC3600 epoxy/resin mix.
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General>Registration and certification
General>Registration and certification

The accuracy of records and correct administrative procedures are just as important as the quality of
workmanship in your project.
By now you should have established the regulations under which you will build your aircraft.
In Australia you have two options:
1. Experimental Rule
2. CAO 95.55 Amateur-built Ultralight Category
Option 1 is administered by the Sports Aircraft Association of Australia (SAAA)
Option 2 is administered by Recreational Aviation Australia (RAA)
Aircraft built under Option 1 can only be General Aviation (VH-) registered and must carry
EXPERIMENTAL markings.
Aircraft built under Option 2 can only be registered with the RAA and must carry 19 series
registration numbers.
You should consult the appropriate administrative association on their requirements for
documentation, inspections and project administration.
Contact details are:
Sports Aircraft Association of Australia (SAAA)

PO Box 169
Clifton Hill, VIC 3068
Phone: 03 9482 4716
Fax: 03 9482 3936
Recreational Aviation Australia (RAA)
PO Box 1265
Fyshwick, ACT, 2609
Phone: 02 6280 4700
Fax: 02 6280 4775
Internationally you will need to establish the requirements for building your aircraft under the
appropriate regulations governing amateur aircraft building in your particular country.
Your local Jabiru distributor can give you guidance on who to consult and how your project should
be administered.
In all cases, however, it is your responsibility as an amateur builder to ensure that you are fully
informed of the requirements and to ensure that you meet these requirements.
General>Reference documentation
The FAA Advisory Circular Aircraft Inspection, Repair and Alterations (publication AC 43.132A, ISBN: 1560270985) is an excellent reference work that covers all aspects of aircraft building
and repair, and it can be downloaded or purchased online from several suppliers of technical
publications.
The FAA Advisory Circular Amateur-Built Aircraft and Ultralight Flight Testing Handbook
(publication AC 90-89A), addresses the topic in considerable detail and which may be obtained
here: www.faa.gov/library/manuals/.
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General>Unpacking and support
General>Unpacking and support

Unpack the wing box first and inspect the contents: there should be two wings. Inspect for transit
damage then close the box and store, as the wings will not be required for some time.
Unpacking the main box is a much more complicated task as there are hundreds of parts and they all
have to be inspected for transit damage.
The first thing you should do is locate your packing list which is in with all the individual
components that have been packed with your fuselage. This list will show you all of the
components that have been packed, each of which should correspond with the specific type &
model of aircraft that you have ordered.
Your kit was triple checked when it was packed in our factory, but PLEASE check off every
single part as you unpack it: mark off every item so that YOU can be sure that you have received
them.
You could also make a note of where you plan to store each part or group of parts.
Please notify Jabiru of any missing parts within 3 months of the receipt of your kit.
At this stage it would be a good idea to store your instruments in a low humidity environment.
Store your propeller in a horizontal position.
Treat all the steel components with an anticorrosive substance.
Fibreglass components will soften and change shape when heat is applied, so keep this in mind
when deciding where to store your parts. For example: storing your flaps between the rafters in the
heat of the roof is a very bad idea if you live in a hot sunny climate.
Here at Jabiru we pride ourselves on our after-market support, and if you have any difficulties
through the building process we would be happy to help you to resolve them.
We provide product support via email, phone or fax.
Start by checking the resources on our web site at: www.jabiru.net.au and contact us:
Email: [email protected] (please send us a fax or call if no read receipt is received)
Phone: +61 (0)7 4155 1778 - (8.30 am-4.30pm AEST (Australian Eastern Standard Time))
Fax:
+61 (0)7 4155 2669
Spare Parts Department
Email: [email protected]
Phone: +61 (0)7 4155 2917 - (8.30 am-4.00 pm AEST)
Service Department
Email: [email protected]
Phone: +61 (0)7 4155 2811 - (8.30 am-4.00 pm AEST)
Postal Address:
Jabiru Aircraft Pty. Ltd.
P.O. Box 5792
Bundaberg West QLD 4670
AUSTRALIA
Location:
Airport Drive
Bundaberg West QLD 4670
AUSTRALIA
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General>Composite standard procedures
Composite introduction
Composite construction techniques may seem mystifying to those who have never been involved
with composites before but they are straightforward and require only a few basic procedures.
Composite surface preparation

For bonding composite-to-composite or composite-to-metal the surfaces must be prepared in the
following ways:
With peel cloth
Where it is known that a surface will be bonded to another
surface, peel cloth is usually incorporated in the lay-up
under the gelcoat to provide a bare, clean virgin surface
to aid the builder.
Typically peel cloth is included in the lay-up for all
structural components: vertical fin, horizontal stabiliser,
flaps, aileron pre-molds, etc.
To prepare the surface for bonding simply cut at the edge
of the peel cloth with a knife and peel the peel cloth off as
shown in the photo at right, then lightly roughen the
surface by sanding to provide a good key for the epoxy to
bond to.
Bare
surface
Peel
cloth
Gelcoat
Peel cloth is typically red in colour as shown, although other colours are sometimes used.
If you are in any doubt about the area that you intend to glass to, sand away the gelcoat and if you
see anything that is not bare fibreglass then do not glass to it until it is bare fibreglass.
NEVER, NEVER, NEVER glass over the top of peel cloth!

Without peel cloth
Where there is no peel cloth for a bonding surface the surface must be free of gelcoat, grease and
contaminates and must be sanded lightly to provide a good key for the epoxy to bond to.
Metal
If it is necessary to bond to composite to metal, the metal surface must be degreased and roughly
sanded to provide a good key for the epoxy to bond to.
Summary
Careful surface preparation is extremely important when working with composites: all surfaces to
be bonded must be absolutely clean and must be roughened in order to provide a good key for the
epoxy to bond to.
17 of 377

Epoxy measuring and mixing

Quality assurance and record keeping
Before starting the requirements for record keeping with regard to composites should be check with
your local administering organization. For example in Australia it might be the SAAA or RAAus. A
small sample of each mix or resin should be kept and inspected after 24 hours to ensure correct
curing. The cured resin should be hard and scratch-able.
A good sampling device is a small plastic medicine measure cup: wipe the interior of the cup with
wax before each use to facilitate easy removal of the sample. Samples should not exceed 10mm in
depth otherwise the heat generated during curing may affect the result.
Measuring epoxy
The Epoxy system used for the production of Jabiru Aircraft is LC3600, which is mixed in a 3:1
ratio, which means that 3 parts of resin are mixed with 1 part of hardener.
The best method for ensuring accurate measuring is to use a digital kitchen scale as described in the
section General>Required tools and equipment which is what we do in our factory.
Curing times
The LC3600 is a room temperature (24 Celsius minimum) curing epoxy so it requires no elevated
temperature curing unless you are working in a particularly cold climate or perhaps during winter
months. The recommended curing time depends upon temperature but a minimum of 24 hours is
good rule of thumb. If the daytime temperature is below 15C it would be a good idea use a heater
to aid curing.
The epoxy resin used in the jabiru is not adversely affected by humidity, however it is best to avoid
using it when the relative humidity is above 95%.
Mixing epoxy
When mixing the epoxy the mixture will initially appear 'cloudy' then as you mix the mixture will
become clearer but 'stringy', keep mixing and finally you'll be left with a clear mixture with no sign
of being 'stringy'.
Note: The smaller the mix the larger the possibility for errors, so consider combining several tasks
and doing a larger mix wherever possible.
Mixing in flock
As a general rule, mix flock so you can take a sample with a mixing stick turn it over & it does not
dribble off. If it is a little too runny, add more fibre flock.
Mixing epoxy and milled cotton flock together creates an excellent filler which is used in many
places to form edges and fillets. The mixture is referred to as 'flock' but is often used as a verb, for
example: "flock the bracket into the position shown...
Mixing 5-minute Araldite
5-minute Araldite is a fast curing epoxy and is very useful for bonding non-structural items into
place. If you find that your Araldite wont cure it is usually because 2 lots of the same part were
used instead of 1 each. We have all made that mistake at least once.
Mixing 5-min Araldite with cotton flock creates a good paste for 'bedding' parts into place.
Same rule applies as for mixing Epoxy.
18 of 377

Composite general
Glassing procedure
Any lay-up of glass fibre cloth should follow this general procedure: make a mix of resin and brush
a coat of resin onto the entire area to be glassed, then lay the first piece of cloth on and carefully
brush it into place, adding small amounts of resin to the brush as required to wet the cloth, until the
resin has completely saturated the cloth: the cloth seems to change colour slightly from a silvery
white to a colour close to that of the surrounding surface when it is saturated with resin.
Once the first layer of cloth has been successfully brushed on, apply the second layer and brush that
on in the same manner, adding small amounts of resin as required to wet the cloth.
Repeat for as many layers of cloth as the task requires.
Peel cloth
Peel cloth is supplied in the bags of glass fibre cloth in the kit. The intended use for this peel cloth is
to brush it onto the top of a layed-up area of glass fibre cloth.
The peel cloth will smooth out the finished surface by allowing the resin to level off across the
weave of the glass fibre cloth and provide a good surface for painting preparation.
Trimming edges of glass fibre cloth
There are two times for trimming edges, these are before curing while the epoxy is 'tacky'
(approximately 2 to 4 hours after mixing) and when the structure is fully cured.
Various tools are used for trimming edges but for thin or 'tacky' lay-ups a sharp utility knife may be
used. Thicker cured edges may require a jigsaw and a rough file to trim. A heat gun may be used to
soften cured edges so that a utility knife can trim them.
Inspection and evaluation
Each lay-up will require an inspection and evaluation after curing.
Inspect for soft or wet patches after a reasonable time for curing has been allowed, as such wet or
soft areas may indicated an improperly mixed batch of epoxy.
Care must be taken to check that areas have actually been bonded together and that there are no air
gaps or bubbles between the layers of glass, especially in curves/radii.
Removing screws
Self-tapping screws are used to hold parts in place while epoxy is curing but once the epoxy has
cured it can be difficult to remove the screws.
Use your soldering iron to heat the head of the screw and the composite around the screw will
soften allowing the screw to be removed easily.
This is also a handy trick to use if any bushes are not perfectly in line and need a slight adjust.
Clecoes
Clecoes are used to hold hinges while they are being flocked into place prior to riveting and so they
must be free of oil and grease that could contaminate the surface to be bonded, and they will
inevitably get flock onto them during the bonding or flocking process.
To prevent these problems, keep your Clecoe fasteners stored in a sealed tin of Acetone to ensure
that they remain clean and ready for use the Acetone will dry off them in seconds.
19 of 377

General>Aircraft grade bolts and lock nuts

General
All bolts 3/16 or larger in diameter that have been supplied with your Jabiru kit are Aircraft grade
bolts.
Under no circumstances must any bolts other than Aircraft grade bolts be used on your Jabiru.
Aircraft grade bolts are significantly stronger than regular commercial grade bolts and have features
such as corrosion resistance that have been designed specifically for aircraft use.
Aircraft grade bolts are quite different in appearance to regular commercial grade bolts in several
ways: Aircraft grade bolts are usually gold or silver in colour; they have a relatively short thread
length and a longer plain shank or grip length.
In almost all cases the supplied and specified bolts will be the correct length for each task, but kit
builders need to be aware of the correct method of determining and/or checking the correct length
of bolts and also the correct method of tightening lock nuts.
The parts of a bolt
There are 2 variable lengths to an Aircraft grade
bolt: the overall length, usually just referred to as
the length, and the grip length, which is the length
of the plain shank of the bolt, which is measured
from underneath the head of the bolt to the
beginning of the threads (see the drawing at right).
The thread length is generally fixed in relation to
the diameter of the bolt.
Bolt identification
Aircraft bolts supplied with your Jabiru kit are identified in this Manual and in Jabiru drawings by
the prefix letters AN, the diameter (measured in 1/16 increments) and the length (measured in
1/8 increments) of the bolt and a suffix, which is usually A.
Examples of bolt identifiers would be: AN3-6A, AN4-14A, AN3-22A, AN4-72 and so on.
For example, for an AN3-5A bolt:
AN means the bolt has been manufactured to Aircraft (Military) standards
3 the diameter of the bolt in 1/16" increments: (3/16 in this case)
-5 (the dash number) the length of the bolt in 1/8" increments: (5/8 in this case)
A not drilled for a lock pin. Bolts with no A here are drilled for a lock pin
If the dash number defining the length of the bolt has two digits, the first digit is the length in whole
inches and the second number is the length in additional 1/8" increments. This can become complex
and if you feel the need to delve deeply into the subject you can locate an AN bolt chart online or
purchase an AN bolt gauge from suppliers of Aircraft grade fasteners.
The last example given above (AN4-72) there is no A suffix, which indicates that the threaded
end has been drilled during manufacture for a lock pin while the other 3 examples all have the
suffix A and do not have provision for a lock pin.
20 of 377

Determining and checking bolt lengths
A bolt must be long enough to ensure that no more than one thread will be inside the bolt hole when
the bolt is fitted. This grip length should be equal to the material thickness that is being held by the
bolt.
What this means is that the correct bolt length must be used in every case, and if a nut cannot be
tightened to safety then measures must be taken to correct the length, either by packing with
washers (an absolute maximum of 3 flat washers may be used for packing, starting with the
required washer under the nut, then one washer under the head of the bolt and finally, if needed,
another washer under the nut) or using a different length bolt.
Lock nuts
All bolted components on your Jabiru aircraft are held in place with lock nuts, either a Nyloc type
fibre lock nut for most uses or a steel lock nut for hot areas such as in the engine bay.
It is important to understand the procedure for tightening Aircraft lock nuts: each nut must be fitted
with a flat washer under it and tightened to safety, which is defined as having a minimum of 1
threads and a maximum of 3 threads showing beyond the end of the lock nut.
!!WRONG!!
Less than 1
Correct
!!WRONG!!
More than 3
This is considered critical for load-bearing bolts and good practise for all other bolts.
Any less than 1 threads showing beyond the end of the lock nut means a risk of the nut not
locking correctly while any more than 3 threads showing beyond the end of the lock nut could mean
that the lock nut is bottoming on the thread and there is a risk overstressing the bolt and nut and/or
not gripping the joined material correctly. Examples of each case are shown above.
In general all nuts should be fitted so that they face outward so that they can be easily inspected.
Nuts inside the cabin should face out and towards the pilot if at all possible.
Nuts that have been tightened to safety should be marked with a dab of TorqueSeal.
21 of 377

General>Rod ends
General>Rod ends
It can truthfully be said that the rod ends are the sole connection between the pilot and the control
surfaces of your Jabiru.
A very important item of hardware indeed!
Given the vital role that each and every rod end performs in your Jabiru it is equally important that
you familiarise yourself with the correct method of connecting rod ends.
There are 2 parts to connecting a rod end: the cable connection and the drive connection.
Cable connection
All cable rod ends are
Jam nut
female rod ends, which is
say that the cable (the
male end) is screwed into
rod end (the female end)
cable length can be
adjusted by screwing the
end further onto the cable
further off the cable, and
Safety
hole
then the cable is fixed to
Cable
rod end by means of a
nut on the cable that locks the threads from turning.
to
Rod end
the
the
rod
or
Spherical
bush
the
jam
There must be enough cable thread length in the rod end to provide strength and security, and each
female rod end has a small hole, called the safety hole, part-way along one side through which the
cable threads must be visible if you cannot see the cable threads through the safety hole, then you
must not fly the aircraft until adjustments have been made so that the cable threads are visible
through the safety hole.
This is of the utmost importance and cannot be overstated!
Drive connection
Most of the rod ends on your Jabiru are driven by a 3/16 bolt through the spherical bush, and they
must be connected in the following manner: between the rod end and the drive lever, fit one 3/16
flat washer (or more in the case of the flap drive arms details in the Flaps task).
Between the rod end and the retaining nut (or the head of the bolt, depending on which way the bolt
is fitted) fit one flat washer (one size larger than the bolt).
The purpose of this larger flat
washer is that should the spherical
bush in the rod end fail, the large
washer will provide a margin of
safety by preventing the rod end
from leaving the drive bolt. In the
photo at right you can see the way
the washers are fitted.
that
In practical terms, should a rod end fail internally in flight the rod end will still remain connected to
the drive bolt and the control will continue to function.
Thus the correct fitting of the flat washers to rod ends is extremely important.
22 of 377

General>Health and safety
General>Health and safety

Working with composites is no different than working with other chemicals and flammable
materials, and caution and common sense should prevail at all times.
NO SMOKING
Do not smoke or have any exposed flames near your kit or resin storage area.
Epoxy will burn.
Warning: the fumes from burning epoxy are extremely toxic!

Epoxy
Long term exposure to epoxy can lead to an 'epoxy allergy' so suitable safety precautions should be
taken as follows:
Contact
Do not expose your skin to epoxy. Neoprene, latex or nitrile rubber gloves (with pure cotton gloves
worn underneath to wick away sweat from your hands) and protective (industrial) clothing should
be worn when handling epoxies.
If epoxy is spilt onto the skin, wash off with warm water and soap immediately.
Barrier cream can help the skin to avoid becoming sensitised. Note: if barrier cream is used take
care to keep it away from any surfaces to be bonded by wearing gloves the cream could
contaminate and weaken the join so keep the cream inside your disposable gloves at all times.
Fresh Air
Epoxy fumes should not be inhaled. Blow fresh air across the work face at all times.
The use of an external fresh air source and facemask is strongly recommended along with the use of
a fan for blowing the epoxy fumes away. In our factory we use several industrial pedestal fans to
blow fresh air across the work surfaces at all times.
Dust
Always wear a dust mask when sanding or cutting composites. Cutting and sanding composites
creates a lot of dust and the extremely fine glass dust should not be inhaled.
A half-face respirator with suitable filters is highly recommended and should be worn at all times
when sanding fibreglass parts.
Ok lets get building!
23 of 377

Pre-Paint>Fuselage>Fit ventral fin and trim horn

Objectives of this task:
To fit the ventral fin, trim horn and cut the related rear fuselage penetrations. This task is carried out
while the fuselage is inverted and supported on trestles.
Materials required:
Epoxy resin and flock, 5-minute Araldite
Hardware box #4
Cut the cable and tube slots
The cable and tube slots are marked on the underside of the fuselage with marker pen.
Cut out the marked slots on the fuselage centreline. Each slot should be drilled at each end to about
and then the holes can be joined by cutting along the lines with a jigsaw.
We
fin
150mm
d
that
Elevator cable
mounting bolts
wid
eni
ng
the
ele
vat
or
Trim horn
DO NOT
cab
CUT OUT!
le
slot
Completed ventral fin area showing slots, trim horn and ventral fin retaining nuts
(th
e
slot at the very rear of the fuselage) as shown in the photo above can provide useful access later in
the build.
Do not cut out the line marker for the trim horn! The trim horn marking can be transferred through
the peel cloth by scribing around the marks with a sharp knife, cutting just deep enough that the cut
can be seen once the peel cloth has been removed.
File and sand all cutouts to a good finish. Remove the peel cloth from the ventral fin area (rear
underside) of the fuselage.
Check the elevator cable mounting holes: test fit the horizontal stabiliser to the fuselage and push it
all the way forward. Hold a set square against the rear of the horizontal stabiliser and along the
fuselage and measure exactly 150mm forward from the rear of the stabiliser (and not the fuselage)
as shown in cyan in the photo above the 2 holes should be on that line.
If they are not, fill the existing holes with flock and redrill them so that they are exactly 150mm
from the rear of the stabiliser. This dimension will become critical later when you adjust the
elevator travel so take the opportunity to check it (and adjust it if needed) now.
Remove the horizontal stabiliser and store carefully until required.
24 of 377

Fit the ventral fin
Use a chalk line to mark the fore and aft centreline of the fuselage.
Lay the ventral fin on the rear of the fuselage and seat it so that it matches the curve of the fuselage,
then check that the fin is centred at the front and the rear and tape it in place. Drill 3/16 holes
though each of the marked locations in the ventral fin mounting lip and through the fuselage.
Remove the ventral fin then enlarge the holes in the fuselage to 13/64 and use a fluted wood drill
bit (pictured right) to recess the hole so that the lip of the insert sits flush with the surface and then
tap each hole to a 1/4 UNC thread. Use a screw and spacer (shown
above right) as a tool to place each insert. Before fitting the insert
put a single drop of super-glue onto the outside thread and then
screw it into place.
Fit the trim horn
Sand away any remaining gel coat and roughness from around the trim horn mounting area. The
trim horn is slightly offset from the fuselage centreline so it will be necessary to sand the foot of the
trim horn so that it will sit completely upright when it is mounted. Sand the sides of the trim horn at
the same time so that the glass fibre cloth will bond correctly.
Mix up a small batch of 5-minute Araldite and flock and
coat the foot of the trim horn, then place it on the marked
line and use a length of tape to hold it upright. Put
masking tape over the threaded inserts nearest to the trim
horn to prevent flock getting into the threads.
75 x 170
100 x 170
When the Araldite/flock mix has cured apply a small amount of resin and flock to make a smooth
radius at the foot of the trim horn and then apply 3 layers of AF303 glass fibre cloth to each side of
the trim horn. The bag labelled Trim Horn contains 2 sizes of glass fibre cloth: the larger pieces
(100 x 170) go on the side nearest the fuselage centreline. Leave to cure overnight. The next day
any excess cloth can be trimmed away with a sharp knife.
25 of 377

Finish the ventral fin
Resin
Drain
holes
Cut out
Sand the inside bottom rear quarter of the ventral fin. Mix around 200 grams of polyester resin and
add a few drops of hardener (take care not to use too much hardener or there may be heat issues as
it cures) and pour into the bottom of the ventral fin then prop the fin up at a 45 angle while it cures.
Once the resin has cured drill a 12.5mm hole through at the marked location this will be your rear
tie down point. Drill 2 drain holes, one at the front corner and one at the rear just in front of the
resin.
Cut out the marked area at the top rear this is where the elevator drive arm will travel.
Store the ventral fin for later final fitting and painting.
This completes the Pre-Paint>Fuselage>Fit ventral fin and trim horn task.
26 of 377

Pre-Paint>Fuselage>Prepare the fuselage

Once the Fit ventral fin and trim horn task has been completed the
fuselage can be turned upright and the remaining penetrations made.
This allows the bulk (but not all) of the mess to be made early in the
build.
In the factory we place the fuselage in a jig at this stage, however you
can achieve much the same result by placing a sawhorse or a similar
platform or trestle under the cabin and a higher trestle under the
empennage. Cover both of these items with some padding to minimise
scratching the fuselage.
Large holes should be started with a pilot hole first to accurately place
the hole and then be drilled out with a hole saw.
Slots should have each end drilled out first and then mark and use a
jigsaw to join the holes.
Rectangular holes should have a hole drilled at each corner and then be marked and cut from hole to
hole with a jigsaw. This practise will ensure accurate cuts with no sharply angular corners or
irregular edges.
Tools and materials required:
Orbital sander and hand sanding blocks
Power drill with bits, 30mm and 2 hole saws
Jigsaw
Epoxy resin and flock
Q-Cell filler
5-minute Araldite
Sand the fuselage
Start by using your orbital sander to take any rough edges away: the moulding process can leave
sharp edges and the occasional few glass fibre prickles, so take a bit of time now and remove all of
these potential hand hazards before starting work. Fibreglass cuts are painful and you can do a lot to
avoid them by careful preparation at this early point in the build.
Think of it as an investment in your comfortable building future.
Run your orbital sander lightly across every internal surface: around the door frames, seats, console,
windows, etc and anywhere else that looks even slightly rough. There is no need to sand heavily;
just a light scuff is all that is required. Use a few hand sanding blocks for any hard-to-get-at places.
Remove peel cloth
Remove the peel cloth from the vertical fin stub and around the rear of the empennage generally,
including around the horizontal stabiliser opening.
Lightly sand around the edges of the areas under the peel cloth to remove any peel cloth threads that
remain.
27 of 377

Vertical fin stub
The rudder cable passes from the empennage and through the fin stub as does the static line, VHF
antenna cabling and strobe wiring (if you elect to have a tail strobe). All these items require access
into and though the fin stub.
15mm
180mm
70mm
140mm
Start by marking and cutting the rudder cable slot on the right-hand side of the fin stub: measuring
from the rear of the stub the slot starts at 180mm and is 70mm wide.
The bottom of the slot is located 15mm up from the base of the fin stub. Drill each end of the slot to
15mm and jigsaw the slot out, and then sand any rough edges away. Refer to the photo above left
for detail.
The 30mm access hole on the left-hand side of the fin stub has its centre located at 140mm from the
rear of the stub. Refer to the photo above right for detail.
The 30mm access hole in the top of the fin stub has
its centre located at 30mm from the rear of the
stub. Refer to the photo at right.
30mm
28 of 377

Cabin top penetrations
30mm
45mm
210mm
45mm
12mm
Mark a centreline between the bolt holes in the front and rear wing attach lugs: this will be the
height of the centre of the fuel gauge opening.
Now double check the measurement marked
210mm in the photos above and at right: measure
in the wing root from the front wing lug back to the
210mm
centre of the gauge as shown at right, then measure
on the fuselage from the inside (not the outside) of
the inner front wing attach lug (see photo above) the exact same distance (which should be very
close to 210mm) then mark and drill the pilot hole for the fuel gauge opening. Recheck your
measurements and then use a 2 hole saw to cut the gauge hole: drill a pilot hole first.
Measure forward 45mm from the front wing attach lug and drill a 10mm hole for the stall warning
tube on the left side of the fuselage only.
To mark the fuel system connector slot, draw a line down 12mm from the back of the rearmost
wing lug and another line 45mm below the bottom of the rearmost wing lug, and then mark the slot
at 50mm wide and 10mm high. Drill both ends to 10mm and use a jigsaw to cut between the holes.
File the top and bottom of the slot to a smooth and square finish.
Cabin air vents
Cut a 60 x 44mm opening on each side of the
lower forward fuselage.
The bottom of the opening should be 80mm above
the bottom of the door opening and the fore and aft
location should be centred on a vertical line drawn
down from the rear of the upper cowl joggle, all as
shown at right:
Corners of the opening should be rounded to suit
the vent door the door should fit towards the
front of opening with a 3mm gap at the rear to
allow for the hinge action.
44mm
60mm
80mm
The air vent door surround can be flocked into

place inside the fuselage as shown at right, with the
hinge arm positioned at the rear of each hole and
using the door to aid the positioning.
29 of 377

Fit the header tank enclosure
The fuel header tank sits behind the right-hand seat in a sealable enclosure and an additional rib is
fitted to the left-hand floor rib so that the lid that seals the enclosure also functions as a luggage
shelf behind the seats.
RH floor rib
Header tank
enclosure
Cable slot
Longitudinal rib
Right-angle section
Rear rib
LH floor rib
Support rib
Place the header tank enclosure on the floor behind the right-hand seat so that it fits snugly between
the longitudinal rib and the right-hand floor rib as shown above right and check that the rear lip of
the enclosure sits down on the rear rib. Drill the 3 pilot holes in the enclosure (arrowed below right)
at 3/32 through the fuselage floor and then remove the enclosure.
The drain from the enclosure will be through the
quick-drain fitting hole.
Mix a batch of resin, stir in Q-Cell to make a firm
mix and apply the Q-Cell to the cabin floor as
shown in blue at right, including a circle with a
clear centre of about 1 around the quick drain
hole. Apply the Q-Cell thicker towards the rear.
Refit the enclosure and secure with 3 x 8G selftapping screws and washers: tighten the quick drain
(front) screw so that the enclosure sits firmly
against the floor but only tighten the rear screws
enough to bed the enclosure firmly into the Q-Cell
mix.
Fuel pump
pilot holes
Support rib
Quick drain
pilot hole
Cut the front of the support rib off so that it runs straight down from the rear of the seat to the floor,
then pre-fit it inside the left-hand floor rib and make sure that the top of the support rib is level with
rear rib and the cross beam behind the seats. Araldite a length of split tube along the front edge of
the rib to protect fuel lines and cabling that will later pass in front of it.
Mix some resin and flock and fit the support rib into place and then fit the long right-angle section
of glass fibre to the cross beam behind the seats as shown top right and above. Make sure that the
top front of the enclosure is sealed and leave to cure overnight.
Next day trim the ends of the right-angle section to size, remove the 8G screws (heat if required)
then drill the quick drain hole out to 1 1/8 and the fuel pump holes to 3/16.
Use TLR rivets to fix the tie-down lugs to the floor ribs as shown on the drawing overleaf.
30 of 377

This completes the Pre-Paint>Fuselage>Prepare the fuselage task.

31 of 377

Pre-Paint>Fuselage>Undercarriage>Assemble main wheels

In this task you will assemble the main wheels and tyres and fit the brake discs.
Materials required:
Cards # 21JT Main wheels
Talcum powder for fitting the inner tube
Assemble the main wheels
Use a press or a vise to press a bearing (#PB0029N-1) into
half of the wheel rim use a socket with a slightly smaller
diameter than the outer race of the bearing to press them
each
Both the inner and outer bearings should lie flush with the
and outer wheel rims respectively as shown in the picture
right.
inner
to the
in.
Do not press on the inner race the bearing is not

designed to take pressure in that direction.
Sprinkle some talcum powder inside the tyre and insert the inner tube. Slightly inflate the inner tube
to prevent it becoming pinched then fit tyre and tube over the inner wheel rim and fit the outer
wheel rim to the inner wheel rim with the inner tube inflation valve facing the outer wheel rim.
Make sure the bolt holes between each wheel rim half are aligned and place the brake disc mount on
the inner wheel rim such that the bolt holes are also aligned with those of both wheel rim halves.
Bolt the brake disc mount, inner wheel rim and outer wheel rim with five AN4-17A bolts; placing
1/4 flat washers (AN960-416) under both the bolt and nyloc nut. The bolts are inserted through the
brake disc mount. Before tightening the nuts, make sure that the inner tube is not being pinched, this
is done by rotating the tyre and tube holding the wheel still.
Fit the inner tube inflation valve through the hole in the outer wheel rim and then tighten the five
bolts to secure the wheel assembly. Inflate the inner tube to a pressure of 45psi the tyre will pop
out to the final seated position on the rims so keep fingers away while inflating.
Left wheel
Right wheel
Fit the brake disc to each wheel. It is important that each disc is fitted in the correct direction of
rotation as shown in the photos on the preceding page and in the drawing below. Fit each of the four
32 of 377

AN3-7A bolts though from the disc towards the wheel and secure with AN960-10 (3/16) flat
washers under each bolt head and Nyloc nut. Tighten firmly. Use chalk to mark each wheel as being
either a left or a right wheel.
It is useful to refer to the drawing on the following page during the main wheel assembly.
33 of 377

This completes the Pre-Paint>Fuselage>Undercarriage>Assemble main wheels task.
34 of 377

Pre-Paint>Fuselage>Undercarriage>Assemble main gear

In this task you will assemble the main undercarriage legs, which includes fitting the axles, disc
brakes and wheels.
Materials required:
Cards # 8J Brakes and 21J Main wheels
Rubber grease for assembly of disc brake pistons
Assemble spat brackets
Fit the retained nuts to the spat mounting brackets using
countersunk 3/32 rivets. There are 4 retained nuts
(arrowed) on each bracket. Countersink the actual screw
holes where the spat will be fitted: the countersinks will
help to guide the screws into the holes when fitting the
spats.
Fit the stub axles, backing plates and Spat brackets
Slide the stub axle washer over the stub
then place four bolts with thin washers
(AN960-516L) though the corresponding
holes on the stub axle, the mounting plate
finally the undercarriage gear leg. The two
longer bolts (AN5-24A) must be positioned
though the top two holes, whilst the shorter
(AN5-21A) reside in the bottom two holes.
Ensure that the hole on the outboard end of
stub axle (indicated by a green arrow) is
aligned vertically.
Place the spacer plate on the back over the
longer bolts followed by the newly
assembled spat bracket. The capture nuts on
spat bracket must face outboard (towards
stub axle). The hole in the spat bracket is
placed over the front bolt, while the curved
resides over the rear bolt.
Front of aircraft
axle,
and
AN5-24A bolts
bolts
the
AN5-21A bolts
two
the
the
Front of aircraft
slot
Fix the assembly in place with washers and

nyloc nuts. A penny washer is used to cover
slot on the spat bracket. The purpose of the
is to allow adjustment when it comes time
the wheel spat.
the
slot
to fit
At this stage it is of benefit to mark the legs as left or right with a permanent marker pen. This may
save confusion during the fitting of the main undercarriage gear. One should also note that at this
stage the axles will likely not be correctly aligned on the undercarriage legs. This issue is dealt with
in a later section (Pre-Paint>Fuselage>Wheel alignment).
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Assemble the brake calipers
In this step you will assemble the hydraulic disc brake calipers.
Cleanliness is essential when working with hydraulic brake parts, so clean your working area and
your hands thoroughly before starting this step.
Use compressed air to clean any dust and dirt from the inside of the brake calipers and pistons.
Apply rubber grease to the O-rings and fit one to each piston, then apply a smear of rubber grease to
the inside of the caliper and fit both pistons into each caliper: press the pistons gently into the
caliper with the cupped side of the pistons facing outwards.
Bleed nipple
Thread and tighten a bleed nipple into the

appropriate fitting on the caliper and push a
blanking plug the other fitting as shown at left
the brake lines will be fitted later in PostPaint and the blanking plug will keep the
caliper sealed until then.
Wash any brake fluid off your hands with soap
and water it can irritate sensitive skin.
Blanketing plug
Refer to the drawing on the next page for an
overview of the brake system.
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Assemble the brake and wheel
First place the break caliper on the inboard side of the
plate and slide both caliper sleeves through the holes
mount plate and calliper. The bleed and brake-line
on the caliper should face upwards. Ensure that you fit
correct caliper, since the left and right parts are
different. The picture on the right identifies them.
mount
in the
fittings
the
Left caliper
Right caliper
Now you can place the inboard brake pad over the
caliper
sleeves. Slide AN4-15A bolts into each sleeve with lock tabs under each bolt head, place thin 1/4
plain washers (AN960-416L) on the end of each bolt. Thread the outer brake pad onto the bottom
bolt and leave it hanging down as pictured below on the right.
Sleeve
Lock tab
Inner brake pad

AN4-15A bolt
Caliper
Outer brake pad
Before installing the wheels, slide the stub axle spacer (circled in yellow above) onto the shaft, the
flat face should be facing outboard to provide the wheel bearings with a nice square face to sit
against. Now you can slide the wheel onto the stub axle. Slide it on all the way until the brake disc
rests against the inner brake pad. Secure the wheel with the axle extension, fitting the AN3-12A bolt
from the top with a washer and nyloc nut at the bottom.
Now swing the outer brake pad around and thread
the top bolt into it. Tighten both bolts. Check that
the wheel and disk runs smoothly and is not
impeded by the brake pads. The distance between
the disk and outer pad should be about 1
millimetre.
Fold the large

tab onto caliper
The picture to the left shows the completed brake

assembly of the right hand undercarriage gear.
The last step is to fold one of the small lock tab
leaves up against the bolt head and the large tab
onto the machined caliper housing.
Fold one of two small
tabs up onto bolt head
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It is useful to refer to the drawings on the

following pages during main undercarriage gear
assembly.

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This completes the Pre-Paint>Fuselage>Undercarriage>Assemble main gear task.

40 of 377

Pre-Paint>Fuselage>Undercarriage>Fit main gear

In this task you will permanently fit the main undercarriage to the fuselage. Both main gear legs
will be fitted to the fuselage at the same time and the mounting bolt reinforcing plates will be
flocked to the cabin floor as part of the fitting process.
At this point in the build the fuselage should be upright and firmly mounted on 2 trestles that place
the underside of the fuselage at 650mm high under the cabin.
A standard builders sawhorse placed in front of the main gear recess would provide adequate
clearance.
Materials required:
Card # 7J Undercarriage
10mm / 3/8 ID reinforced hose approximately 80mm long:
Prepare and pre-fit the main gear legs
Fit the centre bolt to the inboard end of each leg: the AN6-24A bolt (the shortest 3/8 bolt on the
Card) goes through a flat washer, a machined aluminium washer and 2 rubber bushes, with the
rubber bushes fitting into the gear leg as shown above left and centre.
Fit the gear leg into the recess in the fuselage and fit the bolt up through the inner hole in the gear
leg recess as shown above right. Place a Nyloc nut loosely on the thread for the moment. Cut out
the yellow packers for the clamp plate and drill 3/8 holes in each end as marked use the clamp
late as a drilling jig.
Fuselage
Plates
Packer
Gear leg
Gear leg
Clamp plate
Assemble the clamp plates: fit 2 x AN6-26A bolts and washers to the clamp plate then fit the yellow
clamp plate packer to one bolt only.
Fit the assembly around the gear leg then fit the yellow clamp plate packer to the other bolt and test
fit by fitting the bolts up through the holes in the fuselage.
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Use a pencil to mark the position of the clamp plate on the top and bottom of the gear leg the
clamp plate will be flocked onto the gear leg and the marks indicate where you will need to roughen
the gear leg in order to provide a key for the flock.
Pilots seat
back
Forward
outer bolt
Centre bolt
Remove the clamp plate; roughen the top of the plate and the marked areas on the top and bottom of
the gear leg.
On each side of the front seats are the centre and forward outer clamp holes for the main gear, while
the rear outer clamp hole is on the floor behind the main beam, and each hole will have a
reinforcing plate flocked over it. (The plates are on the Card, part numbers 6036094 and 6037094,
and can be seen the lower left-hand photo on the previous page.)
Roughen the area around each hole and the back of each reinforcing plate to provide a key for the
flock. The surface around each hole is not absolutely flat, and no attempt should be made to make it
flat because doing so would require removal of glass fibre from the floor which could weaken the
area.
Fit the main gear legs
Mix a batch of resin, keep a small amount aside and add flock to the remainder.
Apply a 2mm layer of flock to the top of the clamp plate and reassemble the clamp plates: fit 2 x
AN6-26A bolts and washers to the clamp plate then fit the yellow clamp plate packer to one bolt
only.
Fit the assembly around the gear leg then fit the yellow clamp plate packer to the other bolt and fit
the bolts up through the holes in the fuselage.
Push the gear leg firmly up against the fuselage and use a softheaded hammer to drive the clamp
bolts and centre bolt fully home.
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Fit the reinforcing plates
Cut 4 x short lengths (~7mm) of reinforced hose (cut square) and slip one over each centre bolt,
then fit the curved reinforcing plates, roughened side down with the curved side facing outwards,
followed by a flat washer and a Nyloc nut.
Fit the other short lengths to the forward outer clamp bolts and then cut 2 x 12mm lengths of
reinforced hose and slip one over each rear outer clamp bolt, then fit each square reinforcing plate,
roughened side down, followed by a flat washer and a Nyloc nut.
Before --- Centre bolts --- After
Reinforcing plate
Reinforced hose
Floor
Floor
Tighten each nut until the first thread on the bolt is just visible above the top of the nut at this
point the bottom of the reinforcing plate will be very close to the cabin floor and the reinforced hose
will be compressed to roughly half of its original thickness and will have formed to suit the shape of
the floor so it will completely seal the bolt from any flock.
Tap each plate around until it is squarely aligned in relation to the console or the sides of the
fuselage as appropriate.
The clamp bolt reinforcing plates have the holes drilled off-centre: the widest part of the plate
should be closest to the higher part of the floor.
Brush some resin on the floor under each reinforcing plate and then pack flock in and around each
plate until all voids are filled.
Use a clean mixing stick dipped in resin to smooth any excess flock from around the plates and also
from around the clamp plates under the gear leg.
Leave overnight to cure.
Next day the clamp bolts can be tightened until 2 threads protrude beyond the nut, which in turn
will provide the required tension.
Tighten the centre bolts until the rubber bush between the gear leg and the aluminium washer has
been compressed to half its original height.
The main gear is now permanently fitted to the fuselage and the saw stool or trestle can be removed
from beneath the cabin, however the trestle that is supporting the tail of the aircraft will need to
remain in place until the nose wheel and engine have been fitted.
This completes the Pre-Paint>Fuselage>Undercarriage>Fit main gear task.
44 of 377

Pre-Paint>Fuselage>Firewall forward>Fit firewall

To fit the stainless steel firewall plate to the fuselage. This task will require accurate measuring and
bending of the firewall plate: it is possible to make an accurate bend by clamping the plate to the
edge of a solid workbench between 2 lengths of heavy angle iron and use a solid length of timber or
heavy angle iron to press the bend to a tight radius, but for a small fee many plumbers or sheet
metal shops will bend the firewall plate for you, and provided that your markings are accurate this
may be a good choice for many builders.
Note that the bends required are not sharp creases but rather tight radius (3mm) bends of 55, which
is the same type of bend that a plumbers sheet folder will make.
Materials required:
Firewall plate (stainless steel)
Dow Corning silicone sealant (dark green tube in kit shown above right)
Firewall insulation sheet (white roll in kit shown at right)
38 x 73 AS 5/32 rivets and matching washers
Mark and bend the firewall plate
The technique that we use in our factory is to temporarily mount the firewall near the lower bend
with 2 self-tapping screws and mark the centre of the bend points, then bend the plate.
Large
hole
Small
holes
screwed here
Level here
Start by having someone help you to position the plate so that the bottom centre of the plate is level
with the bottom of the fuselage and the plate is equally spaced side to side. It is important that the
plate is positioned the right way around: the small holes must be in the upper left and the larger hole
must be in the upper right when viewed from the front. Refer to the photo above left as an example
of the correct positioning.
Drill a 3/32 hole through the plate and into the plywood firewall each side (as arrowed in the photo
at above left) and fit a self-tapping screw, then mark the centre of the lower bend on each side (as
circled at above right). Bend the plate slightly back at the lower bend as a reminder of the correct
bend direction for later when you bend the plate.
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Measure from the centre of the lower bend back to the centre of the upper bend on the fuselage and
transfer that measurement to the firewall plate note that the measurement may be slightly different
from side to side so measure each side independently. Recheck your measurements and then
remove the plate, transfer the lower bend marks to the back of the plate and take the plate to the
bender.
It is particularly important that the bends are made in the correct direction: the lower bend should
take the plate towards the rear of the aircraft while the upper bend should take the plate upwards,
parallel to the lower part of the plate. Take care to make the bends in the correct sense the plate
cannot be reversed if the bends are made backwards.
These photos show the upper bend being made and the plate sitting in place. In our factory the
bending process takes a skilled person about 15 minutes it is not a complicated task so long as you
take care to measure accurately and bend carefully and in the correct sense.
Fill the lower plywood firewall
Due to the moulding process there may be a slight depression in the
lower centre of the plywood firewall where the nose gear will be
mounted. Mix 80 grams of flock and apply to the area, then use the side
of a mixing stick to level the area as shown at right.
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Fit the firewall plate
Run a drill through the engine mount holes in the upper firewall (shown circled in the photo
below left). This will make fitting the top engine mount much easier.
Apply a generous bead of the Dow Corning silicone sealant about 1 in from the edge of the
plywood firewall all the way around the perimeter and also in a zigzag pattern across the firewall
and then lay the small insulating sheet onto the plywood firewall to about 1/3 of the firewall so that
it is held by the sealant. Lay the other large sheet and butt up to the first smaller sheet. Pat the sheets
into place and then cut to size with a sharp knife.
App
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ly the Dow Corning silicone sealant to the back of the firewall plate in the same manner: around the
outside and across the rest of the back, then place the plate onto the insulating sheet and push firmly
into place using the lower part of the firewall sheet as a reference. Secure temporarily with 2 selftapping screws at the base of the upper bend on both sides and 2 more in the holes just below the
upper bend.
Once the plate is held in place in this manner you can start to fix it permanently with pop rivets,
working carefully around the plate, drilling through the pre-drilled holes in the plate and through the
plywood and taking care to always put a washer on the back of each rivet (circled above centre)
unless you have long arms you will probably need another person to help you with this step by
holding the washers in place while you rivet.
Be particularly careful when drilling though the plywood firewall if you push too hard then the
drill can chip a section of ply out when it breaks through the back of the plywood, so drill using
gentle pressure only.
Once the plate has been fully riveted into place use a sharp knife to trim away the insulating sheet
from around the edges of the firewall plate.
Fit a temporary plate (plywood is fine, in the factory we use
aluminium) across the lower centre of the firewall to hold the
plate firmly against the flock filler. 3 screws (2 top, 1 bottom,
arrowed) are sufficient to hold the plate in place overnight while
the flock cures.
Next day remove the plate.
This completes the Pre-Paint>Fuselage>Firewall forward>Fit firewall task.
48 of 377

Pre-Paint>Fuselage>Firewall>Firewall fittings
General:
This task requires the drilling of several holes through the stainless steel firewall. Stainless steel is
hard, and the best way to drill it is to use very sharp drill bits and drill very slowly: drill too fast and
your drill bit will very quickly become blunt and the stainless will work-harden as well. For the
larger holes you will need a hole saw and a few drops of cutting oil on the teeth will make the
cutting easier, once again using a slow speed.
Materials required:
Card #s 10J Firewall, 11J Fuel components, 25JT Cabin heater, Dow Corning sealant
Air box and cable collars
280mm
The
air box needs to have a small amount ground out to allow for the cable collar: mark and remove the
area indicated in the photo above left. Position the air box so that it sits flat on the firewall just
above the upper bend, then measure in 280mm from the left hand edge of the firewall to the main
left hand side of the air box. Check that the air box is level and then fix it in place temporarily with
a strip of cloth tape along the top edge.
With
the air box held in place, make a mark directly behind the cable clamp as shown. Remove the air
box and drill a 22mm hole through the firewall for the cable collar then fit the cable collar with 6G
stainless steel screws (drill 1/8 holes through the firewall plate only for these screws, they will
self-tap into the plywood firewall).
Apply a bead of the Dow Corning sealant around the mounting surface of the air box and fix it in
place with 8 x 5/32 pop rivets, 1 on each corner and 1 at top and bottom centre, with a washer on
each side of each rivet (rivets arrowed in red: left hand side shown above, right hand side shown on
the next page). Apply extra sealant around the cable collar so that there is a good seal with no
possibility of air leaks. Wipe away any excess sealant with a clean cloth.
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290mm
65mm
Fit
the right hand cable collar: measure in 290mm from the right hand side of the firewall and up 65mm
from the upper bend and drill a 22mm hole through the firewall then fit the cable collar with 6G
stainless steel screws (drill 1/8 holes through the firewall plate only for these screws, they will
self-tap into the plywood firewall). Drill and blank the 2 holes arrowed in yellow above right with a
rivet. The air box right hand side rivets are arrowed in red above.
Battery box and battery
50mm
Run a 3/16 drill through the 2 pairs of holes on the right hand mid section of the firewall and bolt
the tie down brackets into place with AN3-6A bolts as shown. Position the battery box 50mm up
from the lower bend and fix in place with 4 x 5/32 pop rivets, with a washer on each side of each
rivet.
Put the battery in the battery box with the terminals to the top and secure it with a tie down strap:
loop the strap through the brackets and through the locking buckle with the free end of the strap
pointing down at the front, then loop that free end back through the bottom bracket and tie it off
around the strap and cut to length as shown. Use a flame to melt the cut end.
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Cabin heater
Measure up 180mm from the lower bend and in 340mm from the left hand side of the firewall step
and drill a pilot hole, then drill a 1 5/8 (41mm) hole for the cabin heater firewall fitting.
The fitting is in several parts: press the machined end of the short section of tube into the hole on
the side of the main body. Assemble the shaft, flap and actuating arm and then push the threaded
end of the main body through the firewall.
Turn the main body so that the pressed-in tube faces the left of the aircraft and fit a small screw into
the notch in the flange to prevent the main body from turning (circled above).
Drill a 1/8 hole in the firewall above the main body and directly below the shaft: pop rivet the
right-angled spring bracket into this hole and connect the spring to it. Drill a 5/16 hole for the
cable directly in line with the end of the actuating arm. Fit the retaining nut to the threaded end of
the main body on the inside of the firewall and tighten firmly.
Spring bracket
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Cable hole
Spring bracket

Fuel fitting
Assemble the firewall fuel line fitting: Press the flat plate of the brass bulkhead fuel fitting into the
top of the aluminium sleeve (this sleeve connects to the plastic fuel sheath on the inside of the
firewall), and bond it into place with 5-minute Araldite.
Drill through the pre-drilled hole in the firewall and fit the assembly, fit the washer and Nyloc nut
and tighten.
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Electrical components
30mm
50mm
Use some 3mm aluminium to make backing plates for the solenoid and the earth terminal as shown
below these are to spread the load and minimise crushing of the plywood firewall.
Draw a line up from each of the 2 blanked off holes (red lines above) and place the starter solenoid
with the mounting holes over the lines and the top of the terminals 30mm below the top of the
firewall. Fix the solenoid into place with 2 AN3-7A bolts, washers and Nyloc nuts.
Fit the main electrical earth terminal (maroon arrow above) by drilling through the pre-drilled hole
in the firewall and fix into place with an AN3-7A bolt, washer and Nyloc nut.
Place the regulator module 50mm in from the side and in line with the bottom of the battery box
(green lines above). Fix in place with AN3-12A bolts, washers and Nyloc nuts.
Inside view
This is how
the finished
job will look
from the
inside.
Solenoid
Cable collars
Air box rivets
Earth
terminal
regulator
Cabin
heater
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Fuel
fitting
Battery

Air box outlet tube
15
Remove the cover from the air box: it is held in place by 4 screws, one at each corner.
Cut a hole in the bottom of the angled lower front part of the cover and fit the supplied short length
of fibreglass tube and fit in place so that when the cover is laying on the workbench as shown at
above left the tube angles upwards at an angle of 15.
Fix the tube in place with a mixture of 5 minute Araldite and flock, filling the area around the inside
and outside of the join.
Use enough of the Araldite/flock mixture to completely fill the area surrounding the tube on the
inside of the cover as shown above right. You may need a second mix to complete this.
When the Araldite/flock mix has cured, grind the protruding lip on the inside of the cover down
until it forms a wide radius into the tube so that the air has a smooth flow from the air box and into
the tube any sharp edges at this transition can have the effect of restricting airflow to the
carburettor so take your time and get the curve just right.
Fit the cover back onto the air box.
This completes the Pre-Paint>Fuselage>Firewall>Firewall fittings task.
54 of 377

Pre-Paint>Fuselage>Firewall forward>Assemble and fit nose gear

To assemble and fit the nose gear including the front wheel to the stage where the aircraft is
standing on its own 3 wheels, the main gear having been fitted previously.
Materials required:
Card # 7J Undercarriage
Card # 19J Nose leg
Card # 20JT Nose wheel
Steps
1. Assemble the nose leg
2. Assemble the nose leg housing
3. Fit the nose leg housing
4. Assemble the nose wheel
5. Fit the nose leg and nose wheel
Assemble the nose leg
Assemble the nose leg by reference to the drawing 2 pages over.
Press the nylon bush through the tube at the bottom of the leg (photo at
right, flock in place if needed) and then fit the machined yoke with an
AN4-72A bolt, washer and castellated nut. Use a split pin to retain the
castellated nut. Fit the lower retaining collar to the machined section of the
nose leg (arrowed above) with an AN3-22A bolt.
Fit the lower part of the suspension shaft to the yoke, placing the nylon
bush through the bottom hole, superglue a washer on each side and secure in the yoke with an AN515A bolt, washer and Nyloc nut as shown circled in yellow in the photos below.
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Slip the tapered lower washer onto the lower suspension shaft and place the red suspension rubbers
over the upper shaft as shown above right. Note that in the photos above the nose leg has been left
out for clarity.
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Lever
Nose leg
Main rubbers
AN3-07A bolt
Rebound rubber
Fit the machined washer and rebound rubber to the top of the inner
suspension shaft and secure to the shaft with the retaining collar and
an AN3-06A bolt and Nyloc nut. Clamp the yoke in a vise and use a
long bar inserted into the top of the nose leg as a lever to compress
the rubbers until the inner shaft can be secured with an AN3-07A
retaining bolt (arrowed above left).
Compressing the rubbers will require substantial pressure: the lower
part of the leg will need to be almost horizontal in order to fit the
retaining bolt. Take care that the yoke is firmly held by the vise and
apply downward pressure on the lever smoothly.
Tighten the Nyloc nut firmly and then slowly release the pressure on the lever.
Assemble the nose leg housing
Assemble the top and bottom plates to the spacer with the supplied cap screws clean the threads,
use a drop of Loctite 620 on each cap screw and tighten firmly. Clean the nylon bushes and the
matching holes in the top and bottom plates with Acetone and sand all surfaces to be bonded and
then fit the bushes into the plates, pushing both bushes from the outside in towards the middle.
Align the flats on the bush collars to clear the cap screws.
Fit the assembly onto the nose leg with the retaining collar bolted to the top and check for freedom
of movement. When you are satisfied that there is no binding, mix a small batch of flock and flock
the bushes into the plates, taking care not to get any flock onto the nose leg.
Use a mixing stick to smooth the flock as pictured above, right and leave overnight to cure.
Drawings of the nose leg and nose leg housing follow on the next 2 pages.
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Fit the nose leg housing
Level the aircraft laterally: a straightedge across the bottom of the front doorframes or across the
front wing attachment lugs will provide a good reference, then pack under the main wheels as
required in order to level the aircraft in the lateral or rolling plane.
20mm
Place a straightedge or ruler under the centre of the fuselage and measure up 20mm. This is the
position for the bottom of the square outer backing plate for the nose gear housing.
Centre the outer backing plate on the lower firewall and drill one top hole only and push a bolt
through, then fit up the nose gear housing and place a digital protractor or a spirit level across the
top of the white bush as shown above and carefully level the nose gear housing.
Once it is level, drill the other top hole and recheck for level then drill the bottom holes and bolt the
nose gear housing in place. You will need to flock the 2 internal braces in place at this time sand
and clean the surfaces to be bonded then mix a small batch of flock and coat the back of each brace
then press into place and secure with 2 x AN4-16A bolts at the top and 2 x AN4-22A bolts at the
bottom and tighten the Nyloc nuts firmly.
10mm
85mm
Drill the holes for the steering links: measure out 85mm from each side of the centre plate and down
10mm from the bottom side of the top plate and mark and drill a pilot hole, then use a 1 hole saw
to drill through the firewall.
Drill the top holes of the internal braces (arrowed in purple above right) from the back of the
firewall and then fit the bolts from the firewall side with 1 penny washer under the head of each bolt
and a normal washer and Nyloc nut on the inside of the firewall.
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Assemble the nose wheel
Press a bearing into each side of
hub until the bearing reaches the
bottom of the machined hole use
large socket or piece of heavy tube
is slightly smaller in diameter than
outside of the bearing to press
against the outer rim of the
bearing. A small hand press or a
bench vise would be ideal for the
purpose. Do not press against the
rim of the bearing this can
damage the bearing.
the
a
that
the
inner
Fit the bearing spacers into the

bearings with a drop of Loctite 480 and slide the axle through the spacers.
Check each end of the axle and spacer: both ends should be exactly level. If this is not the case then
grind either the axle or the spacer until they are level. If the width of the wheel and spacers are
wider than the length of the axle this will put a side load of the wheel bearings.
Partially inflate the inner tube with the valve out, then liberally coat the tube with talcum powder,
fit it into the tyre and place the tyre on the hub with the valve stem facing up and then fit the rim to
the hub, making sure that the valve stem is through the hole in the rim, bolt the rim to the hub,
taking care not to pinch the inner tube, and inflate the tyre to 35 PSI.
A drawing of the nose wheel can be found two pages over.
Assemble Rubber soft-link steering yoke
Rubber soft-link arm placed
between the top and bottom
housing plates
The most current nose legs feature a

rubber soft-link nose leg steering
yoke subassembly which is mounted
between the top and bottom plates
instead of the older solid nose leg
steering yoke. A photograph and
drawing are provided to reference
during the assembly of the rubber
soft-link steering yoke (the photo on
the left shows the nose-leg installed
and finished with the soft-link
steering arm).
Use the nose-leg as guide to align

each part. Slide the steering link
(small teardrop shaped aluminium part) first and the steering arm (larger aluminium part) on-top as
pictured. Insert the cylindrical rubber damper with 1/4 inch penny washers top and bottom and bolt
in place with AN4-16A bolt, nyloc nut and washer under the head of the nut. Remove the soft-link
steering yoke assembly from the nose-leg.
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Fit the nose leg and nose wheel

Slide the nose leg up into the nose leg housing
the steering yoke (arrowed) fitted over the nose
between the top and bottom bushes and with the
arms of the yoke swept back towards the
firewall. Fit the nose leg in place with the
retaining collar above the top bush. Secure the
collar to the nose leg and the steering yoke to
nose-leg with AN3-22A bolts and Nyloc nuts.
with
leg
Roll the front wheel into the machined yoke and

with the AN4-72 bolt. Use a washer and
castellated nut, tighten the castellated nut and
secure it with a split pin.
fit
the
The aircraft is now sitting on its own wheels,

however it will still need a trestle under the
empennage until the engine has been fitted in
next task.
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the

This
completes the Pre-Paint>Fuselage>Firewall forward>Assemble and fit nose gear task.
63 of 377

Pre-Paint>Fuselage>Firewall forward>Fit engine mount and engine

In this task the engine mount will be fitted to the firewall at the top attach points only, the engine
will be attached to the engine mount, then the engine angle of incidence will be set and finally the
engine mount will be fitted to the bottom attach points on the firewall.
The engine angle of incidence is particularly important, both to the general flying qualities of the
aircraft as well as making the fitting of the cowls more straightforward, and should be set carefully
and precisely. You will need either a portable engine lifter or a few strong friends to help you
mount and position the engine in this task.
From this point on the engine will remain fitted to the fuselage.
Parts required:
Engine mount sets: AN4-20A & -31A bolts plus washers, spacers, rubber mounts
From Card # 10J Firewall, the 4 x 4025094 backing plates (photo below right)
From Card # 23J Engine, the washers and lock nuts in Engine mount hardware
Fit the engine mount to the firewall
Now would be a very good time to paint the engine mount! We prefer gloss black.
Drill the top engine mounting holes through the stainless steel firewall plate from the inside,
through the pre-drilled holes in the plywood firewall that you cleaned in the previous task.
Attach the engine mount to the firewall with the top (AN4-20A) bolts
only: fit each bolt from the front, through the mount, firewall, and the
backing plate (shown at right) and fit a washer and Nyloc nut.
Tighten the Nyloc nut firmly but without crushing the plywood
firewall. Do not bolt the bottom of the engine mount to the firewall at
this stage; leave it until the engine angle of incidence has been set.
Note that the bottom centre section of the engine mount rests against
the penny washers of the top internal brace bolts but does not rest on
the heads of the bolts.
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Backing plate viewed from

back of firewall

Fit the engine to the engine mount
Fit the female rubbers to the top mounts and the machined spacers and male rubbers to the bottom
mounts refer to the drawing on the next page for details.
With the rear of the aircraft supported and with the main wheels chocked, lift the engine into
position and fit the rear engine mount plate onto the bottom engine mounts first: you may need to
tilt the engine slightly down at the front to do this. Use AN4-31A bolts fed from the rear of the
mounts with the lock nuts towards the front.
Lift the front of the engine and fit the top rear engine
mount plate onto the top mounts and fit the male rubbers,
machined washers, flat washers and lock nuts to both top
mounts. Fit the female rubbers, flat washers and lock nuts
to both bottom mounts. Note that these are steel lock nuts
and not Nylocs.
It may be necessary to compress the mount rubbers in
order to get the steel lock nuts on: use a G clamp or
similar and clamp across a socket on the head of the bolt
and the side of the machined washer beside the steel lock
nut, as shown at right. The clamping points have been
circled in yellow.
Torque each of the 4 steel lock nuts to 11 Nm (8 foot pounds).
Level the aircraft
For the next step the aircraft must be absolutely level in both the lateral (rolling) and longitudinal
(pitching) planes.
Lateral plane: place a 3 block on the top of each front wing mounting lug and place a spirit level
or a digital protractor across the top of the cabin so that it rests on both blocks. Pack the main
wheels as required to level the aircraft.
Longitudinal plane: the objective is to level the fuselage along the waterline the line of the
join between the upper and lower sections of the fuselage. Use a spirit level or a digital protractor
and pack under the nose wheel or empennage until the waterline is level.
Once the aircraft is satisfactorily levelled make sure it stays that way: chock the wheels and
consider lashing the empennage to the packing with a tie-down strap.
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Set the engine angle of incidence
In this step the engine will be adjusted until a level or digital protractor (pictured below) placed on
the top of the crankcase reads completely level fore and aft, which indicates an angle of incidence
of 0 (zero degrees).
In our factory we usually find that the angle of incidence is correct with the standard mount,
however the following procedure should still be followed.
Recheck that the aircraft is completely level and then measure the angle of incidence and use a
hydraulic jack under the crankcase to lift the front of the engine to a point where the engine has a
very slight (0.5 if using a digital protractor) nose-up attitude then drill the bottom engine mount
holes through the firewall and fit the AN4-20A bolts, backing plates, washers and Nyloc nuts. Now
release the jack and recheck the angle of incidence. If the engine is slightly down at the front you
can fit up to a maximum of 3 penny washers under each bottom engine mount to adjust the angle of
incidence. Bear in mind that a small adjustment at the firewall will result in a large change at the
propeller flange.
Check the lateral angle of the engine while the aircraft is completely level: it should be very close to
level.
Once youre happy with the alignment you can permanently install the lower engine mount bolts,
taking care to remember the backing plate (pictured on the first page of this task), and tightening the
Nyloc nuts enough to hold firmly but without crushing the plywood firewall.
If penny washer spacers were used on the lower engine mounts then equivalent thickness spacers
will need to be used behind the bottom bar on the mount. Drill these mounting holes at 3/16, fit the
appropriate spacers if required, and finally fit 2 x AN3 bolts through the bottom bar and the firewall
and fit washers and Nyloc nuts.
This completes the Pre-Paint>Fuselage>Firewall forward>Fit engine mount and engine task.
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Pre-Paint>Fuselage>Firewall forward>Fit propeller flange extension
Pre-Paint>Fuselage>Firewall forward>Fit propeller flange extension

To remove the universal propeller flange that is shipped with the engine and fit the model-specific
propeller flange extension to the crankshaft. While this is a straightforward mechanical task it is
most definitely a critical task and care must be taken.
If you have a short Propeller flange extension it will need to be changed. See picture below. For the
propeller flange removal and fitting procedures see the engine overhaul manual.
Check the length of the propeller flange you have fitted. If it is right you have nothing to do in this
section.
This completes the Pre-Paint>Fuselage>Firewall forward>Fit propeller flange extension task.
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Pre-Paint>Fuselage>Firewall forward>Fit oil cooler

In this task the oil cooler will be fitted to the base of the sump, the oil filter adapter will be fitted
under the oil filter and the whole assembly plumbed up and the oil overflow bottle will be fitted to
the firewall. There are 2 types of oil overflow bottles, fibreglass moulding or a plastic moulding.
Fireproof sleeving will be used to protect the oil lines.
Materials required:
Card # 24T Oil Cooler Kit
Pipe sealing compound (rated working pressure of 2.6 Mpa, Holdtite brand or similar)
Mount the oil cooler

Mount the rails to the sump: fit the 3/16 cap screws through a flat washer and the rail and into the
threaded holes in the sump and tighten. Drill each of the 4 large holes in the cooler out to 9/16 and
fit a rubber grommet, then fit a Bundy tube in the bolt hole and mount the cooler to the rails using
AN3 bolts fitted from the rear and steel lock nuts with a penny washer under each lock nut as
shown above. Note that the penny washer will need one side cut away.
Refer to the drawing on the next page for detail.
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Fit the oil lines
Fit the 2 brass male barb fittings to the inlet and outlet of the cooler - apply a smear of pipe sealing
compound to the threads and tighten each fitting firmly into the cooler. Take care not to over
tighten these fittings, as the brass threads will strip if excess pressure is applied.
Remove the spin-on oil filter and fit the adaptor
(circled at right) under it with the O-ring side
towards the engine block. Apply a smear of clean
engine oil to the O-rings on the adaptor and the oil
filter, refit the oil filter and tighten gently until
resistance is felt as the seal first contacts the
housing and then tighten exactly one full turn from
that point.
Absolute cleanliness is required here: there must be
no dirt or contaminants anywhere near the oil filter
or adaptor fitting area.
Size the blue oil lines by holding one end beside the fitting on the right-hand side of the oil cooler
and cutting to length to fit the rear adaptor fitting. Allow for a smooth routing.
Repeat the process for the other side of the oil cooler to the front adaptor fitting and then cut 2
lengths of fireproof sleeve to the same length as the oil lines and fit them over the oil lines.
The fireproof sleeve can be difficult to fit, but blowing compressed air into the gap between the oil
line and the sleeve while pulling the sleeve over the oil line works rather well.
Roll the last inch or so of the fireproof sleeve back on each end as shown above left and fit each oil
line into place, securing each end with the supplied hose clamp and cutting off the excess length of
the hose clamp screw.
Now roll the fireproof sleeve over the hose clamp and lock wire into place as shown in the photo
above right, using a double loop and twisting off.
This provides fireproofing to the full length of each oil line.
The completed oil line arrangement is shown on the next page.
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Completed oil line arrangement between the adaptor and the oil cooler
Oil overflow bottle

Fibreglass moulded oil bottle mounting.
The oil overflow bottle, as shown in
the photo on the right, fits into a
fibreglass bracket that is mounted on
the lower right side of the firewall.
Position the oil bottle with the
bracket fitted so that the inlet line
from the engine oil filler will curve
smoothly down to the top fitting in
the oil bottle without rubbing against
the inside of the cowl, and so that the
outlet from the oil bottle can be
routed over the lower engine mount
as shown in the photo at right.
Inlet
Outlet
Bracket
Mark the position of the bracket,

then remove the oil bottle from the
bracket and drill 2 x 5/32 holes in
the flat back part of the bracket.
Place the bracket on the marks and
drill through the firewall and fit the
bracket with 2 x 5/32 rivets with
plain washers behind.
Oil bottle
Fibreglass Oil overflow bottle shown final fitted
Remove the oil bottle and set aside for later fitting in the Post-Paint>Fuselage>Firewall
forward>Final assembly task.
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Plastic moulded oil bottle mounting.
The oil overflow bottle, plastic
moulded type, as shown in the
photo on the right, is mounted to
firewall with a saddle clamp on
lower outlet, on the lower right
of the firewall. The outlet is
identified by an aluminium tube
inserted in the connection stub,
is the larger diameter of the 2
connecting stubs.
and
Position the oil bottle so that the

inlet line from the engine oil filler
curve smoothly down to the top
fitting in the oil bottle without
rubbing against the inside of the
cowl, and so that the outlet at the
bottom can be routed into the
cutaway in the firewall as shown
the photo at right.
Place the saddle over the lower oil
bottle outlet and mark the position
drill through the firewall to fit the
saddle clamp with 2 self tapping
screws 6G x 1/2" long.
the
the
side
Inlet
will
Outlet directed to
cutaway in firewall
in
to
Saddle Clamp
Plastic moulded oil bottle
Remove the oil bottle and set aside

later fitting in the Post-Paint>Fuselage>Firewall forward>Final assembly task.
This completes the Pre-Paint>Fuselage>Firewall forward>Fit oil cooler task.
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for

Pre-Paint>Fuselage>Firewall forward>Fuel pump fittings

In this task the drip tray will be prepared and fitted to the fuel pump and then the fuel lines will be
fitted from the firewall fitting to the fuel pump and then to the carburettor.
Materials required:
5-minute Araldite and flock
Loctite 518 gasket sealant, lock wire
Card #11J Fuel components, Card #15J Spares
Fit the fuel pump drip tray
There is 2 versions of the fuel pump drip tray, one is fiberglass, the other is aluminium. The
fiberglass version needs the following assembly process.
Remove the fuel pump from the engine
Clean the gasket and the spacer block
Remove the drip tray (shown circled in the photo at bottom right) from the Spares card and prepare
it: drill a hole in right rear corner, which will be
the lowest point when the tray is fitted, and flock
the drain fitting into place with 5-minute Araldite
and flock.
Put a piece of tape over the inside of the tray and
over the fitting and leave to cure.
Fit the fuel drip tray to the engine-driven fuel
pump: remove the fuel pump carefully and along
with the fibre spacer block, leaving the gasket on
the engine block.
Clean the threads of the cap screws thoroughly
and apply a drop of Loctite 262 to each screw.
Smear some gasket cement on both sides of the
spacer block and then refit the whole assembly:
hold it together with the Allen head cap screws
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Re-fit the fuel pump with the drip tray underneath

through a flat washer, the drip tray, the pump
flange, the spacer block and the gasket and
screw into the engine block and tighten the cap
screws firmly.
Fit the fuel lines and drain hoses
The fuel lines are connected in 2 runs: from the
firewall fitting to the engine-driven fuel pump;
and from the engine-driven fuel pump to the
carburettor fuel inlet fitting. If you are fitting a
fuel flow or fuel pressure sensor it should be
inserted into the fuel line between the fuel pump
and the carburettor at a point near the midpoint
of the line.
Refit fuel pump with drip tray underneath.

Cut some black fuel line to length for each run,
Aluminum version.``
allowing enough length for the fuel line to be
routed smoothly between each pair of fittings. Cut some fireproof sleeving to the same length as
each fuel line. Slip the fireproof sleeving over the fuel lines and roll the ends back so that you can
fit the hose clamp over each end of the fuel line. Make sure that each fuel line is clear by blowing
through it to remove any dust or debris before fitting.
Note that the fuel pump inlet is on the

side of the pump and the outlet is on the
top of the pump as pictured at right.
Use the flow arrows in the 2 photos on
this page to help you visualise the fuel
flow to and from the fuel pump.
Fit the top fuel line into place: this line
runs from the top fitting on the fuel pump
to the fuel inlet fitting on the carburettor.
Fit the lower fuel line into place: this line
runs from the fuel fitting on the firewall
to the side fitting on the fuel pump.
Fuel out
Fuel in
Breather
Drain
Fuel to
carb
Roll the fireproof sleeving over the hose

clamps and lock-wire the sleeve into
place using a double loop of lock wire around both sides of the hose clamp. Fit the fuel breather
and fuel pump drain (clear) hoses, route back to the firewall and zip tie to the lower right engine
mount tube and leave enough length for the hoses can be routed back to the firewall and end 50mm
below the bottom of the firewall step.
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Fuel out
Fuel from
pump to carb
Fuel in
Breather
Drain
Fuel from firewall
fitting to pump
This completes the Pre-Paint>Fuselage>Firewall forward>Connect fuel pump task
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Pre-Paint>Fuselage>Firewall forward>Fit ram air cooling ducts

In this task the ram air cooling ducts will be assembled and fitted to the engine.
The final step, where the front of the ducts are trimmed to length to match the bottom cowling,
cannot be performed until the bottom cowling has been fitted to the fuselage and so that step is
included as part of the Fit cowling task that follows this task.
Air enters the front of the ducts and is routed up by low air dams, through the fins on the cylinder
heads and barrels and then downwards at the rear by a pre-fitted angled baffle.
An aluminium tube directs cooling air from each duct to the nearest magneto coil.
Materials required:
Epoxy resin and AF303 glass fibre cloth (from the bag labelled Extra Cloth)
Assemble the ducts
Use a length of masking tape on the join line
at the bottom of each duct inlet to hold the
join firm and prevent Araldite/flock from
leaking through.
Mix a small batch of 5-minute Araldite and
flock and apply to the top of each join as
shown at right:
Next the front air dams will need to be cut to size. Take the length of glass fibre sheet with the
curved edge, hold it against the rear of the duct inlet with the curve towards the top rear of the duct
and mark around the bottom of the duct then cut to shape as shown above.
Tape the air dam into place. Mix a small batch of 5-minute Araldite and flock and use it to fix the
air dam into place. Leave to cure, then sand away any rough edges.
Remove the masking tape and roughen the underside of the duct and the back of the air dam.
Mix a small batch of resin and brush 2 layers of AF303 glass fibre cloth to the underside of each
duct, covering the join line and wrapping up around the back edge of the air dam.
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Test fit the ducts
Oil line
Fitting the ducts will require adjustments to be made in several areas: firstly the oil line to the
rockers will need to be accommodated, then the rear baffle and the air dams will need to be adjusted
and then the sequence repeated perhaps 2 or 3 times until the fit is correct.
Remove the front and rear rocker cover cap screws (circled top), test fit the duct and mark the
locations for the cutouts around the oil line (arrowed above). File out a notch for the oil line until
the duct clears it by 1-2mm all round. Leave the cap screws out and set aside until the final fitting of
the ducts is complete.
Right-hand duct
Left-hand duct
The front air dams will need to be trimmed to fit around the fins on the cylinder heads and barrels.
The final fit must have the air dams only just touching the fins as shown above.
It may take few trial fits so take your time and get the fit just right.
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Left-hand duct, shown

here upside down.
The pencil marking is
on the rear baffle
The baffles at the rear of each duct will need to be trimmed to allow the duct to sit down correctly.
Test fit and trim until the inside of the duct sits down on the barrels, between the fins as shown
above right, and the outside sits just on the top of the rocker covers.
Once the rear baffle and air dams are fitting correctly you can mark and drill both of the rocker
cover holes (circled in the photo at the top of the previous page) to and temporarily mount both
ducts using the cap screws.
Mark a point on the inside of the duct directly above each
front cylinder and drill a 3/32 hole, then flock and rivet the
supplied right angle spring bracket into place as shown at
right, placing a washer on the rivet inside the duct.
Fit a loop of lock wire around the cylinder between the third
and fourth fin and through the bottom of the spring and twist
it off.
The spring may be unhooked at the bracket end to remove
the duct.
Fitted left-hand duct
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Fit the magneto coil cooling tubes
Left-hand magneto
coil cut the tube
parallel to the side of
the coil
Starting with the left-hand duct, drill a hole at the top centre rear of the duct and slip the curved
aluminium tube into place until the mark on the tube reaches the duct. Aim the lower end of the
tube at the centre of the left-hand magneto coil, mark the tube at an angle parallel to the side of the
coil, remove the tube and cut along the mark. Shorten the top end of the tube as required it should
fit about 1 to 2 (40-50mm) inside the duct.
Refit the tube to the duct and hold it in position with masking tape. Mix a small batch of 5-minute
Araldite and flock and fix the tube to the duct. Leave to cure, then remove the duct and apply flock
around the tube on the inside of the duct to provide strength. Leave to cure.
Repeat the procedure on the right-hand duct:
Refit both ducts and leave them in place.
This completes the Pre-Paint>Fuselage>Firewall forward>Fit ram air cooling ducts task.
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Pre-Paint>Fuselage>Fit windscreen
The windscreen is an integral structural component of the airframe, providing strength and rigidity,
and the correct fitting method is very important.
The windscreen is made from strong but brittle Perspex and care must be
taken to avoid marking or cracking the windscreen while it is being
fitted. The use of sharp or new drill bits must be avoided: use an old drill
bit and blunt it before use by drilling into some concrete, and then grip
the bit loosely with a pair of pliers while running the drill (see photo at
right) to remove any roughness from the flutes that might bind and cause
damage to the Perspex.
Any shaping of the windscreen that may be required must be done with an 80 grit sanding disc, and
you must never use a jigsaw. Photos are of a J200: the same process applies to all.
Materials required:
x adhesive-backed foam strip (not included in kit)

Pre fit the windscreen
Start by carefully sanding away all of the gel coat from the joggle, then fit a length of the foam
strip around the very inside of the joggle (the grey line in the photo above right) this will keep the
flock from making a messy line around the inside of the windscreen and give a nice clean edge
when the windscreen has been flocked into place.
Test fit the windscreen, holding it in place temporarily with a strip of cloth tape on each side as
shown above. The arrows show the side screw positioning refer to next page.
Note that the protective plastic cover has been folded back from the edges of the windscreen.
Check around the entire perimeter of the windscreen for any areas where the Perspex does not fit
neatly inside of the joggle and carefully sand away the Perspex until it fits. In most cases the
windscreen will fit correctly without any alteration, but nonetheless check carefully.
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Drill the screw holes
With the windscreen still held firmly in place by the tape, the next step is to drill a series of 11/64
holes around the perimeter at the positions shown above. Note that 11/64 is slightly bigger than the
screws this is to make sure that the threads will not bind in the holes and possibly chip or break
the Perspex.
Drill slowly with a blunt drill bit and dont lean on the drill - let the bit do the work.
The holes are drilled well in from the edge of the Perspex at a point where they just miss the
foam tape this gives the maximum amount of meat for the screws to grab. Note that the bulk of
the structural strength is provided by the flock: the main purpose of the screws is to hold the
windscreen firmly and accurately in place while the flock cures.
Start by drilling at each corner, then drill halfway between each corner and then drill halfway
between those holes until you have the holes as shown above and on the previous page.
Once all of the holes have been drilled they will each need to be countersunk to a depth where the
head of each countersunk M4 x 12 screw will be just below the surface of the Perspex.
Prepare the windscreen
Remove the windscreen carefully and clean away any burrs from around the holes and blow away
any dust and debris from the joggle.
Place the windscreen face down on the bubble wrap packing
material, taking care not to allow anything to scratch the
surface, and sand around the entire inside edge with emery
tape roughen to a point level with the inside of the bolt
holes.
By holding the emery tape as shown you can use your finger
to control the width of the sanded area.
When the sanding is complete blow away the dust and then
use a clean soft cloth and wipe right around the windscreen.
Do not use any cleaning agents.
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Fit the windscreen
Mix 160 grams of flock and fill the entire joggle up to the level of the foam strip. Carefully place
the windscreen onto the bed of flock start at one corner and position the windscreen with a rivet or
similar to get the alignment of the holes and then lower it into position.
Once the windscreen is in place start fitting the screws and locknuts, working from the corners first
and then the middle screws and so on in much the same manner as the holes were drilled. Take care
not to over tighten the screws, tighten them just enough so that the edge of the windscreen is level
with the adjacent fuselage.
Check all around to see that the flock has keyed to the
windscreen: the sanded surface of the windscreen edge will
appear to go clear with no bubbles when the flock is in full
contact with it. It may be necessary to gently squeeze the
windscreen to remove any bubbles, although if you have
filled the joggle with flock there should be full contact
anyway.
In the photo at right you can see that the flock is in full
contact all the way around. Note the flock has been wiped
off level at the outside of the joggle and that there is no
flock at all on the surface of the windscreen.
When you are satisfied that the windscreen is positioned correctly wipe away the excess flock with
a clean mixing stick, taking care not to smear any resin or flock over the windscreen: always wipe
out and away from the windscreen. Do not use any cleaning agents; use only a clean soft cloth.
This completes the Pre-Paint>Fuselage>Fit windscreen task.
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Pre-Paint>Fuselage>Fit control cables and lines

The rudder, elevator, elevator trim cables, static line and VHF antenna cable, along with any
electrical wiring, will be routed from the empennage to the cockpit for later connection.
The trim cable will be routed from the front edge of the pilots seat and into the longitudinal rib out
the bottom of the empennage, the elevator cable will be routed from the console through the
longitudinal rib and out the rear of the empennage, and the rudder cable will be routed down
through the fin stub and into the longitudinal rib and out of the lower console.
Cable connections will be performed in the appropriate tasks later in this manual.
Identify the cables
Each control cable is fitted with a white identification tag permanently attached and a bright orange
identification tag just beside it. In every case these tags identify not only the cable but also the
inboard or control end of the cable and you should plan to have the tagged ends end up inside the
cabin when each cable is finally fitted.
Identify the exit holes in the console
All electrical cabling and the fuel line exit the console at the top front of the lower console, just
before the rudder pedals. This slot was enlarged in the Prepare fuselage task.
The trim cable exits the console at the right front of the pilots seat against the console.
The elevator cable exits the console from the right hand side of the centre armrest.
The rudder cable exits the console midway between the front of the pilots seat and the firewall
just above the floor. This slot was cut in the Prepare fuselage task.
Run the electrical cabling and static tube
The rudder cable will be used to push all of the electrical cabling
through from the rear of the fuselage and through the holes in the
ribs then into the lower longitudinal rib to the wiring hole in the
lower forward top of the console.
Use cloth tape to bundle all electrical cabling (2 fuel pump wires,
VHF antenna cable, strobe light wires (if fitted)) and static tube
to the end of the elevator cable as shown above right. You may
want to include a drawstring for any wiring that you decide to add later.
Feed the bundle in from the rear and through the holes in the ribs beside the lower longitudinal rib
and into the slot in the lower longitudinal rib under the lateral beam behind the seats and into the
lower forward part of the console.
When the bundle is visible in the cable hole at the lower front of the
console pull it through until the cloth tape can be removed, then
withdraw the rudder cable slightly while holding the electrical
cables and the static tube from moving back tape them to the side
of the console if necessary.
Pull the electrical cables and the static tube up until they are level
with the top of the windscreen this will give enough length for
later connection.
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Use a wire hook to pull the static tube down though the rearmost slot underneath the empennage as
shown at right.
The static tube from the static probe in the vertical fin will be routed down and through the same
slot and a joiner will connect the 2 tubes both tubes can be seen in the photo at right, tied together
to prevent them slipping back into the empennage.
The VHF antenna cable and the strobe wiring can be left trailing out the rear of the fuselage at this
point they will later be routed up into the vertical fin. The 2 fuel pump wires can be coiled up
behind the seats for later fitting into the header tank enclosure, and any wingtip strobe wiring can be
coiled in the same position for later connection.
Use a wire hook to pull the static tube down
though the rearmost slot underneath the
empennage as shown at right.
The static tube from the static probe in the
vertical fin will be routed down and through
same slot and a joiner will connect the 2
tubes both tubes can be seen in the photo at
right, tied together to prevent them slipping
back into the empennage.
the
The VHF antenna cable and any tail strobe wiring can be left trailing out the rear of the fuselage at
this point they will later be routed up and into the vertical fin. The 2 fuel pump wires can be
pulled up through the hole in the lower longitudinal rib behind the rear bulkhead along with any
wingtip strobe wiring for later connection.
Fit the trim cable
Feed the trim cable (untagged end first) in though
the hole in the front edge of the pilots seat and
feed it back into the longitudinal rib (you may need
to use a wire hook through the access hole behind
the front seats to lift the cable over the main gear
hump) until it can be seen though the front slot
under the empennage, then hook it out of that slot
(the rear of the trim cable can be seen in the photo
above right) and pull it through until it is level with
the trim horn.
Fit the elevator cable
Feed the elevator cable (untagged end first) into the
slot on the right-hand side of the armrest and back
though the longitudinal rib.
You may need to use a wire hook through the
access hole behind the front seats to lift the cable
over the main gear hump.
Feed the cable back and out the T shaped hole at
the lower rear of the empennage.
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Clamp the elevator cable into place using the
supplied clamp bracket, taking care to fit the
pressed locating section of the clamp in the
groove around the outer cable. The clamp
consists of a saddle and a backing plate, and
whole clamp must be fitted onto a tapered
profile plate with the thin end of the wedge
facing the rear of the aircraft and secured to
fuselage by 2 x AN3-6A bolts and Nyloc
nuts. Tighten firmly.
the
the
Fit the rudder cable

The rudder cable was partly fitted with the
electrical cabling, so all that is left to do is to
feed the rear of the cable up and out of the
on the right hand side of the fin stub, as
shown at right: the photo has been taken
from the rear of the empennage looking
forward.
The front of the rudder cable can be seen
inside the console near the rudder slot on the
left-hand side of the lower console, so use a
hook to pull it through the slot and pull it
about 150mm through and into the cabin
footwell.
Rudder
cable
slot
Static
line
Fin stub
Console
This completes the Pre-Paint>Fuselage>Fit control cables and lines task.

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Pre-Paint>Fuselage>Empennage>Fit vertical tail fin

To fit the vertical tail fin to the fuselage, including fitting the static probe, static tube, optional
strobe light wiring and the VHF antenna coax cable.
Materials and equipment required:
Card # 3T Rudder for the
VHF antenna
Glass cloth and peel cloth
bags labelled: Tail Fin and
Outer Reo Tail Fin
2 lengths of 2 aluminium
angle, waxed, each one at
least the length of the join
Plumb bob and string line
Builders level
Completed vertical fin fitted to the fuselage
Fit the spar extender
Spar extender
Tail spar
Sand the matching surfaces of the pre-fitted tail spar and the spar extender. Make sure that the 2
pieces match and then fix the spar extender in place with 5-Minute Araldite.
When the Araldite has cured sand the front and back surfaces of the spar, mix a batch of resin and
coat both surfaces and then brush on 3 layers of AF303 glass fibre cloth to each surface (front and
back) and finish with a layer of peel cloth.
When ready to fit the fin remove the peel cloth and carefully trim the glass cloth from the sides of
the extended tail spar. A heat gun will make the edges of the cloth easier to trim with a sharp knife.
87 of 377

Prepare the vertical fin
Start by laying the vertical fin on its side and drilling out the
marked inspection hole on the left-hand side with a hole saw.
Turn the vertical fin over and cut out the marked slot for the
rudder cable: drill each end of
the slot then use a jigsaw to
join the two holes.
Remove any burrs the exact
sizing of the hole and slot will be finalized once the vertical fin
has been fitted into place.
Remove the peel cloth from both sides of the joining surface.
Use a scraper to remove any edge strips of the peel cloth that
have not peeled off cleanly.
Using a round file, enlarge the static probe mount hole in the top front of the fin it needs to be
large enough to pass the static tube and draw wire through easily. The finished hole size is not
critical. Take care not to file through the pre-installed drawstring: for this reason using a drill is not
recommended. If fitting the optional strobe to the top of the fin then you should fit the mounting
base now: flock the base to the forward top of the fin and screw in place.
Pull the static tube and the VHF cable through the fin
Lay the vertical fin beside the fuselage on trestles set at about the same height as the fin mounting
stub. Lay the strake across the mounting stub.
Locate the drawstring inside the fin that will be used for the VHF cable and the static tube it is
tied in a loop around the internal foam rib. Cut the bottom of the loop to separate the drawstring into
2 parts: the static tube/strobe wiring and the VHF cable.
Run the static tube/strobe wiring up from the
fuselage into the rear section of the fin, through
hole in the internal foam rib and into the front
section of the fin do not let the static tube lay
under the rib or it will be squashed against the
when the fin is fitted. This is critical!
Tie a length of wire to the static tube drawstring
pull it through the friction of the static tube
being pulled may cause a string to break.
88 of 377
the
Through
here:
Static
tube
NOT
under
here!
stub
and
Front:

Tie the drawstring to the VHF cable and the draw wire to the static tube/strobe wiring. The photos
below show how: loop the draw string or wire around the cable or tube to be pulled then tape the
end of the draw wire or string so that when it is pulled it will tighten the knot. Tape the end of the
cable or tube to be pulled to streamline it and avoid it catching on anything. Cloth tape is stronger
than masking tape and is recommended for this purpose.
Pull the static tube/strobe wiring and the VHF cable through the fin and out of their respective
holes, then tie a knot or tape a mixing stick across the end at right angles to prevent them sliding
back inside the fin.
Test fit the vertical fin
Tape the rudder cable threads then push the cable forwards until it can be tucked inside the slot in
the mounting stub. Lift the fin up and over the tail spar and slide the fin down into place. You may
have to trim as small amount out of the fuselage behind the tail spar to clear the fin spar. A jigsaw is
ideal for this task.
Check the fit along the entire joining line and mark and remove as required to achieve a good fit.
Take extra care to ensure that the join at the front of the strake (at the yellow arrow in the photo
below) is smooth so that there is one continuous line along the entire length of the strake if there
is any discontinuity it will look extremely disappointing when paint is applied so take care to get it
exactly right at this time.
Too high here
Remove from
here
89 of 377

Level the aircraft
Because the alignment of the vertical fin is important the aircraft should be fixed in a wings level
attitude prior to the final fit. Place a 3 block on the top of each front wing mounting lug and place a
spirit level across the top of the cabin so that it rests on both blocks. Pack the main wheels as
required to level the aircraft.
Fit the vertical fin

You will need a second person to help you position and fit the vertical fin.
When you are satisfied that the fin will fit correctly, prepare the mounting stub on the fuselage by
sanding all of the gel coat from the surface of the joggle.
Lightly sand the inner surface of the vertical fin
and the mating surfaces of the tail spar and fin
spar.
Mix a batch of resin and carefully coat all
surfaces to be joined. Add flock and mix, then
apply a 3 5mm coat to one side of all surfaces to
be joined: both sides of the mounting stub and the
back of the tail spar.
Do not be overly concerned about getting a precisely even layer of flock the pressure of the 2
surfaces being squeezed together will ensure that the flock is evenly distributed.
With one person holding each side of the vertical fin, lift the fin into position and lower it down
while holding the sides of the fin apart as shown below.
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Take care not to let the fin just slide down into
place because it will push all the flock out of the
join, and do not let the fin slide down past the
joggle! You may want to fit 2 x self-tapping
screws at either side of the rear of the empennage
just where the joggle steps out to prevent this
happening.
When the fin is all the way down push the fin all
the way forward and allow the sides to push in
and onto the flock. Check the fit, particularly at
the strake/fuselage join.
Tie a plumb bob to a string line and fix the string
line to the top of the vertical fin then align the fin
until it is precisely vertical: the string line should
be exactly in the centre of the fin when viewed from the rear. Recheck this vertical alignment at
every step from here on.
Once the alignment is correct, secure the fin in
position. You could use a strip of heavy adhesive tape
from the outside edge of the horizontal fin, over the
top of the vertical fin and down to the other side of
the horizontal fin. Recheck the vertical alignment.
Now hold the fin forward and fix the fin spar to the
tail spar with 2 self-tapping screws as shown at right.
Recheck the vertical alignment.
Rivet the front of the strake into place with a
countersunk pop rivet at each side of the strake and
then rivet at each side of the inspection hole and the
rudder cable and remove the self-tapping screws. Recheck the vertical alignment.
Wax one side of each of 2 lengths of aluminium channel so that the flock will not stick and place as
a rail along each side the full length of the join line and secure with clamps as shown below.
Recheck the vertical alignment. Leave overnight to cure.
Next day remove the aluminium channels and the peel cloth, then use a hole saw to open the
inspection hole and a drill and jigsaw to recut the rudder cable slot. File out any rough edges.
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Fit the VHF antenna
15mm
Lower
section
flock
Ensure that the VHF coax cable exit hole is on the hinge (left-hand) side of the vertical fin
elongate the hole with a file if it is not. Sand the back of the lower section of the VHF antenna and
place it so that it is exactly 15mm below the upper section and fix it in place with 5-minute Araldite.
Note that the factory fitted upper section of the antenna has been offset slightly to the left to allow
for rudder movement: keep the lower section of the antenna exactly in line vertically with the upper
section.
Ensure that the threaded hole for the electrical connection is at the top of the lower section as shown
above right.
Mix some resin and lay up 2 pieces of glass fibre cloth across each section of the antenna in 3
places, using flock to fill the gaps at each side of the antenna before placing the cloth. Leave
overnight to cure.
Next day, shorten the VHF coax cable to length, and fit ferrite toroids, crimp 4.5mm electrical ring
terminal connectors to the inner cable and the outer coax sheath and fit heat shrink tubing over the
terminal joins, as shown in the sketch below.
Screw the inner cable to the TOP section and the braided coax sheath to the LOWER section. Tuck
any excess cable back into the vertical fin and seal completely with silicone sealant.
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Fit the static probe assembly
Assemble the static probe: using a drop of Loctite fit the bullet-nose end to the static tube, making
sure that the vent hole (circled) will be horizontal when the static probe is installed.
Put a smear of super glue around the base of the static tube then slide the PVC tube over the base of
the static tube by at least 25mm and fix firmly in place with 2 lock wire ties.
Take
particular care that the PVC tube is well secured to the static tube because once the static probe
assembly has been flocked in place there will be no access for repair work.
Push the static probe assembly back into the hole at the front top of the vertical fin so that the static
probe assembly is parallel with the top of the vertical fin and centred laterally in the fin.
Secure the static probe assembly in place with 5-minute Araldite and hold it in place while the
Araldite dries. Mix up a batch of resin and coat the area around the base of the static probe
assembly, and then add some flock to make a firm mix and shape around the base of the static probe
93 of 377

assembly to form a smooth transition from the static probe to the fin. Leave to cure overnight and
then sand to a smooth tapered finish.
This completes the Pre-Paint>Fuselage>Empennage>Fit vertical fin task.
94 of 377

Pre-Paint>Fuselage>Empennage>Fit elevator
To fit the elevator to the horizontal stabiliser, to fit the trim tabs to the elevator and the end caps to
the elevator and the horizontal stabiliser.
This task is performed on trestles prior to the fitting of the horizontal stabiliser to the fuselage.
The trim tabs and end caps may be fitted after the horizontal stabiliser and elevator have been fitted
to the fuselage, although it is usually easier to fit them as part of this task.
Materials required:
Card # 17J Elevator for the hinges
Prepare the horizontal stabiliser and the elevator
Remove the peel cloth from the horizontal stabiliser and the elevator.
Mark the top and bottom of the horizontal stabiliser and the elevator: the horizontal stabiliser is premarked and the drive arm of the elevator must face downwards.
Lay the horizontal stabiliser and the elevator on the work surface in the finished position with a
1mm gap (use 2 equally spaced mixing sticks) between them. You will need to place a wedge under
the rear of the elevator. Make sure that that the ends are aligned and then measure and mark a
centreline on each surface. Lightly clamp or tape the horizontal stabiliser and the elevator in
position.
Mark and drill the elevator hinges
Mark out the hinge positions: mark the centreline of the tailplane and then use the drawing on the
next page and mark the correct hinge locations, which will be the same on each side.
Place the hinges in those locations with the flat side of each hinge facing upwards and the hinge pin
aligned in the centre of the gap between the horizontal stabiliser and the elevator.
Do not place the hinge flat side down if you do then the holes will not line up correctly when you
come to fit the hinge.
Use a 3/32 drill to make a pilot hole opposite the pin side of each rivet hole: this is to allow for the
slight slope of the hinge at this point, then check that the hinge and hole positioning is correct and
then carefully expand to 3/16 holes.
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96 of 377

Fit the elevator hinges
Test fit the hinges using 2 Clecoes per side and slide the hinge pin into place as shown above.
Fit the 2 outer hinges first this will hold the elevator in place while the inner hinges are fitted.
Each hinge pin is inserted from the inside towards the outside of each hinge. Mark the location of
the end of each hinge pin (circled at above right). Check that the elevator can swing freely with no
binding in the hinges: adjust the hinge mounting holes if required.
Check that the horizontal stabiliser to elevator gap is even along the full length then remove the
elevator and hinges. Leave the horizontal stabiliser clamped down.
Sand the flat side of each hinge and the locations where they will be fitted, then mix a small batch
of resin and coat each area. Add flock to the remaining resin and apply a 2mm layer of flock to each
hinge and flock into place using clean Clecoes in the outer holes as before.
Using a 120 countersink bit carefully countersink the 4 inner holes just enough so that a
countersunk rivet head will sit flush with the surface when fitted and rivet the 4 inner holes with
countersunk rivets. Now remove the Clecoes from the outside holes one at a time, countersink each
hole and fit a countersunk rivet until each hinge has 8 countersunk rivets.
Take care to keep flock away from the hinge pins during this step: clean the hinges while the flock
is still wet and then separate both parts (horizontal stabiliser and elevator) and leave overnight to
cure. Clean the Clecoes in acetone after use.
Next day use a rat tail file to make a slot into the horizontal stabiliser at each
hinge pin mark (example circled at above right), fit the hinge pin and the hinge
pin retainer, mark the retainer screw hole and drill a 3/32 hole. Pop rivet an
anchor nut under each screw hole using 2 x 3/32 countersunk rivets.
Fit the trim tabs
Mark the trim tab locations on the elevator from the dimensions given on the
drawing on the previous page. Note that the trim tabs fit onto the top of the elevator and face
downwards.
Clamp the trim tabs in position using spring clamps and drill the 3 holes as shown. Lightly sand the
surfaces to be joined, then mix a small batch of resin and coat the surfaces to be joined. Add flock
to the resin and stir in thoroughly, then apply a 2mm layer of flock to each trim tab and fit into place
with 3 self-tapping screws.
Clean away any excess flock with the mixing stick, leaving a smooth radius around the entire join,
and leave overnight to cure. Next day remove the self-tapping screws.
97 of 377

Fit the elevator end caps
Assemble the horizontal stabiliser and the elevator by inserting all of the hinge pins and set the
elevator to a level position.
Use
a
knif
e to
tri
m
out
so
me
of
the
foa
m
in
the
end
of
the elevator and then test fit each end cap. Ideally you want a gap between the end of the horizontal
stabiliser and the elevator end cap (yellow arrows above) the thickness of 2 mixing sticks. When
this gap has been achieved, align the rear of the end cap with the rear of the elevator and fit with
self-tapping screws. Check that the elevator can swing freely: if there is any binding or rubbing
between the end cap and the horizontal stabiliser locate the source and fix it, either by moving the
end cap position slightly or by sanding away part of the inside of the end cap.
Remove the end cap and sand all surfaces to be joined, then mix a batch of resin and coat those
surfaces. Add flock to the remaining resin and apply a 2mm layer to the end cap stub then fit the
end cap to the elevator and fix in place with the self-tapping screws. Smooth away any excess flock
with a mixing stick, recheck the alignment and leave overnight to cure. Next day remove the selftapping screws.
Fit the horizontal stabiliser end caps
With the horizontal stabiliser and the elevator still assembled, test fit the horizontal stabiliser end
caps: the gap between the elevator end cap and the horizontal stabiliser end cap should also be the
thickness of 2 mixing sticks (green arrows above). When this is correct fit the end cap with 3 selftapping screws: 1 at each back corner and 1 at the leading edge. Check for freedom of movement
then remove the end cap and prepare the surfaces and flock the end cops into place and fix with the
self-tapping screws. Smooth away any excess flock with a mixing stick, recheck the alignment and
leave overnight to cure. Next day remove the self-tapping screws.
Fit end caps for Short span horizontal stabiliser

These additional instructions are provided for the end caps specific to the special short span
horizontal stabaliser. If your horizontal stabaliser is part number 2A109F0N this additional
guidance is helpful for end caps.
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The photograph below illustrates the difference between the short span and full span horizontal
stabalisers and their respective end caps. For the Short span stabaliser the end cap is across the
entire chord (not just the front half). As such the joggle on the short stab is full chord to
accommodate bonding this large end cap.
Full span stabaliser
Short span
stabaliser
(p/n
2A109F0N)
One important difference when fitting the elevator cap is that you should first fit the stabaliser
endcap. Remove all peel cloth on the stabaliser and end cap and push the end cap onto the stabaliser
over the joggle. Check the trailing edge of the end cap is aligned with the trailing edge of the
stabaliser. Most likely the end cap will exceed past the stabaliser, to correct this mark and trim and
sand to be flush. Now you can pre-fit the elevator cap as previously detailed. If the gap (indicated
by yellow) on the previous photo is too small you can remove the stabaliser end cap and lightly
sand the edge as indicated by Cyan above and then refit it, until this gap is sufficiently large. If the
gap (indicated by green) on the previous photo is too small then you can lightly sand the edge of the
end cap indicated by red until the gap is sufficient.
Remove the pre-fitted elevator endcap and bond the stabaliser endcap in place. Bonding the short
span horizontal stabaliser end cap is the same as previously detailed for that of the full span. The
only difference is that it is recommended that you use 5 self tapping screws instead of 3 since the
bonding area is larger and additional fixed points will enable a better bond. Now you can bond
elevator endcap as previously described. Check the alignment and leave to dry overnight, next day
remove the self tapping screws.
This completes the Pre-Paint>Fuselage>Empennage>Fit elevator task.
99 of 377

Pre-Paint>Fuselage>Empennage>Fit horizontal stabiliser

To fit the horizontal stabiliser to the fuselage and glass it in place. Note that the elevator hinges
were fitted in the previous task Pre-Paint>Fuselage>Empennage>Fit elevator.
Materials required:
Glass fibre cloth and peel cloth in the bag labelled: Horizontal Stabiliser
Steps
1. Level the aircraft
2. Fit the stabiliser
3. Glass the tailcone
4. Glass the stabiliser
Level the aircraft
The aircraft should be fixed in a wings level attitude prior to fitting. Place a 3 block on the top of
each front wing mounting lug and place a spirit level across the top of the cabin so that it rests on
both blocks. Pack the main wheels as required to level the aircraft.
Clamp a straightedge (a 2 or 3 metre length of aluminium angle works well) across the back of the
door frames at the height of the fuselage join line: ensure that the straightedge is level. This will be
your main reference for aligning the horizontal stabiliser.
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Fit the stabiliser
These instructions only apply to installing tailplanes with part number 2A109A0D (for the J230 kit)
or 2A032D0D (for the J170 kit). Older tailplanes require different instructions.
These fitting instructions also apply to the special short horizontal stabiliser (p/n 2A109F0N, for the
J230 kit) which is about 300mm shorter then 2A109A0D and uses large end caps to make up the
difference.
Note: It is important that you determine which horizontal stabiliser you

have.
Prepare the stabiliser by taping up the inboard elevator hinges to prevent any resin getting into the
hinge pins. From the previous task you will have a marked centreline on the stabiliser: test fit the
stabiliser to the rear of the fuselage using the stabiliser centreline as a lateral location guide against
the fuselage centreline.
Pus
h
the
sta
bili
ser
full
y
for
war
d
into the rear of the fuselage and check that each end of the stabiliser is an equal distance back from
the straightedge use 2 tape measures as shown circled above, one each side, and carefully move
the stabiliser until the measurements are exactly the same. Sight along the fuselage from the rear
and confirm that the stabiliser is level and lined up with the straightedge. The chord line of the
stabiliser is to be angled down 3 degrees at the leading edge. Make any adjustments necessary.
When the stabiliser is aligned correctly, secure the stabiliser to the fuselage with self-tapping
screws, using 10 screws per side. These screws will be removed after the stabiliser has been finally
fitted. Run a pencil line around the stabiliser along the fuselage join.
Remove the stabiliser from the fuselage and remove the peel cloth from the rear of the fuselage,
then lightly sand all the surfaces to be joined the pencil line on the stabiliser will act as a guide for
where to sand and where to coat with resin.
101 of 377

Mi
xa
bat
ch
of
resi
n
and
divi
de
into
2
part
s. Coat all the surfaces to be joined. Add flock to one part of the resin and apply a layer to the rear
of the fuselage then slide the stabiliser in to place, pushing it fully forward. Open the join and use a
mixing stick to force flock into the sides and rear of the join, working from the inside of the
empennage through the hole in the top, then smooth the flock along the outside. Fix the stabiliser in
place with the self-tapping screws, do a final check of the alignment and leave overnight to cure.
Next day, remove the self-tapping screws that were used to temporarily fix the stabiliser in place. If
they are difficult to remove heating each screw with a soldering iron will help.
Lightly sand the surface around the root of the join between the leading edge of the horizontal
stabiliser and the fuselage, then mix a small batch of resin and coat the surfaces where the glass
fibre cloth will be placed. Cut a small square of glass fibre cloth to cover the root of the join as
shown below and brush it into place.
This completes the Pre-Paint>Fuselage>Empennage>Fit horizontal stabiliser task if you have

Horizontal Stabiliser P/N 2A109A0D, 2A109F0N (for J230 kits) or 2A023D0D (for J170 kits), if
your P/N is 2A069A0D then continue.
102 of 377

Glass the tailcone
In this step you will apply 3 layers of 320 x 200mm glass fibre cloth to the tailcone, starting at the
top and wrapping the glass cloth behind the stabiliser and under the tailcone.
First cut a piece of foam 225mm long, 57mm high & 27mm deep and fit it to the rear of the
stabiliser, tapering it towards the bottom as shown in the photo above left, and cut a thin strip of
foam to fill the void under the stabiliser.
Mix a batch of resin and coat the tailcone and the foam blocks and flock them into place. Place the
first sheet of glass fibre cloth centrally on the tailcone and brush it on, then down over the foam
blocks, cut to clear the elevator stop and brush under the tailcone taking care to avoid any bubbles
or gaps.
The second layer of glass cloth is placed offset to the right as shown above and brushed on in a
similar manner, followed by the third layer, which is offset to the left by the same amount.
For reduce sanding then apply peel cloth over all the
glassed surfaces and brush on carefully to ensure a smooth
finish.
This completes the Pre-Paint>Fuselage>Empennage>Fit

horizontal stabiliser task.
103 of 377

Pre-Paint>Fuselage>Empennage>Fit rudder
To fit the rudder to the vertical fin, align the rudder and fit the rudder stops and rudder cable.
Materials required:
Card # 3J Rudder
Prepare the fin
In order for the rudder to correctly swing full travel both left and right, a cutout must first be made
at the top of the vertical fin. Cut about 3mm in from the right side. On the left side cut a similar
profile to the gusset below as the pictures below indicates.
3mm
Gusset
Align the rudder
The first step is to line up the top of the fin and
the top of the rudder: the vertical alignment.
Tape a mixing stick to the fin at the 2 positions
indicated by the yellow arrows at right and sit the
rudder in place.
Place mixing stick(s) as required at the bottom of
the rudder to get an even gap.
It may be necessary to adjust the vertical gap
slightly or sand the top of the fin or rudder in
order to get a precise and visually pleasing
alignment.
Once the vertical alignment is correct the fore
and aft alignment can be addressed: the second
step is to equalise the gaps between the fin and
rudder and the top of the fin and the rudder horn.
It may be necessary to sand part of the forward
section of the rudder horn and/or the back of the
fin ahead of the rudder horn away, taking care
not to make either area too thin. Take your time and get this alignment exactly right the tail
fin/rudder is a very visible part of an aircraft and time spent now will reward you with the pleasure
of a great looking tail on your aircraft. Leave the mixing stick alignment spacers taped in place at
this stage. Use the photo of a finished example above as a guide of how the rudder should look.
104 of 377

Pre fit the hinges, mount and swing the rudder
Mark the initial hinge locations onto the vertical fin from the drawing 2 pages down, then number
the hinges on both sides as well as the matching positions on the fin, including an arrow for up on
each hinge.
Notice that the flat side of the hinge faces out.
With the rudder still in place, hold each hinge centered over the
between the vertical fin and the rudder and mark the final
mounting position of each: the hinge pin should sit in the centre
the fin to rudder gap.
gap
Remove the rudder and set it aside while the hinges are fitted to
tail fin.
the
of
Hol
da
hing
e in
posi
tion
and
drill
the
top
hole
only
and
tem
porarily fit the hinge in place with a rivet as shown above, then carefully reposition the hinge so that
the hinge pin is parallel to the back of the rudder and drill the bottom hole and fit a rivet in that
hole, then drill the remaining 2 holes. Repeat this process for each hinge.
Put the rudder back in place using the spacers that you left taped in place. Make sure that the
alignment is still correct, then drill the top hole of the top hinge and fix in place with a rivet, and
then drill a hole in the bottom hinge and fix that in place with a rivet. Repeat the process until all
holes are drilled and each hinge is temporarily fixed to the rudder with 2 rivets.
Test fit the rudder using Clecoes to hold each hinge in the final mounting position, which is inside
the fin and inside the rudder as shown above. Remove the spacers and check that the rudder can
swing freely left and right at least 100mm from the centreline as measured at the rear of the rudder.
If there is any binding locate the source and correct it.
Mark the location of the end of each hinge pin (on the following page on the left), then remove the
rudder and all hinges.
105 of 377

Fit the rudder

The objective now is to refit the rudder as before with Clecoes but with a 2mm bed of flock under
each hinge, do a final check of the alignment and rivet the hinges into place.
Lightly sand the flat side of all hinges and the inside of the fin and the rudder where the hinges will
be placed. Mix a batch of resin and coat the hinge mounting areas inside the fin and the rudder, then
mix in flock and coat the fin half of each hinge. Clecoe the hinges in place on the fin as before.
Now apply flock to the rudder half of each hinge and mount to the rudder in the same way: with
Clecoes in the centre holes.
Check the rudder for free movement and once you are satisfied that there is no binding then
countersink each hole with a 120 countersink bit and rivet each hinge with countersunk rivets top
and bottom holes first, rechecking for free movement at each step, then take the Clecoes out and
countersink and rivet the centre holes. Take care to keep any flock away from the hinge pins during
this step.
Do a final check for free rudder movement, then carefully remove the hinge pins and rudder, clean
away any excess flock with a clean mixing stick and leave overnight to cure.
Next day use a rat-tail file to make a slot into the fin at each hinge pin mark, fit the hinge pin and
the hinge pin retainer, mark the retainer screw hole and drill a 3/32 hole. Pop rivet an anchor nut
under each screw hole using 2 x 3/32 countersunk rivets.
Fit the rudder stops
Make a template that will sit over the rear of the empennage and tape it in place. Find the centreline
106 of 377

of the fuselage and mark a 5mm offset to the right onto the template, then mark 80mm each side of
the offset as shown above. Refit the rudder.
Swing the rudder to the left-hand mark on the template
and mark the position of the rear rudder stop and fit it in
place with 2 countersunk self-tapping screws. Swing the
rudder to the right and fit the front stop the same way. It
may be necessary to sand inside the right-hand side of the
fin to clear the rudder at full right deflection.
It may also be necessary to sand away part of the lower
right of the fin (arrowed at right) to allow clearance for
the rudder arm at full right rudder deflection.
Check the swing both ways and adjust the stops if required. Once the positions are correct remove
the stops and sand the base of each stop as well as the position in which they will be mounted, then
mix a small batch of resin, coat the joining surfaces and flock both stops in place, holding each in
place with the self-tapping screws. Smooth away any excess flock and leave overnight to cure.
Fit the rudder cable bracket clamp
Fit a rod end to the rudder cable: thread it on to half the thread depth. The total cable travel is
80mm: pull the inner cable all the way out and make a mark at 40mm from the outer cable then
push the inner cable in to that mark. This puts the cable at the centre of its travel.
Fit the rod end to the rudder arm with a bolt.
Locating
groove
Half
travel
Half
travel
Secure the rudder in the 5mm right of centre position on the template, then hold the rudder cable
horizontal and mark the location of the locating groove in the outer cable.
Hold the cable clamp in place and drill a 3/32 pilot hole
into the fin through each hole in the clamp, then check
the holes from the back through the access hole (as
pictured at right) there needs to be enough room above
the top hole and below the bottom hole to fit the head of
the bolt in place.
Make any vertical adjustments that may be required then
drill to 3/16. Test fit the cable clamp: feed the bolts from
the inside and through the side of the fin, then place the
angled cable clamp packer against the side of the fin with
the wider part of the packer to the rear of the aircraft,
then the cable clamp shim and finally the cable clamp.
Secure temporarily with plain nuts final assembly will
require Nyloc nuts.
107 of 377
Top of stub
Clearance
Clearance
Fuselage

Test the movement of the rudder and rudder cable: make sure that the rudder can be moved to each
stop by use of the cable without any binding.
Remove the rudder cable fittings and the rudder and set aside for painting, put all hinge pins, hinge
pin retainers and rudder cable fittings into a labelled container for reassembly after painting has
been completed.
This completes the Pre-Paint>Fuselage>Empennage>Fit rudder task.
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Pre-Paint>Fuselage>Fit cowling
To fit the top and bottom cowl to the fuselage. This is a big task that will require time and patience:
the cowl will need several test fittings and small adjustments to get the fit just right: take your time
and your reward will be a perfectly fitting, great-looking cowl.
Materials required:
Card # 13JT Cowl components and the piano hinges pack (pictured below)
5-Minute Araldite
Match the cowl joins and cut the propeller shaft hole
Start by standing the top and bottom cowls on their bases, align the front of each section carefully
and then tape both sections together using cloth tape (circled above).
Look along the side joins and check the alignment: the top and bottom sections should butt up to
each other with no gaps as shown at above left. Sand away any areas that overlap until each join is
straight and true. Mark the centre front of the propeller boss area then mark a 105mm circle and use
a jigsaw to cut the hole out. In the factory we use a circular jig as shown in the second photo but the
hole can easily be scribed with a compass. Sand any rough edges.
Fit the top cowl to the fuselage
In this step we will need to make up a spacing jig (shown at left)
that will keep the front of the top cowl 20mm behind the propeller
flange and 15mm above and centred on the propeller shaft
extension, plus a 3mm spacer on top of each ram air duct. Wooden
blocks cut to size are fine for the purpose.
Tape the jig into place and test fit the top cowl.
Once the front of the top cowl is correctly positioned and
centred on the propeller shaft extension, move to the back of
the cowl and ensure that it is centred side-to-side: mark the
fuselage waterline on each side of the fuselage (photo at right)
and measure up to the cowl from that line then move the cowl
side to side until the distance is equal on both sides. Recheck
that the front of the cowl is still centred. When the cowl is
centred at the front and back, mark the centreline on the cowl
and on the fuselage in front of the windscreen and then tape the
cowl to the fuselage.
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Waterline
Same both
sides

Mark and cut the cowls to length
In the next 2 steps we will need to cut both cowls to length so that they will fit into the joggle.
Line up
this edge
Front edge of
tape exactly
level with
joggle step
To mark
and cut
this edge
Front edge of
tape exactly
level with
joggle step
Back edge
of tape
In the factory we have a handy technique that we use to mark the cut: we run masking tape all the
way around the outside of the joggle on the fuselage with the front edge of the tape exactly level
with the step of the joggle (left photo above) and then when the cowl is in place we run another strip
of masking tape around the cowl but with back edge of the cowl tape in line with the back edge of
the fuselage tape (left photo below), so we use the width of the tape as a way to accurately mark
where to cut. masking tape is ideal for the purpose.
Line up the back
edges of the
fuselage and cowl
tapes
Cut along the

front edge of the
cowl tape
In the photo above left the back edge of the cowl tape is being aligned with the back edge of the
fuselage tape, while in the photo above right the cut is being made in line with the front edge of the
cowl tape. Sand any rough edges away with a long sanding block and refit the top cowl, using the
centreline mark to position the cowl at the back and checking that the front of the cowl is still
centred, then tape the top cowl into place.
The same masking tape technique will be used to cut the bottom cowl to length.
Drill 3 x 3/32 holes through the top cowl and into the fuselage: each hole should be 10mm in from
the edge of the cowl, with 1 on the cowl centreline and 1 each side 30mm up from the cowl join.
Temporarily fix the top cowl into place with 6G stainless steel screws.
Now that the top cowl has been positioned we can fit the bottom cowl to match it.
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Fit the bottom cowl to the fuselage
Offer the bottom cowl up to the top cowl a well padded saw stool can be used to hold the cowl up
and fit the locating section at the front of both cowls to position the bottom cowl.
Butt the joins together and tape the bottom cowl to the
top cowl.
Using the same technique that you used on the top cowl,
use masking tape to mark the cowl to the correct length
then remove the bottom cowl and cut along the front of
the masking tape. Sand all cut surfaces with a long
sanding block.
Refit the bottom cowl and tape into place, then mark and
drill 5 x 3/32 holes on each side, each 10mm in from
the edge of the cowling and each at 60mm away from
each bend plus one screw near the bottom of the cowl
the lines in the photo above show the positions.
Temporarily fix the bottom cowling to the fuselage with
6G stainless steel screws.
Trim and finish the ram air ducts
10mm
3mm ram air

duct spacer
12mm
Cowl
Remove the top cowl and mark the front of the ram air ducts 10mm back from the inside of the
bottom cowl as shown above left.
Remove the ram air ducts and trim to the mark, sanding away all rough edges.
Mix up a small batch of 5-minute Araldite and flock and bond the rubber sealing strips around the
front of each ram air duct as shown above right, holding the strips in place at 12mm in front of the
ram air duct with spring clips while the flock dries.
Remove the bottom cowl and take both cowls to a cleared workbench.
Pre-fit the cowl hinges
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You will need some Clecoes for this step. The objective is to
position and pre-fit the hinges using the Clecoes and then flock
and rivet the hinges permanently into place.
Lay both hinge pairs side by side on the bench. The hinge with
the first loop at the very end will be the bottom hinge. Mark the
Top and Bottom part of each hinge pair and then mark each
pair Left or Right. Mark and drill 3/32 holes along the
centre of each hinge starting at 10mm in from the end and then at
100mm centres.
Assemble each hinge pair by sliding the long hinge pin through the full length of the hinge. Note
that the hinge pin is much longer than the hinge do not trim the hinge pin to length! The extra
length will be used when the hinge pin is fitted through from the door jamb and into the hinge later
in this task. Put a cloth tape flag on the exposed end of the hinge pin to prevent possible accidents.
Fit both cowls together, fitting the locating section at the
front of both cowls first and then butt the side joins
together. Tape the cowls together with cloth tape on
both the inside and outside of the joins. Now roll the
cowl so that one side join is on the bottom and place the
appropriate hinge assembly 30mm in from the back
edge of the cowl shorten the hinge if required. Take
care that the hinge is placed so that the hinge pin is
exactly in line with the join and with the side of the
hinge marked Bottom in the bottom cowl.
Hold the hinge firmly in place and drill a single 3/32
hole through the cowl at the back end of the bottom
hinge and fix the hinge in place with a Clecoe.
Now align the front of the bottom hinge, drill and
Clecoe into place. Repeat the process on the top hinge
then drill and Clecoe every other hole. Drill the
remaining holes though the cowl.
30mm
Roll
the
cowl around to the other join and repeat the entire
process for the other hinge.
At this stage the hinges hold both cowls together
as shown at right, with Clecoes fixing the hinges
to the cowls.
Mark each hinge and the cowl half that it belongs
to and then remove the Clecoes and the hinge
pins.
Fix the cowl hinges
Sand the bonding surface on each cowl half and
the backs of each hinge half to give the flock a good key to bond to. Clean your Clecoes in Acetone
and dry them. Keep the tin of Acetone handy for later (in fact storing your Clecoes in Acetone can
be a good idea because it keeps them free of oil and other contaminants that could affect an efficient
bond).
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Mix a batch of resin and coat the bonding surface of each cowl then add some flock to the
remaining resin and then, working on one half of one hinge at a time, apply an even layer of flock
approximately 2mm thick to the hinge and fix the hinge in place with clean Clecoes in every other
hole and then rivet the remaining holes before removing the Clecoes.
Working on one hole at a time, drill a 3/32 hole and use a
120 countersink bit to carefully countersink the outside of
each rivet hole just enough to allow a countersunk rivet to sit
slightly below the surface of the cowl (example circled at
right) then rivet each hole before moving on to the next hole.
Drop each Clecoe in the Acetone as you remove it to clean the
flock out of it. Clean away as much flock as possible from around the hinge pin holes, smooth the
flock along the other side of the hinge with a mixing stick and leave the flock to cure overnight.
Next day test fit the hinge pins and remove any remaining flock from the hinges.
In the factory we use a special drill bit (shown above) that is just a standard drill bit welded onto the
end of a spare hinge pin and we clean the hinges through with that (top photo), using a low drilling
speed to prevent any whipping of the long bit. It is important that the hinge pins fit easily into the
hinges without any restrictions.
Fit the hinge pin guides
These guides are the 2 lengths of aluminium tube on the Card that are used to guide the hinge pins
through the door jambs and into the cowl hinges. When the cowls are finally installed the ends of
the hinge pins will be bent in at right angles and the door will hold them in place.
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Refit the bottom cowl to the fuselage and hold the hinge in against the joggle then mark a line
beside the firewall and directly behind the hinge. Drop the cowl and drill a hole at this point as
shown above left: it will be just inside of the fuselage skin.
Mark a point on the front of the door jamb 10mm in and in line with the cowl join as shown above
right, which will be very near to the waterline, and drill a hole towards the hole that you have
just drilled. Use a file to round the ends of the guide tubes slightly.
Cut off
flush here
Araldite/flock
along this area
Guide tube
Firewall
Door jamb
Rib
Continue to drill through the rib until the guide tube can be pushed all the way from the door jamb
and through the firewall.
Allow the guide tube to protrude very slightly, about
as shown circled at right.
Check that the hinge pin will line up with the bottom
cowl in place and then fix the guide tubes in place with
5-minute Araldite and flock.
Hint: a strip of masking tape under the tube acts as a
dam to keep the Araldite/flock mix in place while it
cures. Once the Araldite/flock mix has cured use a
hacksaw to cut the tube off flush with the door jamb.
Clean any burrs and flock out of the guide tube.
Repeat the process for the other side of the fuselage.
Final fit the cowling
Fit the top and bottom cowls to the
fuselage and insert the hinge pins from
the front door openings. Drill one 5/16
hole through each side of the propeller
boss for a Camloc fitting (shown circled
at right).
Starting with the bottom cowl, remove one 6G stainless steel screw at a time and drill the hole out
to 3/16, then drill the 3 holes in the top cowl to 5/16.
Remove the cowls and fit the
captive nuts (a complete
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captive nut assembly shown at right) to the 3/16 holes in the bottom of the fuselage.
Use the captive nut itself as a jig to drill the rivet holes as shown at above right thread the screw
part way through the captive nut from the back and fit the exposed end of the thread into the hole in
the fuselage, then drill the 2 x 3/32 rivet holes.
Repeat this process for each captive nut and then fit the captive nuts to the inside of the fuselage,
countersinking each rivet hole and riveting from the outside of the fuselage.
Use a similar technique for the 5 Camloc fasteners in the top cowl
(3 at the back, 2 around the propeller boss): hold the captive part of
the Camloc centred over the hole and drill the 3/32 rivet holes then
fit the captive part inside the fuselage, once again countersinking
the rivet holes on the outside of the fuselage. A complete Camloc
assembly is shown at right:
Countersink the holes in the bottom cowl enough to allow the Tinneman washers to seat snugly. Do
not countersink the holes in the top cowl, just deburr them.
Fit the machined oil door
Locate the marked position on the right side of the top cowl. Lay
the oil door on the marking and mark around it, then move the oil
door forward 2mm and remark the front this slightly larger gap
(circled at right) is to allow for the forward movement of the hinge
when the oil door is opened.
Assemble the door to the hinge and fit to the hinge surround. Sand
around the inside of the oil door opening and then test fit the door
assembly, taking care to keep the door centred sideways and to the
rear of the opening with the hinge to the front. Tape the door to the
cowl with 2 strips of cloth tape to keep the correct position.
Mix a batch of 5-minute Araldite and flock, then lift the hinge
frame up, apply the Araldite/flock mix to the hinge frame and seat
the hinge frame to the cowl. Take particular care that no
Araldite/flock gets into any part of the hinge.
Fit the cabin air inlet flange
a 30mm hole on the left front of the lower cowl, 100mm below the bottom lip of the air inlet
and 180mm to the left of the
propeller centreline.
Drill
Sand the back of the flange (from

Card # 25JT) and around the
inside of the cowl around the hole.
Mix a small batch of 5-minute
Araldite and flock and fix the
flange into place.
100mm
180mm
Fit the induction air (NACA) duct
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The induction air duct is fitted to the left hand side of the bottom cowl.
90mm
140mm
Assemble the duct with 5-minute Araldite. Hold the scoop on the outside of the cowl in the position
as shown above, keeping the rear edge of the scoop at right angles to the hinge line and mark
around the outside of the unit and then make a second line inside the first about the size of the
actual opening.
Cut the opening and fit the scoop to the
inside of the cowl, holding it in place
with 5 x 6G stainless steel screws and
adjust the opening to match the shape of
scoop. Mix a batch of 5-minute Araldite
flock and fix the scoop into place,
holding it in place with the screws.
the
and
When the Araldite/flock has cured, heat

and
remove the screws, mix a small batch of resin and apply a single layer of AF303 glass fibre cloth on
the inside of the cowl over both sides and across the rear of the scoop. Leave overnight to cure.
Next day apply filler to blend the cowl opening smoothly into the scoop.
Do a final test fit then remove and store the cowls and hinge pins until you are ready to paint.
This completes the Pre-Paint>Fuselage>Fit cowling task.
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Pre-Paint>Fuselage>Fit flap drive shaft bearing blocks

In this task you will position and flock the flap drive shaft bearing blocks to the inside of the
fuselage.
Note that the flap drive shaft will be fitted in the Post-Paint section: only the bearing blocks will be
fitted in this task.
Materials required:
Card # 16T or 16J Flaps
Resin and flock
Prepare the drive shaft
The flap drive shaft is only used for bearing block alignment at this stage, so you will need to
remove all the fittings: one drive arm from each end and the lever arm from one end, until you have
just the bare tube. Note that there are actually 2 tubes, one inside the other: make sure that both
tubes are still together when this task is completed and the shaft is reassembled.
Position the bearing blocks
Place the drive shaft through the pre-drilled
holes (circled) so that the shaft protrudes an equal
amount from each side of the fuselage, then slip
one bearing block on each end with the screw
holes to the top.
Level the top of the block, hold it firmly in place
and drill 2 x 3/16 holes through the fuselage skin,
using the bearing block as a drilling jig as shown
below right:
Mark the blocks to indicate which side of the
aircraft they fit to as well as an arrow towards the
front of the aircraft, then remove the flap drive
shaft and the bearing blocks. Wax each end of the
shaft it will be used to align the bearing blocks
as you flock them into place and the wax will
prevent any flock sticking to it.
Countersink the outside of the screw holes to suit
the Tinneman washers.
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Fit the bearing blocks
Roughen the inside of the fuselage around the area where the bearing blocks will be mounted and
sand the backs of the bearing blocks, mix a small batch of resin and coat the area to be bonded then
add flock to the resin and apply a 3mm bed of flock to the back of each block, then slip them onto
the shaft with the flocked sides facing out and fit the shaft to the fuselage one end at a time,
working from inside the cabin.
Move each block out and bed it against the fuselage and secure it with countersunk screws and
Tinneman washers from the outside of the fuselage and washers and Nyloc nuts on the inside The
photo above shows the bearing blocks (circled) flocked into place with the drive shaft keeping them
in alignment: the photo has been taken from the front of the aircraft facing towards the rear.
Tighten the nuts just enough to hold each
block in place while leaving the shaft free
turn. Clean away any excess flock from
around the block and leave overnight to
cure. The photo at right shows the fitted
block from the outside with the drive shaft
in place, while the photo below shows the
block from the inside with the shaft
removed.
to
still
Next day tighten the Nyloc nuts firmly and do a

final check for binding, then remove the flap drive
shaft completely: pull it out through one side of the
fuselage, clean off the wax, make sure that the inner
and outer shafts are fitted together then reassemble
the drive fittings to the shaft and store for later use.
This completes the Pre-Paint>Fuselage>Fit flap drive shaft bearing blocks task.
118 of 377

Pre-Paint>Fuselage>Interior>Console>Pre-fit handbrake
To pre-fit the handbrake master cylinder and lever to the centre console. At the completion of this
task the handbrake will be removed and stored until final fitting following painting and installation
of the interior trim.
Completed handbrake master cylinder, handbrake
lever and locking cam, as viewed from the right-hand
side
Locking
cam
Materials required:
Card # 29JT Brakes
Loctite 577
Fit the master cylinder
Using a small bead of Loctite 577 on the thread,
attach the brass compression fitting to the master
cylinder and tighten firmly. Put a piece of masking
tape over the hole to keep foreign objects out.
Drill the upper and lower mounting holes out to 5/16
(arrowed below), then, working through the side
access holes in the console, fit the brake lever mount
into the front of the console (refer to drawing
6A027A0D-3 on the next page for detail) using two
hex head bolts in the top and bottom holes, then
mount the master cylinder to the brake lever mount
with the cap screws the photo at right shows the
orientation of the components: note that the brake
lever mount has the pivot hole to the top.
Compression
fitting
The photos below show the fitting of the brake lever

mount and the master cylinder to the console.
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Fit the handbrake lever
Assemble the two red knobs to the handbrake lever, with the longer knob to the left of the lever (the
same side as the machined recess) and secure with the supplied bolt and nut.
Fit the handbrake lever cam to the right-hand side of the handbrake lever with the supplied bolt and
Nyloc nut and with a Bundy tube bush in place to allow free movement of the handbrake lever
locking cam.
The lever assembly can now be fitted to the brake lever mount. It may be necessary to file the cutout on top of the console in order to achieve full fore and aft travel of the handbrake lever as well as
the correct side clearance for the handbrake lever locking cam.
Check that the handbrake lever has full movement and that the handbrake lever locking cam does
not bind against the sides of the console cutout, then remove the entire handbrake assembly and put
aside until the Paint and Interior Trim tasks have been completed.
This completes the Pre-Paint>Fuselage>Interior>Console>Pre-fit handbrake task.
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Pre-Paint>Fuselage>Interior>Console>Pre-fit trim control

To pre-fit the trim pivot assembly, trim stops and the dual trim levers to the centre console and fit
the trim cable clamp to the seat base. At the completion of this task the trim levers will be removed
and put aside until the final fitting following painting and installation of the upholstery.
Trim lever
Rod end
Pivot bush
Trim cable
Trim stops
This task is broken down into three items, which should be done the following order:
1. Align & fit the trim pivot bushes
2. Align & fit the trim stops
3. Align & fit the trim cable clamp
Materials required:
Card # 2T or 2JTrim System
Epoxy Resin and Flock
5 minute Araldite
260 x 160mm 3-ply for template
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Trim pivot and trim levers:
Trim levers
Friction washers
Pivot bushes
Pivot barrel
Pivot shaft
Align and fit the trim pivot bushes

Pilot holes for the pivot bushes are pre-drilled in the console. Start by enlarging the holes for the
pivot bushes slightly with a round file until the pivot bushes can be fitted snugly and the file sits
level through the holes and square to the console when viewed from above.
Screw the left-hand pivot bush firmly into the pivot barrel.
Push the pivot barrel through the console and flock into place then
loosely fit the right-hand side pivot bush. Line up the left-hand side
rivet holes and secure the left-hand side pivot bush with three TLR
rivets as shown at left.
Push the pivot shaft through the pivot bushes and temporarily fit
the trim levers, including the friction washers, and tighten the
castellated nut onto the pivot bolt by hand until the trim levers are
held securely onto the pivot shaft.
Move the trim levers fore and aft: both trim levers should maintain an even distance out from the
console. If this is not the case the hole for the right-hand pivot bush may need to be elongated
slightly to correct the alignment. Note that if the right-hand hole has been elongated you will need
to rotate the right-hand pivot bush 1/6 of a turn and drill three new rivet holes for that side only.
Once the trim levers can move freely fore and aft while maintaining an even distance out from the
console, flock and tighten the right-hand pivot bush firmly into place and secure with three TLR
rivets, fitted one at a time and rechecking the trim levers alignment after each rivet has been placed.
Smooth any surplus flock with a small amount of resin on a clean mixing stick.
Align and fit the trim stops
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Make the template from a piece of 3-ply plywood as shown below and position the hole at the
bottom of the template on the pivot shaft and the top level with the top of the forward console.
Mark the locations for the trim lever stops on the left hand side of the console only and lightly sand
the areas underneath to ensure a solid joint. Using 5 minute Araldite and flock, fit the trim lever
stops in position, temporarily secure each with a self-tapping screw and leave to cure, then remove
the screws and fill the holes.
trim stops
trim pivot bush
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Align and fit the trim cable clamp
It is important that the trim cable clamp is accurately positioned against the left-hand side of the
console in a way that minimises any bending loads on the trim cable. The procedure is as follows:
with the trim cable in place and working from the left-hand side of the console, put a rod end fully
onto the cable end: thread the rod end all the way onto the cable end, then bolt the rod end to the
left-hand trim lever as shown in the first photo below.
Push the inner trim cable all the way into the outer cable then put
the trim lever against the rear trim stop as shown at left. This is the
correct position for the outer cable to be secured by the cable
clamp. Fit the cable clamp to the outer cable and make sure that
the cable clamp grips the locating
groove on the outer cable (circled
at right).
Rod end
Bolt to trim lever
Position the trim cable clamp

against the console in such a way as to line the trim cable up with
the rod end on the trim lever and drill 2 x 3/16 holes through the
cable clamp packer and into the side of the console as shown in the
photo shown below at right. Temporarily position with 2 x AN3
bolts.
Inner cable
packer
outer
cable
inner
cable
locating
groove
clamp
outer cable
Bond the cable clamp packer into place and leave to cure. Remove the aligning bolts. Fit the cable
clamp shim, the trim cable and the cable clamp and mount with 2 x AN3 bolts placed from the
inside of the console and secured with Nyloc nuts on the outside of the cable clamp.
Remove the trim levers, pivot bolt and pivot shaft and put aside for later fitting after painting and
upholstery have been completed.
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Pre-Paint>Fuselage>Interior>Console>Fit control stick

In this task you will fit the elevator cable to the console and then align and fit the two control
column bushes into the console, set up the endplay of the control column and fit the control stick to
the console.
Materials required:
Card # 17T or 17J Elevator System and Control Stick
Fit the elevator cable clamp
The elevator cable runs through the console
and through to the rear of the fuselage inside
the longitudinal rib.
Drill the existing 3/16 holes through and
place both bolts through the mounting holes
from the inside of the console, through the
cable clamp backing plate and then through
the saddle clamp.
Take care to align the locating groove in the
outer cable with the matching point on the
saddle clamp, then secure with Nyloc nuts
and mark the nuts with TorqueSeal.
Press fit the rear bush

The metal rear bush must first be pressed into the
mounting plate - a bench vise is the most convenient
way to do this as shown in the picture at the right.
Note that the flange on the rear bush goes on the
outside face of the mounting plate.
The two photos below show the rear bush fully pressed
into the mounting plate.
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Fit the bushes to the console
Fit the stick pivot plate carefully into the
control shaft and secure with 2 x AN3-13A
bolts, spacers, washers and Nyloc nuts. The
nuts should face the left-hand side of the
aircraft when fitted.
Front bush
Stick pivot
plate
Slip the front nylon bush over the control

shaft.
With the rear bush and mounting plate taped in
place, fit the control shaft into the console
from the front and through the rear bush,
seating the front bush.
Control
shaft
Mount the aileron bellcrank onto the rear of

the control shaft, taking care to keep the bellcrank square
to the shaft, and temporarily secure it by easing an AN3
bolt through the bellcrank and the shaft as shown below
right.
Do not force the bolt through the holes: ensure that the
holes are aligned exactly before fitting the bolt.
Now the control shaft is held in the console by both the
front and rear bushes. At this point make any adjustments
necessary to allow the control shaft to rotate freely in the
bushes you may need to file small amounts out of the
console to correct the alignment of the front or rear
bushes.
Rear bush and mount
Take your time with this step: you want the absolute
minimum of turning resistance!
Make sure that the rear mounting plate is pushed fully
into the console and then move the front nylon bush out
as required to take up any endplay: you require only a
very small amount of endplay, no more than the thickness
of a single sheet of paper.
Right side
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Front bushes flocked into place
Aileron bellcrank fitted
Left side

It is very important that the rear bush and mounting plate are fitted to the console at precisely 90 to
the control shaft, and that there is no friction between the bushes and the shaft.
When you are satisfied with the alignment of both bushes and the endplay is correct, remove the
aileron bellcrank and pull the bushes out enough to coat each bush with flock, then push both
bushes back into place. Refit the aileron bellcrank and reset the endplay very carefully and leave to
cure, taking care not to get any flock onto the control shaft. Smooth off any surplus resin with a
small amount of resin on a clean mixing stick.
Rear bushes and mounting plate flocked into place
Right side
Left side
When the flock has cured, remove the temporary bolt from the aileron bellcrank and withdraw the
control shaft. Clean any flock from the control shaft and from around the bushes then reinsert the
control shaft, check that the control shaft can rotate freely and that the endplay is minimal and then
remove the control shaft and the aileron bellcrank and set aside until the fuselage has been painted.
This completes the Pre-Paint>Fuselage>Interior>Console>Fit control stick task.
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Pre-Paint>Fuselage>Interior>Fit rudder pedal mount blocks

In this optional task the lower rudder pedal mounting blocks will be checked for vertical alignment
and if necessary the lower blocks will be flocked into place on the floor brackets.
This task shows how to ensure that the blocks are aligned correctly.
Materials required:
Rudder pedal mounting blocks (3 pairs)
3 x and 2 x 3/16 bolts, 3 or longer
Rudder pedals
Check the alignment
Fit the rudder pedals into place as shown above, with the mount blocks supporting the pedal
assembly. Check each lower block to see if it is touching both the floor mounts and the rudder pedal
assembly main bar. If any block can be moved up and down then you should follow this procedure,
otherwise skip this task and go to the next task.
Align the Mount Blocks
The key to correct alignment is the use of a bed of flock under each mount block to allow for any
unevenness in the height of the three floor mounts sometimes there may be a slight height
difference that, if not corrected, could lead to binding of the rudder pedals.
Position the three mount blocks by placing a centre bolt through the centre hole of each mount
block only. Mark a pencil line around each mount block and then remove the mount blocks.
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Sand a slightly bigger area than the marked area and sand the bottom of each mount block to ensure
a good key for the flock.
Mix a small batch of flock and apply to the marked areas, taking care to keep flock out of the three
captive nuts under the centre mount block, then loosely place each mount block into position again
with a single bolt in each centre hole. Gently place the rudder pedals shafts into the blocks and
apply a slight downward pressure to seat all three mount blocks firmly into the flock.
Now fit the top of the mount blocks: working on one mount block at a time, remove the centre bolt,
place the top of the mount block in place and replace the centre bolt. Place all three bolts in the
centre mount block and do them up by hand until the bolts reach the bottom of the captive nuts
this will ensure that no flock will get into the threads.
Carefully rotate the rudder pedal shafts by moving the rudder pedals forwards and backwards
there should be no binding whatsoever.
Smooth off any excess flock with a small amount of resin on a clean mixing stick. Leave to cure,
taking care that no flock has contacted the rudder pedals. When the flock has gone off and is firm,
carefully remove the bolts. Once the flock is completely cured remove the top of each mount block
and the rudder pedals and set them aside until after the paint and upholstery tasks have been
completed.
Run a drill through the holes in the left and right mount blocks to remove any excess flock.
This completes the Pre-Paint>Fuselage>Interior>Fit rudder pedal mount blocks task.
131 of 377

Pre-Paint>Fuselage>Interior>Controls>Fit aileron cable brackets

In this task the aileron cable brackets will be positioned and mounted to the seat backs.
Positioning of the aileron cable brackets is absolutely critical and great care must be taken in this
task.
Materials required:
Card # 5JT Aileron System
73AS 6-6 rivets from box 3 of the hardware pack
220 x 270mm plywood or heavy cardboard for the alignment
template
Position and fix the aileron cable brackets
completed aileron cable mounts as viewed from the rear facing forwards
Preparation
Start by making the positioning template from the drawing on the next page. Heavy cardboard is
quite adequate for the template as long as care is taken to cut the lines and drill the holes accurately.
It will be necessary to redrill the top rivet holes in the aileron cable brackets scribe a line parallel
to the top of the bracket and in line with the centre of the existing hole.
Centre-punch and drill 2 new 3/16 holes as shown at right.
Make sure that you leave enough
clearance around each hole for a
3/16 washer.
Clean around each hole and test a
rivet in each hole it should be a
snug fit.
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Aileron cable bracket positioning template
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Align the template and
mark the bracket positions
Temporarily attach the template
to the control yoke with 2 bolts
placed through the yoke and
into the template as shown
circled at the bottom of the
photo at right.
Level the top of the template in
line with the top of the seat
backs.
Working with one bracket at a

time, hold the bracket in place
in the angled part of the
template (circled at the top of
the top photo) and carefully
mark around the outside and
bottom edges.
Remove the template.
Trim the seat backs for

aileron cable clearance
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It will be necessary to trim a section of the seat back out in order to provide clearance for the aileron
cables cut the hatched area shown in the left-hand photo below: cut just far enough to remove the
curved lip from the side of the seat back, about 10mm.
A
jigs
aw
is
ide
al
for
the
tas
k.
San
d
off
any
rough edges.
Drill the aileron cable bracket rivet holes
Working from the rear of the seats, hold each bracket against the seat back so that the outside and
bottom of the bracket is in line with the marks on the front of the seat back you will be able to see
the marks through the seat back. Hold the bracket firmly and drill the bottom outside hole through
the seat back.
Place a rivet from the front of the seat into the bracket to position it, check that the bracket is still
lined up with the marks and drill the inside top hole.
Place another rivet into the inside top hole and drill the outside top
hole.
Make sure that all the rivets fit snugly through the seat back and into
each bracket, then remove all the rivets and clean all the holes
carefully there must be no burrs or rough edges remaining.
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Attach the aileron cable brackets
Sand the back of each aileron cable bracket as well as the positions on
the seat backs where they will be placed.
Clean all surfaces to be joined.
Prepare a small mix of resin and use a brush to undercoat the positions
on the seat backs where the aileron cable brackets will be placed.
Working from the front of
the seat, place all of the rivets through the holes in the
seat backs.
Add flock to the resin and apply an even layer of flock

approximately 2-3mm thick to the back of each aileron
cable bracket.
Working on one bracket at a time, place the bracket onto the rivets, then fit a washer over the
bottom rivet and hold it in place while using the rivet gun to secure the rivet. Repeat the process
with the top outside and top inside rivets.
Using a little resin on a clean mixing stick, clean any squeezed-out

flock from the brackets.
This completes the Pre-Paint>Fuselage>Interior>Fit aileron cable

brackets task.
136 of 377

Pre-Paint>Fuselage>Interior>Fuel system
To install the fuel system from the wing tank connectors to the firewall fitting.
The fuel system consists of wing tanks (covered in the Wings tasks) that flow to a header tank
situated behind the right-hand seat and then through a filter and an electronic pump to a shutoff
valve located beside the pilot and then through a firewall fitting to the engine.
Note that the fuel lines to the wing tank fittings and the fuel line to the firewall will all be fitted in
this task and then sealed off for later final connection.
Materials required:
Card # 11J or #11T Fuel Components
Fuel header tank
Blue fuel line, black fuel line and clear fuel line sheathing
Lock wire
Epoxy Resin and Flock, 5-minute Araldite
Assemble and test the header tank
Start by assembling the fuel fittings and pressure testing the header
tank. Make sure that there are no foreign objects in the tank, then
loop the inlets and breather holes (all at the top front of the tank)
together with short lengths of line (it doesnt matter in what order
this is just to seal the tank for the pressure test) then fit the quick
drain with a drop of Loctite 577 and tighten firmly. Fit an O-ring to
the finger filter and fit into the outlet hole, once again with a drop of
Loctite 577 and tighten firmly, then connect a short length of line to
the finger filter and apply a small amount of pressure by blowing
into the line, seal and check for leaks by spraying soapy water over
the tank and fittings and check for bubbles.
Fit the header tank to the enclosure
The header tank sits in the header tank enclosure behind the right-hand seat (the enclosure was
fitted in the Prepare fuselage task) and is held in place with the enclosure lid, which also forms the
luggage floor when it is fitted.
Prior to mounting the Electric Fuel pump, two M4 Captured nuts are first fitted. Using a captured
nut as a template, mark and drill two 3/32 holes in each of the fuel pump retaining flanges.
Countersink these holes on the bottom surface. Rivet the captured nuts to the fuel pump flange with
two 3/32 rivets through from the bottom.
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Rivet M4 captured
nut to fuel pump
Mark holes
Drill and countersink

3/32 holes
Fit the 2 brass nipple fittings to the inlet and outlet of the pump
in each case use a drop of Loctite. Fit the electric fuel pump,
with the flow arrow facing towards the front of the aircraft, to
the floor of the enclosure with 3/16 countersunk screws and
Tinneman washers from underneath the fuselage, through the
pump mount and secure with Nyloc nuts.
Araldite a square of rubber sheet and a piece of sponge to the
inboard side of the pump, the side that will contact the side of
the tank. Araldite a 50mm square of rubber sheer to the front of
the enclosure and then sit the tank in place and check that the
quick drain is centered in the hole. Add more rubber sheet to
pack the tank back if required.
Now fit a length of rubber sheet to the floor of the enclosure that
is wide enough to prevent the tank from contacting the floor at
any point.
At this point the tank is positioned fore and aft by the quick drain fitting through the floor and the
rear of the tank is touching the padded side of the electronic fuel pump, so now you will need to cut
dense foam or timber packers to hold the tank from moving sideways or backwards.
The photo at right shows a fitted tank note the location of the 3 packers (circled): 1 at the rear of
the enclosure and 1 on each side. Each packer has a piece of rubber sheet on the end that touches
the tank and the other end of each packer is flocked to the side of the enclosure.
Note that the packers do not go all the way to the bottom of the enclosure the space under the
packers is where the fuel line is routed from the tank to the filter and then to the pump.
Cut and fit the packers and when you are satisfied with the fit then flock each packer to the side of
the enclosure. When fitted correctly you will be able to take the header tank out of and into the
enclosure. Add a strip of foam to the top of the tank where it will touch the lid and the tank is fitted.
Plumb from the header tank
As you can see in the photo above right, the filter is located just behind the right-hand packer, so cut
a short length of blue fuel grade tubing to suit, then cut a longer length to run from the outlet of the
filter to the inlet of the fuel pump. Check that the filter is correctly positioned, with the flow arrow
facing in the direction of the fuel flow, which is from the header tank to the filter and from the filter
to the pump, then use the supplied hose clamps to fit each length of tubing into place. Wrap the
filter with rubber sheet and fix in place with 2 zip ties. 5 minute Araldite the supplied bracket
(arrowed above) in place and zip tie the filter to the bracket.
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Plumb to the header tank
Cut 3 lengths of blue fuel grade tubing at 990mm and another 3 at 1300mm. The shorter ones will
run from the header tank to the right-hand connector and the longer ones will run from the header
tank to the left-hand connector. Cut 2 lengths of the clear sheathing, 1 at 950mm and 1 at 1250mm.
Fit the 3 shorter lengths of blue fuel grade tubing to the ferrules on the right-hand front of the
header tank, and mark the other end of each line by wrapping short length of cloth tape around the
line and marking it either Breather, Front or Rear as appropriate.
Fit a hose clamp to each line and tighten firmly.
Feed the lines out through the grey plastic
fittings in the upper side of the enclosure
(arrowed in yellow at right) and slip the
sheathing over the fuel lines and over the
grey plastic fitting (arrowed in purple at
right) and then lock wire the sheath to the
grey plastic fitting.
Repeat the process for the left-hand fuel lines,
which will pass in front of the support rib as
shown at right.
Outlet
Fit the tank connectors

The tank connectors must be fitted the correct side
of the aircraft: when fitted out through the slots in
the tops of the cabin walls the brass ferrules must
face forwards, towards the front of the aircraft,
while the circular sleeve and ferrules will face
downwards inside the cabin, allowing the fuel lines
to run smoothly to the header tank.
Left
Working on one side at a time, place the tank

connector through the slot in the top of the cabin
wall and check the length of the fuel line sheath,
which will be slightly too long.
Right
Back
Front
Breather
Trim the sheath to length then fit each fuel line to the correct fitting
on the circular inboard part of the connector: the Breather line
connects to the outside ferrule, while the Front line connects to the
centre and the Rear line connects to the inside.
Fit the sheath over the circular ring and lock wire into place as
shown at right. Note that the right-hand side connector is shown.
Seal the open ends of the connector with tape and repeat the process
on the left-hand side.
Fit the fuel tap and fuel line

Remove the lever from the fuel tap and set it aside.
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Look for a mark or pilot hole on the left-hand side of the centre console around 50mm in front of
the base of the armrest and 30mm below the forward section of the console as shown at right:
Drill a 16mm hole at that position.
Working through the access hole in the right-hand side of the console, hold the fuel tap in position
against the inside of the left-hand side of the console and mark the positions for the alignment pin
and screw holes, which will be visible through the fibreglass, then remove the fuel tap and drill the
holes. Pre-fit the fuel tap with the two screws and then remove the tap and set it aside.
Cut a length of blue fuel hose of sufficient length to reach from the fuel tap all the way back to the
electronic fuel pump outlet plus ~100mm, and a length of black fuel hose of sufficient length to
reach from the fuel tap down along the floor and back up to the firewall fitting plus ~100mm.
Fit both fuel hoses to the fuel tap and secure with the
supplied hose clips, making sure that the flow arrow on the
face of the fuel tap is facing towards the black (outlet) fuel
line.
Place a length of fuel line sheathing over both fuel lines
and secure with lock wire to each boss on the fuel tap.
Fit the fuel line/sheath and tap assembly: tape over both
ends of the fuel lines to prevent foreign objects from entering and then insert the blue fuel line end
into the console through the access hole in the right-hand side and feed the blue fuel line down and
back towards the rear of the fuselage and into the lower part of the console.
Feed the fuel line back until it can be seen in the hole in the lower
longitudinal rib under the beam behind the seats, then, using a
length of wire with a hook in one end, lift the fuel line and sheath
out of the lower longitudinal rib and run it back beside the header
tank enclosure.
Keep feeding the fuel line back until the end of the black fuel line
and sheath can be inserted into the access hole in the console and
then feed the fuel line/sheath down and forwards, taking care to
route the line under the trim pivot, until it can be lifted out of the
hole in the forward section of the lower console behind the rudder
pedals.
Using a length of wire with a hook in one end, reach down into the
console through the right-hand access hole and lift the fuel line
assembly up and move the fuel tap into position.
Mount the fuel tap to the console with the two screws.
Cut the end of the blue fuel line and sheath to the correct lengths
and connect to the electric fuel pump with a supplied hose clip and
then lock wire the sheath to the grey plastic ferrule on the header
tank enclosure (arrowed at right).
Cut the black fuel line and sheath to length and clamp the fuel line to the firewall fitting and lock
wire the sheath to the firewall fitting collar. Cover the open (top) end of the firewall fitting to
prevent dust or dirt from entering the fuel system.
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Checks
At this stage you should have
connected the fuel lines all the way
from the fuel tank connectors
through to the fuel header tank,
then to the fuel filter, the electronic
fuel pump, the fuel tap in the
console and the black fuel hose
which is connected to the firewall
fitting.
Check that all the flow arrows on
the fuel filter, the electronic fuel
pump and the fuel tap are pointing in the correct direction, which is away from the header tank and
towards the engine.
Check that all of the fuel line sheathing is lock wired in place and that the sheathing does seal the
fuel lines correctly.
Check that all fuel lines are routed smoothly with absolutely no kinks and that there are no rough
edges anywhere nearby that could rub against the fuel lines or sheathing, and then check that all of
the open ends of the fuel lines are sealed so that no foreign objects can enter.
Coil the tank connectors and related fuel lines behind the seats where they will not be damaged
during construction.
Best practice when routing fuel lines between tanks of different heights is to have a positive
gradient in the line at all times i.e. there should be no dips (U shapes) or humps (upside-down
U shapes) in the line. In extreme cases these humps or dips can create an airlock effect and
prevent fuel from flowing along the line.
The images below are included for guideance. Will be seen again during installation.
Lines dip slightly as they
exit the header tank and
pass through the side of the
baggage shelf.
Figure 1 J160-C Fuel Lines Showing Typical U Requiring Correction
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Hole in baggage shelf
wall raised, zip-tie used
to hold line bundle up.
Outlet from tank

enclosure raised
slightly
Figure 2 J160-C Corrected Fuel Lines
This completes the Pre-Paint>Fuselage>Interior>Fuel system task.
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Pre-Paint>Fuselage>Interior>Fit seatbelt anchors

This task shows how to fit the seatbelt anchors. While this is quite a simple task it is also an
extremely important one the seat belts must be anchored correctly because if you ever really need
your seat belt (and heres hoping that you never do) it has to be attached to the airframe in the
designed manner for maximum safety.
The photos that follow are of the pilots seat: the same applies to the other seat but in reverse.
Materials required:
Card # 9J or #9T Seatbelts
Bottom anchor brackets
Both inner bottom anchor brackets are attached to the main beam that runs behind the seats.
Pilots seat
back
50mm
100mm
Inner bracket
Outer bracket
Console
Start by marking a horizontal line 100mm up from the base of the main beam on the inside of each
seat, and then mark a vertical line 50mm out from each side of the centre console.
Hold a bottom inner bracket inside and below where each pair of lines meet and drill a 3/16 hole
through the top hole and slip a bolt through and then check each anchor bracket for square and drill
the bottom hole. Fix each inner anchor bracket in place with AN3 bolts through the bracket, the
beam, the rectangular backing plate, a washer and a Nyloc nut.
The bottom outer brackets are held with a single AN5
bolt and the hole is drilled from the outside of the
fuselage: 25mm up from the main gear leg recess and
65mm back (left-hand side) and 75mm back (righthand side) from the front of the recess: each bracket
should sit in the lowest, rearmost corner inside.
Fix in place with an AN5 bolt through the fuselage
from the outside, through the bracket with a flat
washer and a Nyloc nut.
Tighten all the Nyloc nuts firmly.
25mm
65mm LHS
75mm RHS
Left-hand side
shown
Top anchor brackets

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The top anchor brackets mount behind the
whalebone with the centre of the bracket precisely
level with the bracing rib in front of the whalebone
as shown at right.
Whalebone
Hold the bracket in position and drill a 3/16 hole

at the top of the bracket and slip a bolt through then
line up the bottom of the bracket and drill the
second hole.
The top bracket will not be finally fitted until the
aircraft has been painted and the upholstery has
been installed.
Pre-fit the bracket in place with an AN3 bolt
through the bracket, the whalebone, the backing
washer and a Nyloc nut.
Bracing
rib
Front of aircraft
Remove and store the top brackets for later final fitting.
This completes the Pre-Paint>Fuselage>Interior>Fit seatbelt anchors task.
144 of 377

Pre-Paint>Fuselage>Pre-fit doors
In this task you will size and pre-fit the doors to the fuselage and pre-fit the striker plate, all of
which will be finally fitted after the fuselage has been painted.
In the photos that follow the pilots door is shown, however the exact same technique is used for
each door.
Materials required:
Card # 1J of #1T Doors
Size the door

The door may require a slight trim to fit the opening: either tape the door in place or have a friend
hold it firmly in place. Working from the inside, make sure that the door is centred in the opening
and mark the inside of the door around the edge of the opening.
Remove the door and use a sanding disc to trim the door to the mark. Hold the door in the opening
and carefully mark and sand as required until the door is a good snug fit all round.
Fit the hinges

Fit the top and bottom hinges to the arms on the door, then tape the
door back into position and mark the centreline (vertically and
horizontally) of each hinge screw. Remove the door and extend the
marks to locate and drill each hole.
Trial fit the door with the hinge screws fitted and check that the
door is sitting flush with the fuselage. If it requires adjustment
outwards then an Araldite/flock mixture will be used to pack the
hinges out the required amount.
Remove the door and roughen the area around each hinge screw
hole to provide a good key for the Araldite/flock mixture. Apply
wax to the hinge and screw to prevent them sticking to the flock and
refit the door.
Loosely fit the hinge screws, then mix up a small batch of 5-minute
Araldite and flock and pack the flock mixture behind the hinges as
required, check that the alignment of the door and the fuselage is
correct and leave the flock mix to cure.
Open and close the door a few times and mark any points that are
binding then use a long sanding block to remove those points the
door should open and close smoothly with nothing rubbing at any
point right around the opening.
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Pre-fit the striker plate
Hold the outside door latch in the open (forward) position and close
the door until the rear of the door is sitting flush with the fuselage
and with an even gap top and bottom and, working from the inside
of the cabin, carefully mark the vertical position of the latch pin on
the door jamb.
Open the door and measure the horizontal distance from the outer
door skin to the centre of the latch pin and mark that on the door
jamb then drill a hole at the point where the 2 lines cross.
Temporarily tape the striker plate to the door so that the latch pin is
just through the hole in the plate then close the door carefully and,
working from the inside of the cabin, mark the top and bottom of
the striker plate onto the door jamb.
Remove the striker plate from the door and pre-fit it to the door
jamb as shown in the photo above, with the plate sitting against the
lip of the door jamb.
Do not rivet the striker plate into place; it will be finally fitted after the painting is complete.
Fit the top latch

Measure back 35mm from the
top of the curve at the front of
the door and drill a pilot hole
and then a hole down
through the door frame. Refer
to photo at right:
Fit the latch barrel up through
the hole until it is about 2mm
above the top of the door jamb
and mark that position, then
flock the barrel into position
with 5-minute Araldite and
flock.
30mm
Top
handle
35mm
Top latch
Make sure that the open end of the barrel faces upwards as shown in the photo above.
Smooth the flock to a uniform radius around the top and bottom of the barrel and leave to cure.
With the door closed, hold the top front of the door flush with the fuselage and drill a 3/8 hole up
through the latch-pin hole in the barrel and through the door jamb.
Open the door and fit the latch pin to the barrel from the bottom with the rubber sleeve and circlip
fitted from the top as shown above. Test the latch for free but firm movement.
Fit the top handle 30mm behind the top latch mark and drill the screw holes through both surfaces
then drill the top holes to for access to the screws.
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Final fit the door
Shut the door using both latches and check right around the door to see if there are any areas that
need final adjustment, for example if the door does not fit easily inside the opening, and sand to fit
as required.
Fit the fairing to the top hinge

Centre the fairing on the top hinge and tape it in place then test that
the door can open and close freely and make adjustments to the
hinge arm slot as required then fix in place with 5-minute Araldite
and flock.
Test that the door can open and close freely and adjust the clearance
of the hinge arm slot if required.
Cut and fit a section of glass sheet to the hinge arm (arrowed at
right) to suit the opening in the fairing and fix to the hinge arm with
an Araldite/flock mixture and leave to cure.
Fit the fairing to the bottom hinge

Centre the fairing on the bottom hinge and tape it in place then test
that the door can open and close freely and make adjustments to the
hinge arm slot as required then fix in place with 5-minute Araldite
and flock.
Test that the door can open and close freely and adjust the clearance
of the hinge arm slot if required.
Cut and fit a section of glass sheet to the hinge arm (arrowed at
right) to suit the opening in the fairing and fix to the hinge arm with
an Araldite/flock mixture and leave to cure.
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Fit the key lock
30mm
130mm
60mm
20mm
20mm
Mark a position 30mm out from the rear of the opening and 130mm up from the bottom of the
opening and drill a pilot hole, then drill out to 18mm and elongate the hole with a round file until
the door lock barrel can be mounted snugly into the hole.
Now mark and cut a slot 60mm long and 6mm wide 20mm in from the fuselage skin in the door
opening, with the bottom of the slot square with the bottom of the lock hole. This is the slot that the
lock arm will operate through. Close and latch the door and mark the slot onto the back of the door
use a builders pencil or any similar thin marker and mark through the slot.
Unlocked
Locked
Cut the slot in the back of the door and check that it matches the slot in the door opening.
Fit the lock barrel into the 18mm elongated hole and secure with the large nut, then fit the lock arm,
which will need to be bent slightly in order to swing freely into the slot.
Turn the key so that the top of the key moves forward and fit the arm in the locked position.
Test that the door can be locked and unlocked with no binding of the lock arm.
Leave the doors fitted for now, they will be removed later in Painting>Pre-paint disassembly.
This completes the Pre-Paint>Fuselage>Pre-fit doors task.
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Pre-Paint>Fuselage>Fit windows
The windows are formed from strong but brittle acrylic and care must be taken to avoid marking or
cracking the windows while they are being fitted. The windows are fixed in place with flock and
without screws, however screws are used around the windows to hold the windows in place while
the flock cures and are then removed.
Any minor shaping of the windows that may be required must be done with an 80 grit sanding disc
or a hand-held sanding block: you must never use a jigsaw on acrylic.
The description and photos that follow show the window being fitted to a pilots door, and the exact
same technique should be used for any window.
Materials required:
Epoxy resin and flock, wax
x adhesive-backed foam strip
8G self-tapping screws in heavy duty (coax) cable clamps:
Pre fit the window
Start by carefully sanding away all of the gel coat from the joggle, then fit a length of the foam
strip around the very inside of the joggle (the dark grey line in the photo below) this will keep the
flock from making a messy line around the inside of the window and give a nice clean edge when
the window has been flocked into place.
Close and latch the door and then test fit the window, holding or taping it in place and making any
minor adjustments that may be required so that the window fits snugly inside the joggle.
Remove the window and, working very carefully, drill 1/8 screw holes in the door frame just
outside of the joggle as shown arrowed above. Note in the photo of a completed window above that
the protective plastic sheet has been folded and taped back from the edges of the window so that the
bulk of the window area is still protected from scratching.
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Prepare the window
Remove the window carefully and clean and blow away any dust and debris from the joggle.
Place the window face down on the bubble wrap packing material,
taking care not to allow anything to scratch the surface, and
carefully sand around the entire inside edge with emery tape sand
only to a point just short of the inside of the joggle, level with the
centre of the foam strip.
By holding the emery tape as shown you can use your finger to
control the width of the sanded area.
When the sanding is complete blow away the dust and then use a
clean soft cloth and wipe right around the window.
Do not use any cleaning agents on the window.
Fit the window
Close and latch the door, wax the self-tapping screws and cable clamps and then wash and dry your
hands to prevent wax from getting onto the window or the joggle.
Mix a batch of resin and coat the joggle, then add flock to the resin and fill the entire joggle out to
the level of the foam strip. Carefully place the window into the bed of flock - start at one corner and
position the window until the alignment is correct and it fits inside the joggle - and then gently press
it into position.
Once the window is positioned correctly, take the self-tapping
screws and cable clamps and start fitting them around the door
frame as shown at right, working from the corners first and then the
middle screws and so on.
The clamps will pull the window into the joggle level with the door
frame and the wax will allow easy removal once the flock has
cured, while the screw holes will be filled during the Paint
Preparation tasks. Take care not to over tighten the screws, tighten
them just enough so that the edge of the window is level with the
adjacent door frame.
Check all around to see that the flock has keyed to the window: the sanded surface of the window
edge will appear to go clear with no bubbles when the flock is in full contact with it. It may be
necessary to gently squeeze the window to remove any bubbles, although if you have filled the
joggle with flock there should be full contact anyway.
When you are satisfied that the window is positioned correctly wipe away the excess flock with a
clean mixing stick, taking care not to smear any resin or flock over the window: always wipe out
and away from the window. Refer to the photo of a completed window on the previous page for an
example of how it should look. Leave overnight to cure. Next day remove the screws and cable
clamps.
The same process should be used for all the remaining windows. You may do more than one
window at a time if you are confident of your ability to do so but we would suggest that one
window at a time is a great way to start.
This completes the Pre-Paint>Fuselage>Fit windows task.
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Pre-Paint>Fuselage>Wheel alignment
To ensure that the main wheels are correctly aligned.
Overview:
Some aircraft have reported shuddering through the undercarriage and airframe on rotation or
landing. The amount of shuddering seems to be variable, depending on the all up weight of the
aircraft. Investigations on factory built aircraft have revealed that this phenomenon is caused by a
combination of two factors: toe-in or -out and the camber of the main wheels.
This procedure outlines how to check the wheel alignment and make the necessary adjustments to
correct the issue. Its a fairly basic technique, but weve had success with it.
Procedure:
Firstly, a reference point is required from centerline (longitudinal axis) of the fuselage. This can be
achieved by dropping a plumb bob down from the tip of the spinner, and one from the ventral fin
and then, using a string line, join the two points. As seen in the picture below, we have used the join
line in the concrete slab as the reference line.
Place a straightedge (weve found a length of box

section to be the best) along the outside wall of the
tire, and eyeball from above to check that both the tire
and the straight edge are parallel.
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Mark the position of the straightedge in both forward and aft positions and join the two points,
repeating the same procedure for the opposite side.
Take measurements from the straight edge positions to the centreline of the fuselage, repeat for the
opposite side and compare the numbers to see if the wheels have toe-in or toe-out. The wheels will
naturally want to rotate outwards when the aircraft is at gross weight, so it is recommended to have
a slight amount of toe-in to allow for this.
If adjustments are required, washers are used as spacers between the stub axle and the undercarriage
leg. Typically 2 washers are required on each of the lower stub axle mounting bolts to give the
wheel slightly less camber, and usually only one half size washer installed on either the front or the
back two stub axle bolts is sufficient to shift the toe in/out.
Pack with flock, reinstall and tighten and leave overnight to cure before using the aircraft.
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Pre-Paint>Fuselage>Pre-fit wheel spats

To pre-fit the spats to the main wheels and the nose wheel. This is a task that will require several
trial fits, and it should be done in the stages described below.
Main wheel spats
The main wheel spats are held in place by a single bolt on the outside that fits into the axle
extension and 4 screws on the inside that fit to the spat mounting plate. The inside holes (arrowed at
centre right) should all be countersunk to accommodate Tinneman washers.
Prepare the spats by trimming out the bottom of the wheel opening as shown above once the
bottom opening is correct the spat can be test fitted and the gear leg opening shaped to suit.
55mm
Mark back 55mm from the axle bolt hole and drill a 1 1/8 hole for access to the valve as shown
above left. Slip the spat down over the wheel until the outside axle bolt hole lines up with the axle
extension: you will probably have to trim the main gear leg opening slightly to get the spat fully
down over the wheel. A typical inside cut is shown
marked above right, but check your own spat to main
gear leg fitting then mark and trim accordingly.
Fit the spat into position with the axle bolt and the
inside screws and make sure that there is a gap
between the main gear leg and the top of the spat that
will allow the hydraulic brake line to pass through
without any risk of chafing on the spat.
9
(230mm)
Loosen the 2 top bolts that hold the spat mounting

plate one hole is slotted to allow adjustment and
rotate the spat until the top rear is 9 (230mm) above the ground, then tighten the bolts.
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Check that the tire has about 5mm clearance all round the bottom of each spat, then remove the
spats and set aside for painting. Completed main wheel spats are shown above.
Nose wheel spat
The nose wheel spat is in 2 sections, front and back. The front section is fitted to the nose wheel
with the axle bolt and a single threaded screw into each side of the nose leg yoke, while the rear
section is attached to the front section with 8 x
3/32 screws into captive nuts.
Start by fitting both sections together and taping
them to each other, then drill 3/32 holes around
the join, 4 on each side, for the captive nuts that
will hold the 2 halves together as shown at right.
Captive
nuts and
screws
Machine
screw
Valve
access
Axle
nut
Countersink the screw holes in the front section

and fit captive nuts (shown above) to the rear
joggle use countersunk 3/32 rivets to hold the
captive nuts in place.
Screw both halves of the spat together and check
the fit around the gear leg opening in the top of
the spat. Trim the gear leg opening so that it is
even on both sides. The opening should look like
the example shown at right: note that the rear of
the opening (arrowed in green) is slightly behind
the join line.
While the spat halves are screwed together,
measure back 55mm from the axle bolt on the
left-hand side only and drill a 1 1/8 hole for
access to the tire valve.
Grind out a gentle notch in the joggle of the rear
section of the spat (as circled at right) to allow
clearance for the front axle spacers.
Captive nuts fitted to the joggle can be seen in
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the photo at right.Now both halves of the spat can be
fitted to the nose wheel and held in place with the axle
bolt, then the spat can be aligned and the hole for the
machine screw in the yoke can be marked.
Support the front of the aircraft so that the nose wheel is
off the ground and remove the front axle and wheel.
Fit the front of the spat over the yoke and refit the front
wheel and the axle, passing the axle through the spat,
yoke and wheel as shown at right.
Lower the nose wheel back onto the ground.
Fit the rear of the spat to the front section and move the
back of the spat up or down until the whole spat sits
level or slightly low at the back (the back will tend to move up as weight is added to the aircraft),
then hold the spat in that position and mark the location of the holes for the machine screws on each
side of the yoke. A completed nose wheel spat is shown below.

Support the front of the aircraft again so that the nose wheel is off the ground and remove both spat
halves along with the front axle and wheel. Leave the wheel out of the yoke for the moment so that
you will not accidentally drill through the yoke and into the tire.
Drill a 9/64 hole in each side of the yoke at the marked locations and thread to 3/32 UNF then
refit the spat and wheel again, this time fitting the short 3/32 screws into the yoke.
Lower the nose wheel back onto the ground and check that the alignment is satisfactory and that the
tire has about 5mm clearance around the bottom of the spat, then remove both halves of the spat, set
them aside for painting and refit the nose wheel.
This completes the Pre-Paint>Fuselage>Pre-fit wheel spats task.
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Pre-Paint>Wings>General
Pre-Paint>Wings>General
In our factory we combine several smaller tasks on the wing into the one three day operation: we
work on the top surface first, starting with the fuel filler body and then the winglet, then we move to
the wing root and install the fuel fittings, fit the breather tube and cut the recess for the flap arm.
The next day we turn the wing over and work on the bottom surface, cutting the aileron cable mount
inspection hole, fitting the flaps and the quick drains, and then on the third day we fit the ailerons.
Other minor tasks, such as fitting the strobe mounts, can be done at any time.
In this section of the manual each step of the operation is broken out as one of a series of tasks that
are ordered in the sequence that we would normally perform them.
The homebuilder could (and should) follow the same sequence but with the whole operation spread
over several days, perhaps at a rate of one task per day.
We support each wing on a pair of trestles that place the wing at a convenient height for working,
about 900mm high or bench height, and we cover the tops of the trestles in carpet to protect the
wing surface. When working on the bottom of the wing we use a foam wedge on each trestle under
the rear of the wing to stop the wing from rocking when the curved surface is facing downwards.
Tools may be placed on the wing surface while you are working but you must take care not to drop
anything onto the wing surface the surface is not designed for that type of loading, so treat it with
respect and place your tools carefully and gently onto it.
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Pre-Paint>Wings>Fit fuel tank filler body

In this task the fuel tank filler body location will be determined for each wing, a hole will be drilled
into the upper wing surface and a smaller hole will be drilled into the wing tank and then the filler
body will be fitted and then flocked into place and covered with peel
cloth while the flock cures.
Materials required:
-
from Card # J11 or #11T Fuel Components
2 x fuel tank filler bodies:

Mark the position of the opening
First we need to mark the side-to-side distance from the wing root to the centre of the filler body
opening and in order to do this we must determine the exact length of the wing tank. To do this take
the supplied breather tube and shape the end to a point as shown below. Feed the breather tube into
the tank from the top front wing root fitting and carefully work it past the tank ribs until you find
the end of the tank.
Mark the breather tube level with the wing root at that point then withdraw the tube and mark where
the position of the end of the tank on the top of the wing. Measure back 150mm from that point and
that is the initial side-to-side location of the filler body. Repeat the process of finding the end of the
tank and measuring back 150mm on the other wing and then make any adjustments that may be
required to make both filler bodies the same distance from each wing root. Mark this final side-toside position of each filler body.
Take a set square and place it under the wing and against the leading edge and then measure back
365mm from the leading edge mark this fore and aft position of each filler body.
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Cut the opening
Now we can drill through the outer surface of the wing with a hole saw, clean away excess filler
and then drill a slightly smaller hole into the wing tank.
During cutting care must be taken to prevent any drilling waste from falling into the tank.
If you have a compressor and an air line with a variable flow valve you could place a line into the
tank through one of the wing root fittings and very slightly pressurise the tank, but be careful to
only use a small amount of pressure too much pressure may rupture the tank! Otherwise you
could have someone hold a strong vacuum cleaner nozzle near the hole saw while you are drilling,
but whatever you do make sure that no waste falls into the tank.
Drill a 66 - 68mm hole into the upper wing surface only, and not into the fuel tank. Hold the drill at
right angles to the wing surface and very gently drill until you can see darkness at the bottom of the
cut (as indicated in the yellow circles in the photo above right) this will mean that you have reached
the gaps in the expandable filler between the upper wing surface and the fuel tank.
Lever out the cut out piece and carefully grind away all of the filler until you reach the top of the
wing tank, then drill a 54mm hole into the tank, taking care not to drop anything into the tank.
In these photos, taken in our factory, the tank has been slightly pressurised so that all waste is blown
away from any opening, but a vacuum cleaner hose held close to the surface being cut could
achieve much the same result.
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Fit the filler body
Now, working slowly, enlarge the hole in the tank (sandpaper taped to a section of tubing is useful
for this) just enough so that the filler body is a good firm fit into the tank. Remove the filler body
and clean all of the area surrounding the holes. Sand/roughen the outside of the filler body and place
masking tape around the inside to keep flock from entering.
Mix a batch of resin and coat the outside of the filler body and the top of the wing tank area where it
will be mounted. Add flock to the resin and carefully fill the area around the filler body, working
the flock into the gap between the tank and the wing surface first and then filling back towards the
opening, making sure that any bubbles are worked out.
Place the filler body in position, aligning the locating holes (circled at above right) fore and aft and
with the earth wire hole facing forwards, and level the upper rim of the filler body with the top of
the wing surface. Flock and fill back around the filler body.
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When the flock is almost level with the top of the wing surface, cut a piece of peel cloth and
carefully brush it into place with no wrinkles or bubbles. Leave overnight to cure.
Next day remove the peel cloth and seal the opening with a square of plastic or heavy card secured
with masking tape to keep the tank free of dust and dirt.
Final filling of any slight depressions in the flock will be covered in the Painting>Pre-paint
preparation task.
This completes the Pre-Paint>Wings>Fit fuel tank filler body task.
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Pre-Paint>Wings>Prepare wing root

To fit all of the fuel and breather fittings in the wing root and trim the flap arm cutouts.
Materials required:
Card # 11J Fuel Components
Steps
1. Fit the fuel fittings
2. Fit the breather tube
3. Cut out the flap arm recess
Fit the fuel fittings
Breather
Blank
Fuel gauge
Finger filters
Start by removing all the protective tape from the openings, then thread a finger filter into each of
the bottom fuel fittings and remove this will clear any surplus sealant that may have accumulated
around the fittings. Clean the finger filters and apply a smear of Loctite 577 to the threads then refit
the filters and tighten firmly. Take care not to cross-thread any fittings.
Apply a drop of Loctite 577 to the threads of the blanking plug and fit to the top rear fitting.
Assemble the fittings onto the breather
tube as shown and then insert the
breather tube into the front top fitting and
work it fully into the wing tank there
are cut-outs in the top of the tank ribs to
allow the breather tube to fit along the
top of the tank and it may be necessary to
gently manoeuvre the tube through them.
A very slight bend about 200mm back
from the end of the tube can be useful.
Push the tube in until the end of the tank
is felt and then back it out roughly 5mm.
Once the tube is in place, apply a smear
of Loctite 577 to the threads of the brass
nipple and tighten it into the fitting, then
do the same with the gland nut. The 90 curved end of the breather tube should face the rear of the
wing and be horizontal when finally fitted.
Place a square of tape over the fuel gauge opening for the moment. Due to the breakable nature of
the fuel gauge it will be calibrated and installed after the wing has been painted.
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Fit the breather tube and the fuel cap
The breather tube will now be visible through the fuel filler opening on top of the wing.
Move it to the rear of the opening and behind the filler body, then take the plain earth wire and
thread it into the tank from the filler and work it along the bottom of the fuel tank and through the
gap in the bottom of each tank baffle towards the wing root as shown in the photo above. Proceed
carefully until the entire length of plain earth wire is inside the tank.
Aluminium
Breather Tube
Fuel Filler
Body
6g x self
tapper
Earth wire & fuel cap

retaining wire
Plastic
P clip
6G Speed
Nut
Fit
the
spe
ed
nut
ont
o
the
P
clip
, fit
the
P
clip
around the breather tube and then fit the 6g self-tapping screw through the 4mm ring terminal,
through the fuel filler body and into the speed nut on the P clip. See the drawing on the next page.
You may need to make up a tool to assist in the fitting of the P
clip here is a photo of the tool that we use in our factory for the
purpose. The end (circled) is used to push the breather tube up and
towards the fuel filler body so that the screw can be fitted. The tool
is shown in use on the next page.
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The drawing above shows the components and the process of assembly so that you can see how the
parts all fit together, while the photo below right shows the actual fitting taking place in the fuel
filler opening.
Note that the blue ring terminal will be pushed
down to a horizontal position before the screw is
tightened so that the earth wires will not foul the
fuel cap when it is fitted.
The braided length of the earth cable is the fuel cap
retaining cable and it should now be connected to
the bottom of the post on the fuel cap with a
machine screw with a drop of Loctite 243 on it.
The fuel filler cap, which comes partly assembled
on the card, can now be placed into the opening
with the locating dowel fitted into the recess at the
rear of the opening and tightened in place and the
vent tube opening can be taped over until after painting.
The vent tubes will be fitted to the fuel filler caps when the wings are being prepared for final
fitting in the Post-Paint>Wings>Prepare wings for fitting task.
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Cut out the flap arm recess
You will need to cut out the marked flap arm recess in the top of the wing root. Care is needed
around the wing attachment lug (circled): under no circumstances must any material be removed
from the lug.
When using a jigsaw near the wing attachment lug you will need to make sure that the shoe of the
jigsaw is completely level when cutting near the wing attachment lug as shown above.
Use a hacksaw in a holder to remove the final section of the wing skin above the wing attachment
lug, finishing off carefully with a flat file as shown above.
Cut down the rear of the wing as shown at right, angling out from where the saw is in the photo to
finish the cut level with the bottom

surface of the wing, shown indicated the
red line.
Sand all cut surfaces to a smooth finish.
This completes the PrePaint>Wings>Prepare wing root task.
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Pre-Paint>Wings>Cut aileron cable openings

Check the position of the wing rib near the aileron cable inspection openings and then check, mark and cut
the aileron cable openings.
Check and cut the aileron cable inspection opening
Turn the wing upside down and pack under the trailing edge so that the wing is stable.
Start
by
drilling a 38mm hole in the centre of the shaded rectangular area, and then place a ruler into the hole
towards the wing root until it touches the rib. Mark a reference line on the wing (140mm has been used as
the reference circled in the photos above).
Now remove the ruler from the hole and lay it on the wing with the reference mark lined up and mark where
the end of the ruler lies, which is where the outboard side of the rib is located, and draw a line fore and aft at
that point. Measure 12mm from that line towards the wing root and draw another line: this marks both sides
20mm min
65mm max
of the wing rib.

The position of the inspection hole should be no closer than 20mm from the outboard side of the rib and no
more than 65mm from the trailing edge of the wing. If it is not then you will need to move the markings
accordingly.
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Use a jigsaw to cut the rectangular inspection hole slightly undersize and then carefully widen to 80mm
wide and 120mm front to back with rounded corners to fit the clear cover (drawing on next page). Set the
clear cover aside until after painting.
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Now look into the hole that you have just cut look for the
black marks (arrowed at right) on the rib that shows the
location of the aileron cable clamp bolt holes. Drill a second
38mm hole as shown at right, slightly inboard of the wing rib
with the fore and aft alignment being exactly in line with the
aileron cable clamp bolt holes. This hole will be used to
access the rear of the cable clamp bolts.
This completes the underwing work, now we need to check
the aileron cable slot marking on the upper wing surface.
Check and cut the aileron cable exit slot

With the wing still upside down, lay a setsquare on the wing and use it to transfer the location of the
outboard side of the wing rib to the upper wing surface. Mark the rib location and then turn the wing right
side up.
It is critical that the aileron cable slot be accurately positioned in relation to the wing rib because the aileron
cable will be clamped to the wing rib and it must align with the aileron drive arm. The aileron drive arm and
thus the aileron is positioned in relation to the slot in the later task Pre-Paint>Wings>Fit ailerons.
The marked slot should be slightly (~2mm) outboard of the wing rib. If that is not the case then move the
slot marking laterally until it is slightly outside of the wing rib. The fore and aft position of the slot will be
correct as marked and the overall slot dimension should be approximately 15mm wide and 70mm long.
Once the location has been confirmed then cut the slot out: drill each end of the slot slightly undersize and
use a jigsaw the join the holes then widen to the marked size with a file.
If the aileron cable inspection hole on the underside of the wing has been correctly marked then the aileron
cable slot will usually be correct too, but it is still good practise to check carefully before cutting it is much
better to check first and then cut.
This completes the Pre-Paint>Wings>Cut aileron cable openings task.
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Pre-Paint>Wings>Fit quick drain sumps

To flock the quick drain sumps into the wing tanks at the rear of each wing root and then clean and seal the
fuel tanks.
Materials required:
Card # 11J Fuel components
Mark and drill the wing
Turn the wing upside down and wedge the wing so that the top surface is level and solid.
If you have a compressor and an air line with a variable flow valve you could place a line into the tank
through one of the wing root fittings and very slightly pressurise the tank, but be careful to only use a small
amount of pressure too much pressure may rupture the tank!
Otherwise you could have someone hold a strong vacuum cleaner nozzle near the hole saw while you are
drilling, but whatever you do make sure that no waste falls into the tank.
Now we can drill through the outer surface of the wing with a hole saw, clean away excess filler and then
drill a smaller hole into the wing tank.
Measure the
distance from the wing root to the first rib, which should be between 55mm and 60mm: that defines the
inboard end of the wing tank. Now measure a further 60mm into the tank for a total of approximately
115mm to 120mm and mark a line, then measure back 580mm from the leading edge and mark another line.
Where these lines cross is where the quick drain sump will be fitted.
Drill a 1 hole into the outer wing surface only, and not into the fuel tank.
Hold the drill at right angles to the wing surface and very gently drill until you can see darkness at the
bottom of the cut: this will mean that you have reached the gaps in the expandable filler between the wing
surface and the fuel tank.
Lever out the cut-out piece and carefully grind away all of the filler until you reach the surface of the wing
tank, then drill a 3/8 hole into the tank, taking care not to drop anything into the tank. You could turn the
wing right side up for this step if you wish.
In these photos, taken in our factory, the tank has been slightly pressurised so that all waste is blown away
from any opening, but a vacuum cleaner hose held close to the surface being cut could achieve much the
same result.
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Fit the quick drain sump body
Clean away any dust then sand and test fit the quick drain body.
Mix a small batch of resin and coat the quick drain body and the mounting hole, then add flock and bed the
quick drain body into place.
Add flock to build up to surface level and smooth away any excess with a clean mixing stick. Make sure that
no flock sets across the drain hole clean away any excess inside the drain hole with a length of wire or
similar. Leave overnight to cure.
The flock will be partly covered by the glass fibre cloth lay up for the flaps and any roughness in the finish
will be rectified in the Painting>Pre paint preparation task.
Clean the wing tanks
The fuel system will be flushed through in the Testing phase prior to flight.
Next day thoroughly clean the fuel tanks to remove any dirt or debris that may have fallen into the fuel tanks
during the construction process: vacuum inside the fuel gauge opening then remove the cover from the fuel
filler cap and blow compressed air into the tank to move debris and at the same time hold a vacuum cleaner
nozzle at the fuel filler and fuel gauge openings so that you have a continuous airflow through the tank.
When you are satisfied that the tank is clean, seal all openings into the tank: the fuel filler opening, the quick
drain fitting, the fuel gauge opening and all wing root fuel fittings.
This completes the Pre-Paint>Wings>Fit quick drain sumps task.
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Pre-Paint>Wings>Mount flaps
In this task the flap will be positioned and the flap brackets will be glassed onto the wing.
The flaps are designed to stow in the flap recess at the rear
of the wing with the front upper surface of the flap fitting
snugly against the lip at the top of the flap recess as shown
arrowed in the drawing at right.
Wing
Flap
In order to achieve an aerodynamic fit the top rear of the

wing must be carefully prepared before the flap can be
positioned and the flap brackets glassed into place.
This is a critical issue that can affect the aerodynamic
efficiency of the wing and considerable care must be taken
with this task.
Flap post
Flap
bracket
Materials required:
Card # 16J Electric Flaps
Prepare the wing
Turn the wing upside down and pack under the trailing edge so that the wing is stable.
There are 4 squares of peel cloth under the gel coat at the trailing edge of the wing where the flap brackets
will be located carefully cut one corner then lift and remove the peel
cloth from each area then lightly sand the area under the peel cloth.
The rear of the wing as supplied should be a uniform distance back from
the rear of the flap recess. The photo at right shows the workshop tool that
we use to check the depth and a line that has just been marked.
If your wings have a black line like this marked along the rear of the
underside of the wing then you should trim carefully to that line before
starting on the next step.
Note that the wing is upside down in all photos in this task.
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Grind back the underside of the lip on the trailing edge of the wing from the wing root to the start of the
aileron mount recess to at least 30 degrees as shown above (the angle has been emphasised with red lines in
the photo) this will allow the flap to retract and seat snugly under the lip with minimal gap.
Do not grind too far into the aileron area, which can be identified by the recess along the underside of the
wing at the outboard end. If in doubt, hold an aileron level with the outer end of the wing to see where the
inboard end comes to.
Finish off with a long sanding block to ensure an absolutely straight edge, both at the rear of the wing and
along the angled section.
When the angle shaping is getting close to finished use a straightedge as a final check: the rear of the wing
(left-hand photo above) and the angled section (right-hand photo above) should both be absolutely straight.
Use the long sanding block to correct any irregularities the importance of having both the rear of the wing
and the angled section absolutely straight cannot be overstated.
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Position the flaps
Initial flap position: lay 2 lengths of aluminium angle on the wing surface between the outer peel cloth
squares and secure with cloth tape on the forward end.
Place the front of the flap onto the lip at the rear of the wing and clip the trailing edge to the aluminium
angle with spring clips (circled in yellow). At this stage the flap should be touching the aluminium angle at
the front and the rear as shown above and the aluminium angle should be in contact with the wing over the
full length.
Now the flap

is positioned laterally. The intention is to position the flap so that the distance from the centreline of the
wing mounting bolt hole to the first rib of the flap will be 8mm.
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In the factory we use a method that entails measuring the distance from the centre of the wing mounting bolt
hole to the outside of the wing mounting lug, then adding 8mm to that distance, which gives us the distance
that the first rib of the flap must be from a ruler or straightedge held against the wing mounting lugs.
Move the flap gently until you are satisfied that the distance from the centreline of the wing mounting bolt
hole to the first rib of the flap is exactly 8mm.
When that position is correct mark the wing and the flap with a line from front to back (use a marker pen) so
that you can easily see if the alignment changes for any reason, such as someone bumping the flap
accidentally.
Place some thin spacers (paint thickness or about 0.2mm) between the top of the flap and the lip at the rear
of the flap recess (arrowed in yellow above left).
Flap to wing spacing: tape 6 pairs of mixing sticks together. Place 2 pairs into the gap between the flap and
the wing and 1 pair under the aluminium angle each side of the flap to wing gap to create the required curve
to the underside of the wing as shown above right.
Prepare to flock the flap brackets
Remove the peel cloth from the outside and the inside of the flap brackets. Lightly
sand the inside and outside of each bracket.
Using regular brown packing tape, tape over the gap between the flap and the wing
to prevent flock from entering the gap:
Place a bush in each flap post and carefully sand off the sharp edges from the
rounded end of each flap post (circled at right).
Cut the glass fibre cloth from the bag marked Hollow Wing as marked cut slightly outside the marked
area.
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There will be 3 pieces of glass fibre cloth for each flap
bracket. Place them on the wing in front of each flap
bracket position.
Fit the flap brackets
In this step the flap brackets will be flocked into place and then covered with 3 layers of glass fibre cloth.
This all needs to be completed in the one continuous operation. In our factory this step takes over an hour
with an experienced person, so allow perhaps 2 hours or slightly more.
Mix a batch of resin and coat the inside of the flap brackets and the wing surface where the flap brackets
will be attached. Mix a small separate firm batch of flock and fill the inside of the angled end of the flap
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brackets as shown above right (note that there will only be 3 brackets on a J160 due to the shorter wing and
flap length).
Place each bracket: holding the bracket clear of the wing, insert the bolt through the bracket and the bush,
then let the bracket rotate down to the wing. Do this for each bracket.
At this point recheck the marker pen mark across the wing and flap to be sure that nothing has moved.
Once all four brackets have been placed apply a gentle downward pressure to seat each one and then round
off any excess flock around the base of each bracket to an even contour with the rounded end of a mixing
stick. This rounded contour will help to avoid air bubbles when you apply the glass fibre cloth in the next
step.
Working on one bracket at a time, wet an area around each bracket that is slightly wider than a piece of the
glass fibre cloth that you cut out in the Prepare to flock the flap brackets step above, then place a piece of
glass fibre cloth onto the bracket and brush it on, working down the sides of the bracket and onto the wing,
taking care to brush out any air bubbles and paying particular attention to the curved flock join between the
bracket and the wing. Repeat this process for each of the 3 layers. Note that the first layer should be slightly
wetter than the following 2 layers.
The photos above show the second layer being applied.
There will be some excess cloth that will cover the brown packing tape this will be cut off after the resin
has cured.
Next day heat the excess cloth along the wing-to-flap gap and cut it away carefully with a sharp knife.
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Remove the brown packing tape and clean away any excess fibre and flock.
Remove the flap from the wing, taking care to save the pivot bushes and bolts, and store for later painting.
Check the slot size

At this point you have mounted the flap to the wing with the flap upper surface correctly aligned in relation
to the trailing edge of the wing. Now the slot size the gap between the trailing edge of the wing and the
leading edge of the flap must be checked.
The slot size is very important when the flap is extended the airflow through the slot provides control of
the airflow velocity over the flap, and thus the slot or gap size must be identical along the width of the flap
or there could be a rolling moment when the flaps are extended.
To check this, turn the wing right side up and fit the flap, taking care to fit the bush before each bolt.
Deflect each flap to as close to full flap deflection as you can and hold the flap in that position at each end
with cloth tape.
Now measure the slot size at each flap post as shown in the drawing at right: the slot size should be as
shown, but the critical measurement is that the slot size should be the same across the full width of the flap
and the slot size should be the same for both wings at the same flap deflection.
If you have been careful in the initial flap alignment the slot size should fall within the acceptable tolerance
range, but if you need to make adjustments then they should only be minor and these adjustments should be
made with a long straight sanding block, starting by slightly altering the angled under-face of the trailing
edge of the wing and only if necessary then altering the trailing edge of the wing itself.
Final adjustments will be made in the Testing>Flight testing task.
This completes the Pre-Paint>Wings>Mount flaps task.
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Pre-Paint>Wings>Fit wing tips

Materials required:
Fit the wing tips
If you intend to fit strobe lights to the wingtips, drill a hole in the wing root and use a long rod to route the
strobe wiring along behind the leading edge and out of the wing root. The wiring will need to be routed out
through the strobe mount before fitting the wingtips.
Pre-fit the wing tip to the end of the wing and make sure that the tip sits firmly over the wing and that the
leading edge of the tip is level with the leading edge of the wing.
Make adjustments as required some material may need to be removed from inside the very front of the
wing tip. The wing tip should fit up hard against the joggle step.
Hold the wing tip in position and fix in place with 6G self-tapping screws, then remove the wing tip.
Remove the peel cloth from the end of the wing and sand the surfaces to be joined.
Mix a batch of resin and coat the surfaces then add flock to the remainder. Apply a 2mm layer of flock to the
wing and fit the wing tip into place: hold the wing tip slightly open as you place it over the end of the wing
and then let the wing tip close onto the wing so that the flock is not pushed ahead of the wing tip. Fix in
place with the 6G self-tapping screws.
Wipe away any excess flock with a clean mixing stick and leave overnight to cure.
Next day remove the self-tapping screws apply heat if required to loosen the screws.
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Pre-fit the winglets
With the wing inverted, clip the winglet into place on the end of the wing, then place a set square against the
leading edge of the wing and measure back 990mm from the leading edge as shown below.
This is the position of the back of the winglet. Move the winglet to this position then push the winglet firmly
onto the wing and pre-fit the winglet with 2 x 6G self-tapping screws (shown circled on the pictures below):
place one in front of the winglet facing in to the centre of the wing then turn the wing right way up and place
one near the rear of the winglet on top.
Mark around the winglet with a marker pen.
Remove the winglet and sand away all of the gel coat from inside the marked area on the wing tip. Take care
not to sand anything more than just the gel coat.
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Fit the winglets
Remove the peel cloth from the inside of each winglet and lightly sand to remove any roughness.
Mix a batch of resin and coat the surfaces to be joined. Add flock to the mix and apply a 2-3mm layer of
flock to the inside of the winglet. Clip the winglet into place and fix with the 2 self-tapping screws that were
used to pre-fit the winglet, then, working from the front to the back, drill and fit self-tapping screws one at a
time at approximately 50mm spacing around the top of the curve only (as shown on the previous page) and
slightly wider spacing along the straight section. There is no need to screw the underside of the
winglet/wing.
Wipe away any excess flock with a clean mixing stick.
Leave to cure overnight and then remove the screws. The screw holes will be filled later as part of the PrePaint preparation task.
Fit the strobes (optional)

Should you elect to fit strobe lights to the wingtips you will find a shaped fibreglass strobe mounting base in
with the strobe packing. Decide exactly where you want the strobe to fit: on the wingtip or on the winglet
and in what position, and then shape the underside of the strobe mount so that it will fit in the desired
location and fix it in position with flock and hold it with 2 self-tapping screws until the flock has cured.
You will then need to route the wires out through the strobe base before fitting the wingtip and winglet.
This completes the Pre-Paint>Wings>Fit wing tips task.
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Pre-Paint>Wings>Fit Z-spar ailerons

In this task the ailerons and the pre-mould strips will be sized and trimmed, then flocked onto the wings and
glassed in place, and the next day the ailerons will be fitted to the wings.
Card # J5 or #5JT Aileron for the hinges
2 Lengths of flat timber 1150mm long, about 300 - 400mm wide
Clear or brown packing tape
White masking tape
Pavers or half bricks for weights to hold the pre-mould strip in place while the flock cures
Fitting the Pre-Mould Strip
First the wings should be flipped over up-side-down with foam wedges placed underneath to protect the top
surface and steady it, ready for the installation processes to follow.
The holes to be drilled into the pre-mould strips have already been marked, however you should check that
the positions marked are correct. Take a stainless steel hinge plate and place it up again the strip to check the
spacing of the holes is correct. Also check the hole marks are placed the correct distance from the edge, they
should be 12mm in from the visible edge. Re-mark if necessary before drilling.
12mm
Check the hole

spacing using a
hinge
Now drill the holes out to 3/16. Make sure to position a wedge of
timber on the other side. This is to prevent the drill bit going too far
and damaging the other side of the pre-mould strip. It also ensures
that the Aluminium plate will not be unseated from the pre-mould
strip when hard pressure is applied with the drill. Once all holes are
drilled, remove the peel cloth from the pre-mould strips and sand
these areas to roughen them slightly.
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Now the pre-mould strip is to be adjusted in order to
correctly fit it to the wing. Remove material from each side
of the pre-mould strip until it fits in between wing tip and
the flap, there should be a small gap (about 3mm from the
flap end). Material should be removed evenly from both
sides, NOT all from one side.
From the wing tip trailing edge and the flap trailing edge
mark 200mm plus a 5mm gap (205mm in total) with a
pencil. These marks dictate where the trailing edge of the
pre-mould strip should align to.
FLAP
PREMOULD
STRIP
Need a 3mm gap,

remove all
material on the
left of the red line
Remove material from the leading edge of the pre-mould

strip until the trailing edge comes up to the marks made
on the wingtip and flap previously. With all adjustments
made to the pre-mould strip it can now be fitted to the
wing.
Remove material from

leading edge of strip
205mm from wingtip

trailing edge
Sand back the area around the wingtip/wing junction.

Sand back about 40mm all the way around. Sand back
40mm on both ends of the pre-mould strip.
Sand back about 40mm around

(also sand back the pre-mould
strips 40mm at both ends)
Take both timber lengths and apply brown or clear packing tape across the entire surface of one side. Apply
White masking tape to the entire outside face of the pre-mould strip. Mix up some 5-minute Araldite and
coat the masking taped surface of the pre-mould strip. Press the pre-mould strip firmly onto the packing tape
covered edge of the length of timber, it should overhang the timber board by about 40-50mm on both sides.
Place pavers or bricks on top of the strip and allow the araldite to set.
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Blow away any dust on the wing and pre-mold strip with compressed air. For each wing, mix a 200g batch
of resin, and divide into a 160g batch and a 40g batch. Add flock to the 160g batch of resin and mix it in
thoroughly. Apply a layer of flock to the recess on the wing the layer should be around 3 to 5mm above
the level of the wing.
Apply flock (6-8mm) to

pre-mould strip here
Using the 40g batch of resin, coat the curved part of the wing and the edge of the curved section on the premould strip, then apply a D-shaped layer of flock to the bottom of the curved rib the layer should be as
wide as the bottom of the curve and about 6-8mm deep.
Fit the pre-mould strip attached to the timber board onto the wing and firmly press it on. Lay pavers or half
bricks on top. Apply a coat of resin to the back of the curved rib/wing join and lay in a single length of
AF303 glass fibre cloth (30mm wide, from the Wing bag). The lower edge of the glass should be slightly in
from the trailing edge of the wing. Brush the layer in carefully taking care to avoid any bubbles or gaps. At
the wingtip/wing junction coat resin on the sanded areas then apply a single layer of AF303 glass
(100x70mm) and brush it on with resin. Brush on a piece of peel-cloth to cover the glass
Apply peel cloth

over this glass
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Leave the wing/pre-mould assembly for 24 hours to cure before continuing with the next task.
The next day the timber boards can be removed (simply pull them straight off) and remove all the masking
tap from the surface of the pre-mould strips (which are now firmly bonded to the wing). Sand the excess
flock back to the same level as the pre-mould strip. Sand inside the trailing edge channel (at the join between
the wing and the pre-mould strip) to remove excess flock.
Sand excess Flock back

level
Size the ailerons
Sand inside trailing edge
For this step you will measure, trim and prepare the both ailerons for fitting. First place the aileron on the
bottom surface of the wing (which is facing up since the wing is upside down). Align the aileron horn with
the edge of the aileron cable slot as shown in the picture below (note that the picture shows the right wing,
the horn should be on the opposite side for the left wing). With the aileron in this current alignment mark on
the trailing edge of the aileron 3mm in from the wing tip and flap edges respectively. This is where you will
trim the aileron to. Draw a straight line all the way around the aileron (use masking tape to go around the
curved corners. Now cut off the marked sections with a pneumatic saw or jigsaw using a fine tooth or
carbide blade.
Align aileron
RIGHT
WING
Slot
Horn
Mark around aileron
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Sand the cut edges smooth, while sanding check that the aileron is square and sand accordingly to achieve
good square ends. Check that the aileron fits. If you have the required 3mm gap on either side but the fit is
still tight then you may need to remove some material from the wingtip (this is assuming that both your
aileron and flap surfaces are square, check first beforehand). If required sand the inside of the wing tip,
continually recheck the fit of the aileron so as not to sand too much from the wingtip.
You may need to sand

the wing tip
Prepare and fit hinges

Take each of the six hinges, remove the hinge pins and roughen the flat surface of the hinge plates with a
very course sanding wheel. Now the hinge plate can be installed on the wing. Mix up an 80 gram batch of
resin, make most of this into flock. Brush resin onto the flat roughened faces of six hinge plates, brush resin
onto the attachment positions on the wing (i.e. where the holes were drilled in the pre-mould strip). Apply a
2mm layer of flock to the flat faces of the six hinge plates. Rivet the hinge plates onto the wing using the
supplied 3/16 pop rivets (AS 6-6 rivets). Repeat for all six wing hinge plates. Wipe away any excess flock.
Get a clean rag and lightly sock in Acetone. Wipe the hinge pin barrels on each of the six attached wing
hinge plates. Wipe a hinge pin and insert a number of times into each hinge such that the hinge pin barrels
are also cleaned inside of any resin or flock that might have gotten there during installation. Install all the
loose hinge plates onto those fixed to the wing.
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Fit Ailerons
First tape up the aileron hinge plates back onto the wing so they
the way. Fit the aileron with the trailing edge aligned with that of
and wingtip and apply masking tape to hold the aileron in
Bring down the aileron hinges and mark the sides on the aileron.
aileron, mark down 14mm from the visible edge and draw a line.
hinge plate and align the edges with the marked edges and align
with the 14mm line. Mark the positions of the holes. Now drill
holes at each of the marks. Sand back the gelcoat around each of
positions.
are out of
the flap
position.
Remove
Take a
the holes
3/16
the hinge
14mm
Mix up another 80 gram batch of resign, once again making most of this into flock. Brush resin onto the flat
roughened faces of six hinge plates, brush resin onto the sanded attachment positions on the ailerons. Apply
a 2mm layer of flock to the flat faces of the six hinge plates. Rivet the hinge plates onto the wing using the
supplied 3/16 TLR rivets, only install two rivets for each hinge at this stage. Check that the hinges are in
the correct position by installing the aileron onto the wing with the hinges pins, check that the aileron swings
freely without excessive friction. Remove the aileron and install the other two rivets, clean away excess
flock
It is of critical importance that you DO NOT USE REGULAR POP RIVETS for this installation. As the
picture shows, TLR rivets spread three legs which better distribute load. This is required for the aileron since
it does not have aluminum backing plates. Ideally TLR rivets should be installed with a specialty rivet gun.
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Ordinary rivet guns can be used, however they will often break the rivet tail above the rive head surface. If
this occurs you should very carefully grind the remaining tail off.
TLR
rivet
Pop rivet
Grind off tail
The final step is to install the hinge pin retainers. First consult the diagram below and note the direction each
of the hinge pins are facing (for the left wing it is the opposite). Install the ailerons as such with the bent end
of the hinge pins facing outwards. Position the hinge pin retainer over the bent end of the pin and mark the
screw position on the wing.
Drill out (HOLE SIZE), install the captive nut. Fix the hinge pin retainer to the wing with the 5/32 screw.
The assembly should resemble that shown in the picture below.
WING
Hinge pin retainer
AILERO
N
This completes the Pre-Paint>Wings>Fit ailerons task.
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Pre-Paint>Wings>Fit pitot tube to strut

To fit the Pitot head and tube to the right-hand strut prior to painting.
Take the
right hand
strut and
measure
down
340mm
from the
upper/wing
end of the
airfoilshaped
section,
mark and
drill a
10mm hole in the front of the strut.
340mm
Feed the supplied ID plastic tubing into the hole and down
the strut until it can be seen at the bottom, then fit the top end
of the tube over the pitot fitting and superglue and lock wire
the tube in place as shown at right.
Feed all the tube into the strut until the pitot head mounting
plate sits against the strut then pop rivet the plate in place as
shown in the photo below.
Lock
wire
Refer the drawing on the next page for details.

Tie the excess plastic tube to the outside of the strut and set
the strut aside for test fitting and painting.
Pitot
head
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This completes the Pre-Paint>Wings>Fit pitot tube to strut task.
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Pre-Paint>Wings>Fit vibration damper to strut

To fit the vibration damper strips to the rear underside of both struts prior to painting.
Materials required:
Vibration damping strips (approx 975 x 11 x
3mm, pack of 2)
TAPK 3-3 1/16 CSK pop rivets (10 of, 5 per strut)
Fit the vibration damper
Lay both struts on your workbench and mark them as being either left or right
(the right side has the pitot head fitted) and then mark the top and bottom end of
each strut. Mark the top side and the underside of each strut as they will be
when fitted to the aircraft.
Measure and mark a position 460mm up from the bottom of each strut on the
rear underside of each strut. This is the locating mark for the lower end of the
vibration damper.
Place the damper strip on the strut as shown at right and on the drawing on the
next page, 2mm in from the rear edge of the strut, 460mm up from the bottom of
the strut, and hold it in place with tape or by hand.
Damper
strip
Drill a 1/16 hole through one end of the damper and the strut and place a pop
rivet into the hole to locate the damper, and then, working one hole at a time,
drill 4 more evenly spaced holes through the damper and the strut, using a rivet
in each hole to locate the damper as you work along the damper strip.
Once all of the holes have been drilled, remove the damper from the strut and
use a 120 countersink bit to countersink the holes on one side of the damper
strip just deep enough to flush fit a countersunk pop rivet.
Remove the burrs from all of the holes and roughen both surfaces to be joined
with 240 grit sandpaper and then clean the area thoroughly with acetone.
Mix a small batch of 5-minute Araldite and flock and coat the back of the
damper with a thin layer and then pop rivet the damper to the strut, working
along from the bottom to the top.
Wipe away any excess Araldite and flock with a clean cloth.
Leave to cure and then set the struts aside for later use.
460mm
Bottom
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This completes the Pre-Paint>Wings>Fit vibration damper to strut task.
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Pre-Paint>Wings>Test fit wings

To test fit the wings and flaps to the fuselage prior to painting. This task is intended purely to make sure of
the fit and to make any adjustments that may be required so that there will be no issues during the final fit
after the wings and fuselage have been painted.
Each wing will be held in place with 4 bolts in this task and no nuts will be used this is purely a test fit task
after which the wings will be removed and prepared for painting.
In our factory we use 3 people for this task, so ask 2 friends over to help you.
Do not try to do this task with less than 3 people or you risk dropping the wing.
While the wings are in place the strut to wing fairings will be fitted and the strut/main gear to fuselage
fairings will be pre-fitted and then removed for painting.
Equipment required
2x4 timber for wing support see the 3rd page of this task for details
Preparation
Place 2 trestles beside the fuselage and lay the wing on them.
It is very important that the AN4-14A wing attach bolts fit snugly through the holes in the attach bushes on
the wing and the aluminium wing attach lugs on the fuselage. Test fit a bolt in each hole, and if the bolt will
not fit through to full depth then very carefully ream the holes with a hand reamer out until the bolts fit
correctly.
It is also very important that the AN175-15A strut attach bolts fit snugly though the holes in the strut attach
lug under the wing, the lower fuselage mount and the top and bottom holes in the strut itself. Test fit a bolt
in each hole, and if the bolt will not fit through to full depth then very carefully ream the holes with a hand
reamer out until the bolts fit correctly.
Do not ream any more than is absolutely necessary to get a snug fit, and do not use a drill in place of a
reamer!
These are critical fit items and great care must be taken!
Using a sanding block, lightly sand both sides of each wing
attach lug and the upper and lower strut mounts to clean
any debris away.
Fit the bottom of the strut to the lower fuselage mount with
an AN175-15A bolt. Rest the outboard end of the strut
against a saw stool as shown at right.
Lay 2 AN4-14A wing attach bolts on top of the fuselage
where you can easily reach them.
Now you are ready to test fit the wings.
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Test fit the wing
Because the precise alignment of the wing bolts is critical the bushes in the wing attach lugs in the wing
root that the bolts pass through are mounted in a bed of flock to allow for fine adjustment during fitting.
The
process that we use in our factory is to get the wing prepared and ready to fit, then heat up the wing root
bushes and fit the wing. Heating of the bushes is done by placing a soldering iron in each bush as shown
above and waiting until the other side of the bush is too hot to touch comfortably. This gives 3 or 4 minutes
working time, which is usually enough.
One person holds the outboard end of the wing while the other 2 hold the front and back of the wing root.
Walk the
wing in to
the fuselage
and guide
the wing
attach lugs
into the
aluminium
wing attach
brackets on
the
fuselage.
The fit will
be tight and
it may take
some
careful
positioning
of the wing
to get them to fit the outboard end of the wing may need to be moved forward or backwards to get the
correct alignment. As soon as one bolt can be fitted though then do so and then that bolt can be used as a
pivot to work the other lug into place.
The wing attach bolts are fed in from the front and back of the wing toward the centre of the wing.
The fit of the bolts will be tight and you will have to tap the bolts into place using a soft hammer and a brass
drift/punch. Be careful and resist any temptation to tap the bolt too hard but rather gently encourage each
bolt to pass through the bracket and the wing bush.
While the wing is being fitted the strut mount bush under the wing can be heated by the same method so that
it will be ready. Once both wing root bolts are in place the top of the strut can be fitted to the strut mount
and the wing is fitted.
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The important thing at this stage is to relieve the weight of the wing while
the flock cools and sets in the correctly aligned position, and this is done by
lifting the outboard end of the wing up about 35mm from the resting
position and supporting it overnight.
We use a simple wooden support for this (pictured at right) but an even
simpler T shape of 2x4 timber cut to length would be fine. Leave the wing
undisturbed overnight and the next day the support can be removed and the
other wing fitted in exactly the same way.
Once both wings and the flaps and strut fairings have all been satisfactorily
test fitted the wings can be removed and set aside for painting.
Test fit the flaps

We use 2 people in the factory to carry out this step and we recommend that
you do the same, as the flap is too long for one person to handle comfortably and safely.
Flap fitting
Each flap post bolt hole has a short length of Bundy tube spacer fitted inside (tip: a smear of grease will hold
the spacer in place while fitting) and each post fits into each flap hanger and is held in place with an AN3
bolt.
Size the inboard end of the flap
The inboard end of each flap is manufactured slightly over length to allow for variations in flap hanger
placement and it will now require trimming to allow it to clear the fuselage at full deflection.
Ideally the flap should clear the fuselage by a small amount, nominally 5mm, when at full deflection. Full
deflection in this case is defined as being 30 from the fully retracted position.
The first step is to hold the flap in place and check for overall length with the flap in the fully retracted
position, then manually lower the flap by hand in stages until the end of the flap touches the side of the
fuselage. Take care that you do not scratch the rear window.
Working in small stages, mark and trim the end of the flap until the flap can be lowered to the full deflection
position without touching the fuselage. In the factory we find that the use of a marker pen held flat against
the fuselage to mark the underside of the flap at each stage can be quite useful. A jigsaw is used the trim the
flap.
Remember that the top of the flap will not be trimmed quite as much as the bottom of the flap due to the
shape of the fuselage at this location.
Work slowly and in stages until the flaps clear the fuselage by 5mm at full deflection.
When you are satisfied that the inboard end of each flap is correctly cut and shaped, use a long sanding
block to smooth off the cut surfaces.
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Fit the strut to wing fairing
While the wing and strut are fitted the strut to wing fairing can be fitted and the back half of the fairing can
be flocked into place on the wing.
Assemble each fairing on the bench fit the front section
over the joggle on the back section and fit the 2 halves
together with 4 x 6G stainless steel self-tapping screws on
the outside and 1 screw on the inside and then take them
apart again. Refer to the photo at right for the outside screw
placement.
Now reassemble each fairing around the strut and locate the
fairing on the wing: carefully centre the assembled fairing
on the strut so that there is an even gap all around the strut
and make sure that the fairing is lined up fore and aft.
Back
Front
Strut to wing fairing, final fitted and painted
Mark around the back half of the fairing and tape it into place, then drill 6 evenly spaced holes through the
mounting lip of the fairing and through the surface of the wing. Do not drill any deeper than 5mm or you
risk hitting the fuel tank! Fix the back half in place with a few 6G stainless steel self-tapping screws, then
remove the screws and lower the fairing.
Repeat the process on the other wing.
Prepare the surfaces to be bonded: sand both surfaces and ensure that they are clean.
Mix up a small batch of flock and flock the back half of each fairing to the wing, holding it in place with 6G
stainless steel self-tapping screws. Leave overnight for the flock to cure, then next day remove the screws
use a soldering iron if necessary to loosen the screws in the flock.
The join between the fairing and the wing will be filled and finished in the Painting task.
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Pre-fit the strut/main gear to fuselage fairing
Right hand side strut/main gear fairing from below (top photo) and side on (above)
The strut/main gear fairing comes in 2 sections (left and right) and it covers the strut to fuselage join, the
main gear to fuselage join and also fairs the main gear mounting recess.
Fit the right hand section first: fit the fairing into place and hold it there temporarily with some cloth tape,
then fit the left hand section of the fairing and tape it into place also and check all round each half of the
fairing and adjust as required for the best fit. When the fit is correct all round drill 5/32
holes around each fairing and the fuselage in the pattern shown in the photos above.
Remove the fairings and enlarge each fuselage hole to 13/64 and tap each hole to a 1/4
UNC thread. Each hole will have a threaded insert (shown circled at right) recessed,
screwed and super-glued into it, using the screw and spacer (also pictured) to drive the
insert home in exactly the same manner as the Ventral Fin in the PrePaint>Fuselage>Fit ventral fin and trim horn task.
This completes the Pre-Paint>Wings>Test fit wings task.
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Paint>General
Paint>General
To paint the aircraft, which involves disassembling the fuselage, empennage and wings, then the preparation
filling, sanding, priming and so forth, and finally application of the topcoat.
Body filler adds weight to your aircraft and Q-Cell is the lightest filler available so we suggest that you use
Q-Cell for the larger fills and finish off with a lightweight body filler.
Paint also adds weight to your aircraft and so we recommend that you keep the amount of paint to the
minimum necessary to achieve a good finish: just enough of a light-coloured undercoat to cover filler and all
of the bare spots, followed by a single topcoat.
The topcoat must be white for heat rejection purposes, and any coloured striping or detail can only be
applied to vertical surfaces all horizontal surfaces must be plain white.
Filler and paint:
In general we use automotive grade paint preparation products and automotive grade 2-pack epoxy paint.
The specific brands that we use here in Australia may not be available where you live and you may have to
find similar products locally.
Lightweight body filler
2 tins
K&H Mercury brand or similar (photo #1)
Spot putty
4 tubes
Ever-Glaze brand or similar (photo #2)
2 pack epoxy primer undercoat
5 litres
Protec Autofleet brand or similar (photo #3)
2 pack polythane white topcoat 12 litres Protec Barrier brand or similar (photo #4)
Q-Cell and polyester resin lightweight body filler a 3-part mix consisting of:
Q-Cell microspheres
1 kg
mix with resin as required, about 20% by weight
Polyester resin
4 litres
40% M.E.K.P. solution
20ml
catalyst for the polyester resin/Q-Cell mixture
Etching primer
250ml
for priming metal parts: noseleg, etc
Wax and grease remover
1 litre
for final washdown prior to topcoat
Thinners, retardant, etc as required to suit the chosen products and conditions.
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Paint>General
Tack cloth available from automotive paint suppliers, removes fine dust prior to the application of the
topcoat.
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Paint>General
Sandpaper:
Generally we recommend and use 3M brand (or 150mm Stickit brand pads for a random orbital sander)
aluminium oxide sandpaper in the following grades and quantities:
First all over sand
180-grit
1 box
Filler sand
80 and 120-grit
1 box of each
Spot putty and final sand
240-grit
2 boxes
Equipment required:
Cork or rubber sanding blocks, flat and curved.
150mm random orbital sander, either electric or pneumatic, preferably with dust extraction.
Compressor and spray gun we use a low-pressure pot gun (~80psi) in the factory, but follow the
instructions of your chosen paint supplier.
Half-face respirator with suitable painting filters.
Disposable coveralls, gloves, boots and safety glasses or goggles.
Assorted saw stools, wire hooks and trestles will be required to support individual parts while they are being
prepared and painted. In the paint booths at our factory we hang smaller parts in rows from roof-mounted
rails, while wings are fitted to purpose-built supports that hold the wing root and support the outer end with
a hook through the flap brackets.
Disassembly
Preparation and painting is done with the aircraft completely disassembled - all parts will be prepared and
painted separately and then reassembled after the paint has cured.
We suggest that you bag all the hardware (bolts, nuts, washers, clips, etc) for each component separately and
clearly label what each bag is for this will make your life so much easier during reassembly.
Remove the ailerons and flaps from the wings, then remove the wings and wing struts.
Remove the elevator, rudder and ventral fin from the empennage.
Remove the wheel spats and any other fairings.
Remove the doors and the engine cowlings.
Remove the noseleg assembly and place a saw stool or prop under the attach point, or alternately leave the
noseleg in place and mask around it.
Remove any other small items such as ventilation doors, oil door and so on.
Clean everything thoroughly
The entire aircraft should be disassembled (see above) and then everything should be blown out thoroughly
with compressed air and then vacuumed out to remove dust and debris from every part of the airframe. You
do not want dust being blown into the finish because it didnt get cleaned out properly beforehand.
While you are cleaning, take the time to clean out your work area too blow and sweep all dust and rubbish
from the walls, benches and floor and get into the habit of doing this at the end of every work day so that
when you come to apply the paint the work area will be substantially clean to start with and you wont get
any little surprises in the finish.
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Paint>Masking
Paint>Masking
General: we recommend and use regular automotive masking tape and brown masking paper. We do not
recommend the use of newspaper for masking due to its porous/absorbent nature.
We recommend and use Fine Line brand edging tape (photo below left) to define the edges of windscreen
and windows then follow up with normal 1 wide tape and brown paper to fill.
The
windscreen,
door and
side
windows
will all need
to be
masked
very
carefully,
paying
particular
attention to
the shape of
the masked
area, which
should
closely match the shape of the underlying glass fibre structure. Use the Fine Line tape and mask slightly
(~5mm) inside of the structure line and then use a folded piece of 240-grit paper and sand right up to the
tape to provide a good key for the paint to adhere to. Take your time with this you will see the shape of
your windscreen and windows every time that you fly so make them even and pleasing to the eye. The photo
above right shows a side window fully masked note the blue Fine Line tape defining the edge and the
regular masking tape and paper infill.
Do not rush the masking stage, but rather take your time and do it carefully: care at this stage will save you a
lot of time and grief later overspray is not easy to remove, particularly with 2-pack paint, so mask up very
carefully. Overspray will sneak though the smallest gaps.
Mask all control surface hinges on both the control surface and on the adjoining structure.
Mask the VHF antenna and static tube.
Mask inside the door openings so that the door opening
will be painted but overspray will not get inside the cabin
and foul the inside of the windows.
Mask the engine and engine bay back to the outside edge of
the firewall wrap the entire engine and engine mounts in
masking paper and seal off at the firewall.
Mask the main wheels and brakes.
Mask the suspension rubbers on the noseleg.
Masked and undercoated J170 fuselage
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Paint>Surface preparation
It is true that any paint job is only as good as the preparation shiny paint will most definitely not hide
anything, and in fact shiny paint will only magnify any lack of preparation so surface preparation will be the
most time-consuming (and ultimately rewarding) part of the painting process. If you want a slick-looking
finish this is how to get it: prepare carefully!
The surface preparation process is: sand everything with 180 grit paper; fill where required (Q-Cell for
larger areas and lightweight body filler for smaller areas, nicks etc); sand the filler smooth with 80 and then
120 grit paper; apply undercoat; fill pinholes and small nicks with spot putty; sand spot putty with 240 grit
paper; touch up with undercoat; final sand with 240 grit paper; wash with wax and grease remover, dry off
and wipe over with a tack cloth.
Wear your half face respirator all the time during the sanding and painting process there will be a lot of
fine dust generated and your lungs will thank you for it.
Lets get started!
Sand the entire surface of the aircraft and all parts to be painted with 180-grit sandpaper we use a random
orbital sander for this task and for most of the sanding in the factory. This will provide a key for filler and
undercoat to bond to. Be careful not to sand through the gelcoat and into the structural glass fibre if you do
go through the gelcoat do not sand any deeper.
Filler is used to fill imperfections in the surface to be painted, so you will use filler for things such as filling
in ripples or dents. When filling large areas we have found that the use of a very wide (~9) spatula (make
your own from plastic) provides a good finish with little waste.
Mix up a large batch of Q-Cell and polyester resin to a creamy consistency and keep it in a sealed tin: this
mix will last about 5 days. Stir the Q-Cell mix thoroughly before each use and then scoop out one handsized amount at a time onto a flat mixing board, add 3% of M.E.K.P. catalyst/hardener and mix it in
thoroughly - this will give you about 15 minutes working time - and apply with a wide spatula. Allow to
cure for a few hours until it cannot be scratched with your fingernail and then sand back to a smooth finish
with 80 and 120 grit paper.
Smaller areas can be filled with lightweight body filler and sanded back in the same manner.
You might find it easier to work on one area at a time when applying filler so that you dont loose track of
where you are. If you decide that this way or working appeals to you, you might want to consider working
on a specific area until you are happy with the finish and then undercoating that area before moving on to
the next area. Working in this manner means that you are less likely to miss anything and the undercoat
allows you to see where you have been.
Metal surfaces such as the noseleg must be cleaned and primed with an etching primer.
Now spot putty can be used to fill smaller imperfections such as pinholes and the like. Spot putty is applied
with a spatula, left to dry and sanded back with 240-grit paper. Work your way around all surfaces in this
manner and then apply undercoat to all spot puttied areas.
By now many days will have passed and all surfaces should be smooth and undercoated.
All surfaces can now be hand-sanded with 240-grit paper as the final stage in surface preparation, then all
dust can be blown away and everything can be wiped down with a clean cotton cloth. Wash everything with
warm water and detergent and then with automotive wax and grease remover and then allow all surfaces to
dry off completely.
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At this point the entire work area must be thoroughly cleaned and the floor and walls washed with water to
wash away and damp down any dust.
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Paint>Topcoat
Paint>Topcoat
This is what you have been working towards the application of the topcoat.
This is a critical task where you only get one chance to get it right. If you are unsure of your ability to apply
the topcoat then you may want to hire a professional painter perhaps the local car painter would do the
final coat for you on an hourly rate, or maybe you have a friend who is good at such things. You could even
find someone who can teach you how to paint; perhaps there is an adult education facility near you who
could help.
The work area should have all dust and debris removed and then be thoroughly wetted down to minimise the
chance of dust settling into the final finish. Hose the floor and sweep it out.
All parts should be supported or suspended in such a way that you can paint them and leave them to dry (it
might be necessary to paint the fuselage separately from the smaller parts if you are working in cramped
conditions).
Ensure that you have plenty of ventilation while painting and that any air being directed over the work
surface is clean air in our paint booths we use automotive grade air filtration across the inlets to each booth
with large extractor fans that vent above the booth, however you should be able to achieve a reasonable level
of filtration by drawing air from openings that are above ground level and screening them with clean insect
screens with muslin or similar open weave cloth placed over them. If using the prevailing breeze you may
have to wait for a day when the wind is blowing in the right direction before painting, or perhaps you could
use an industrial fan as an extractor fan to draw clean air over the work surface.
It bears repeating here that the topcoat must be white under no circumstances must any other colour be
used, and any coloured trim can only be applied to vertical surfaces: never use any colour other than white
on the horizontal surfaces.
Finally all surfaces should be wiped over carefully with a new tack cloth.
It is not possible to give written instructions regarding painting technique and so all that can be written has
to be this: read the directions from your chosen paint supplier very carefully and follow them to the letter.
Expect to use about 4 litres for the fuselage, 4 litres on the wings and 3 litres on the remaining parts.
Mix your paint and hardener together thoroughly and in the exact ratio given in the paint manufacturers
instructions, clean and lay out your air hoses so that you will not trip over them and make sure that you wear
your coveralls and respirator at all times while painting.
Take your time, apply the paint in an even pattern and good luck!
Once you have finished painting leave the area and keep the ventilation system running for a few hours.
Leave the paint to cure undisturbed read the manufacturers directions for guidance on how long to wait
and resist the temptation to rest anything on the newly painted surface for at least a few days as it might
make a mark in the still curing paint.
Peel the Fine Line tape back very carefully from around the windscreen and windows, taking care to peel
back along the masked line, which will give you a nice clean edge.
Unmask the engine and the door openings, refit the noseleg and nose wheel and remove all other masking.
In general peel masking back away from the painted surface.
Reassembly will be addressed in the next major section of this manual: Post-Paint.
This completes the Painting task.
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Post-Paint>General
Post-Paint>General
Objectives of this section:
This is the beginning of the Post-Paint section of the Constructors Manual.
At this point you should have a shiny white painted fuselage and a large number of painted aircraft parts
along with boxes of upholstery, wiring and instrumentation in your workshop.
The task at hand now is to assemble all of these parts into a complete and flyable aircraft, and the sequence
of assembly can make this process either enjoyable or painful depending on how you choose to proceed.
The suggested sequence that follows is exactly the same as we use in our factory and in general it involves
leaving the wings off until the very last, which will save you a lot of ducking and bumps on the head. The
wings have been pre-fitted at the end of Pre-Paint so you know that they will fit correctly, but we suggest
that you forego the final fitting until last.
That beautiful shiny white paint should be left for at least 5 days to cure before starting on reassembly
fresh 2-pack paint is surprisingly vulnerable to marking until it is fully cured and such marks can be difficult
to touch up, so it is far better to let all the painted surfaces sit and cure fully before starting work. Patience
will be rewarded in this case.
During this paint curing time we suggest that you start by fitting the panel mounted throttle to the instrument
panel housing and assembling and wiring up the instrument panel, all of which is done out of the aircraft on
the workbench.
The assembly sequence then is to fit all of the upholstery apart from the seat covers: firewall, console,
floor/sides/roof, etc, electrical wiring can then be fitted and terminated, then install all of the controls and the
static and pitot systems, brake system and fuel system (all of which have all been pre-fitted during PrePaint).
The instrument panel housing is now fitted, engine control cabling is connected, the instrument panel is
fitted to the housing and the seat covers are fitted.
Moving back to the empennage, the elevator and rudder are fitted and the trim system is installed, although
the ventral fin will be left off until final adjustments are made.
Finally the doors and door seals can be fitted and the interior is complete.
Now we can move to complete the engine bay and fit the propeller and spinner and fit the cowlings. The
front and main wheel spats are also fitted at this time.
Now that the fuselage is complete the wings can be assembled (aileron cables, ailerons and flaps) and fitted
to the fuselage and the fairings are fitted. This completes Construction.
Now you are into Testing: rigging checks can be performed and final adjustments can be made as required.
The ventral fin can now be fitted.
A weight and balance check can be conducted, then the fuel tank levels can be calibrated and then interior
placards and decals can be affixed.
Registration markings and stripes are fitted at this time along with all fairings.
A thorough pre-flight checklist must now be completed and the aircraft can be prepared for a test flight.
Each of the foregoing tasks will now be described in detail.
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Post-Paint>Fuselage>Fit panel mounted throttle

To fit the panel mounted throttle linkage to the instrument panel housing.
Materials required:
Resin and flock
Card # 4J or #4T Panel Mount Throttle
Fit
the
Bearing blocks
Input levers
Output lever
Cross shaft
Rear view of the panel showing the bearing blocks in place and the cross shaft ready for assembly.
cross shaft bearing blocks

The throttle cross shaft is used to determine the side-to-side position for the bottom half of each bearing
block, so the first task is to assemble the cross shaft as shown above.
Output lever
Rod end
Now, working from the rear of the panel, make a mark 50mm in
from the bottom of the rear lip on each side (as shown at left) and
position the bottom half of each bearing block behind each mark.
Sit the assembled cross shaft in each bearing block and move the
bottom half of each bearing block out until the cross shaft has no
side-to-side movement.
Make sure that the cross shaft is evenly spaced in from each side
of the panel, then mark the position of each bearing block and
flock each block in place, using the cross shaft to keep the blocks
in alignment. Leave overnight to cure.
Input lever
50mm
Next day run a 3/16 drill through each hole in the

bearing block and drill through the panel housing,
then grease the throttle cross shaft, put each bearing block cap in place and fix it to the panel
housing with 3/16 screws, bearing plates (shown at right), washers and Nyloc nuts and tighten
the nuts to safety.
Too much tension will make the throttle stiff to move, so test the amount of friction as you
tighten the nuts.
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Fit the rod ends to the inside of the input levers with AN3-8A bolts fitted through the input levers, then an
AN960-416 (3/16) flat washer, then the rod end followed by an AN960-515 (1/4) flat washer and a Nyloc
nut as shown in the photo on the previous page.
Fit the input shaft pivot blocks
In this step we will fit the input shaft pivot blocks to the sides of the panel housing.
With the cross shaft secured in place, put the panel housing on its back so
that the panel opening faces upwards. Screw the throttle input shafts onto
the rod ends on the input levers with a drop of Loctite 242 on the threads
and tighten firmly.
Temporarily fit the instrument panel to the panel housing with cloth tape,
making sure that the throttle input shafts go through the correct holes in the
instrument panel. Centre each throttle input shaft in its hole in the panel by
using a small length of rubber hose as shown arrowed at right.
80mm
Pivot block
mount spacer
Pivot
block
3/16 hole
30mm
hole
12mm
Front of
panel
Outside right-hand side of panel housing
Front of
panel
Inside right-hand side of panel housing
Mark a line on each side of the panel housing along the centreline of each throttle shaft.
Remove the instrument panel and set aside. Mark and drill the 3/16 and 1/2 holes as shown in the photo at
above left.
Mix a small batch of flock and apply to the base of the pivot block mount spacer and then bolt the pivot
block mount spacers to each side of the housing with an AN3 bolt through the 3/16 hole as shown in the
photos above.
Drill 3 x 3/16 holes evenly spaced around the flange of the pivot block mount spacer and fit in place with
TLR pop rivets as shown in the photos above. Leave overnight to cure.
Cut a length of Bundy tube to fit through the bolt hole in the pivot blocks.
Next day slip a throttle stop ring and a pivot block over each throttle input shaft and bolt through the pivot
block and Bundy tube and the pivot block mount spacer with an AN3-17A bolt with a penny washer under
the Nyloc nut tighten the nuts to safety.
The 1/2 hole will be used later for throttle idle stop adjustment.
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Fit the instrument panel retaining nuts
At this point tape the instrument panel back in place and drill
through the instrument panel mounting holes in the panel with a
5/32 drill.
Remove the panel and fit captive nuts behind each hole use the
captive nut as a jig (a complete captive nut assembly is shown below
right) as a jig (shown at right) to drill the rivet holes thread the
screw part-way through the captive nut from the back and fit the
exposed end of the thread into the hole, then drill the 2 x 3/32 rivet
holes for the countersunk rivets.
Countersink the rivet holes just enough to make a countersunk 3/32
rivet sit flush and rivet the captive nuts in place and then enlarge the
5/32 holes in the panel to 3/16 to provide clearance for the screw
threads.
Now the excess lip in the panel housing can be trimmed away
around the captive nuts mark a line and trim generally as shown in
the photo above.
Leave enough of a lip for the panel to sit against, about 10mm, and mark around the captive nuts. Leave the
solid section across the bottom of the panel this will support the Carb Heat, Choke and Cabin Heat knobs
later.
There may need to be some fine adjustment of the trimmed edge once the instrument panel has been
assembled in the next task, after which the panel housing can be covered with your selected upholstery
fabric.
This completes the Post-Paint>Fuselage>Fit panel mounted throttle task.
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Post-Paint>Fuselage>Assemble instrument panel

To fit all instruments into the instrument panel, fit all of the electrical wiring and terminate to multi-pin
connectors ready for installation into the instrument panel housing.
There are 5 panel options as well as builder variations and so this task will address the fitting of hardware
and both analogue and digital instrumentation in general terms and will use photos of Standard (analogue)
and Jumbo (digital) panels to illustrate various aspects of the task. Refer also to the PostPaint>Fuselage>Electrical wiring diagrams task.
Fitting of the hardware and instrumentation to the panel is not particularly difficult but the actual wiring is a
task that requires considerable care and attention to detail.
A kit builder can do the wiring provided that he or she is careful and methodical. If you are not experienced
at electrical wiring and the reading of electrical wining diagrams then you may wish to consider having the
wiring of the panel done by a specialist technician, or possibly a friend or acquaintance may have the
necessary skills.
Materials and tools required:
Card #14JT Option 1 & 2 Hardware or Option 3 & 4 Hardware or Option 5 Hardware
Card #16J or 16T Electric Flaps specifically the flap actuating switch and flap switch handle
Wire stripping and crimping tools
Prepare the work area
You will need a clean well lit workbench and a piece of foam about the same size as the panel so that the
panel can be placed face down without any risk of scratches to the front face of the panel or the faces of the
instruments.
All electrical connectors should be close at hand and your heat gun will be needed to shrink the coloured
tags onto the wiring. All tools should be within easy reach.
There will be a lot of packing waste so empty your rubbish bin before starting.
Unpack the hardware and fittings
Strip all of the hardware and fittings from the Cards use a knife to cut around each item and then peel the
plastic shrink-wrap back and away from the item. Be very careful when cutting the noise suppression filter
out of the wrap: do not cut near or through the wires.
Sort all of the items into groups: switches, circuit breakers, wiring, lights, etc.
Empty the bag of electrical connectors onto your bench top and sort the items into groups: note that the red
female spade connectors are for single wires and the blue ones are for 2 wires. Do the same with the screws
and fittings bag: select the black screws (2 lengths) and nuts, the silver screws and Nyloc nuts (M3 and M4)
and the gold anodised captive nuts. The remaining items should be put aside for later use when installing the
panel into the aircraft.
The M3 silver screws and Nyloc nuts will be used for busbar to circuit breaker connections, the M4 silver
screws and Nyloc nuts will be used to fix hardware to the panel, while the black screws will be used to
mount instruments to the panel. The gold anodized captive nuts will be clipped into the analogue
instruments as each instrument is being fitted.
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On factory built aircraft we sandblast and paint the heads of the M4 silver screws satin black so that they
blend into the panel. You may wish to do the same before assembling your panel.
Fit the hardware to the panel
The panel assembly sequence is: prepare and fit the circuit breakers, then the switches and panel lights, then
the instruments, radio(s), intercom and transponder.
The Standard panels have a single long earth busbar while Jumbo panels have 3 earth busbars, 1 for the
circuit breakers, 1 for the panel lights and 1 for general use.
Circuit breakers end of the earth busbar
Prepare the circuit breakers and switches earth busbar by filing a 6mm notch on each side of each circuit
breaker hole in order to clear the circuit breaker attachment clips as shown above.
Rear view of the panel
Prepare the panel for the circuit breakers by very carefully filing a 6mm wide 45 recess on the back of the
panel at each side of each circuit breaker hole as shown above this allows the circuit breaker attachment
clips to seat firmly into the holes. Work carefully and take care not to mark the front of the panel. File the
recess on all circuit breaker holes, even spares.
Prepare the 5 and 10 amp circuit breakers only by carefully drilling out the hole in each bottom spade
connector to 3.3mm. This allows the main busbar to be bolted to the connectors. Support the connectors
while drilling by placing a piece of plywood between them.
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Fit the circuit

breakers to the panel from the front check the etched labels on the panel and the circuit diagram and fit the
correct value circuit breaker to each hole. Press each circuit breaker in until the attachment clips click into
place. Standard panel shown above.
Lay the panel face down on a soft surface and fit the earth busbar over the back of the circuit breakers. Fit
the switches though the earth busbar and though the panel. Each switch has 2 retaining nuts: one nut will
remain behind the panel and be used to tighten the switch in place and the other nut will be fitted to the front
of the switch on the panel face.
Each 2-way switch is labelled on one side with the direction of the OFF and ON positions.
All 2-way switches follow the convention of UP = ON and DOWN = OFF which means that for most
switches the machined groove in the threaded barrel of the switches will face downwards. The Magneto
switches will be the opposite, where the DOWN position will connect the magneto to earth while the UP
position will remove the earth and make the magnetos live. Accordingly the magneto switches will have the
groove facing upwards.
The 3-way flap switch should be fitted with the groove facing downwards.
Place all the switches into the panel and tighten the front nuts finger tight, then check that each nut is flush
with the end of the threaded barrel. Adjust the rear nuts to suit.
Lay
metal ruler along the bottom flats of the front retaining nuts as shown above and gently adjust each nut until
all the flats are in line, then use a spanner to tighten the rear nuts firmly.
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Recheck each switch for alignment and make any final adjustments that may be needed.
Drill
through the 2 mounting holes in the earth busbar between the circuit breakers and bolt the busbar to the
panel with 2 M4 screws and Nyloc nuts (shown circled above). Dont tighten the nut closest to the centre of
the panel just yet (shown as the right hand nut above); the master earth will fit under this later during the
wiring process.
Fit the LED lights through to the panel and busbar. The green light is the Master light; the rest will be red
lights. The connectors are labelled [+] and [-] align all the [+] connectors to face in the same direction.
Tighten the retaining nuts firmly. Fit the Electric Turn Coordinator (ETC) OFF/ON switch near the
instrument.
Fit the Starter button and the keyed Master switch if using one, tighten using pliers.
The earth busbar(s) have earthing tags that must now be bent up 90 - use a screwdriver and pliers to bend
each tag up, circled in photo below. These tags will be used as earth terminals.
Bolt the main busbar across the lower side of the bottom contacts on the 5 and 10 amp circuit breakers only
using the M3 silver screws and Nyloc nuts as shown above. Tighten firmly only: these screws and nuts are
very small so take care not to over-tighten them.
Note that the main busbar does not connect to the Master 15 amp circuit breaker.
Fit the black U shaped safety bracket between the Mag switches.
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Standard panel
Digital panel
Now the
Avionics busbar can be fitted.
For a Standard panel the avionics busbar is located behind the No Smoking label above the engine
instrumentation, see photo at left above hold the busbar against the front of the panel and carefully mark
and drill through the hole in each end of the busbar, first positioning the busbar so that the screw holes will
not obscure the labelling.
For a Jumbo panel the avionics busbar will be located vertically to the right of the analogue instruments as
shown in the photo above right.
There are 2 nylon standoffs in the hardware pack these must be used to isolate the avionics busbar from
the panel itself, as the panel will be earthed. It will be necessary to countersink the screw holes at each end
of the busbar to allow the screws to thread into the nylon standoff.
Mount the avionics busbar to the panel and tighten the mounting screws firmly.
Unpack the instruments and radios
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Each instrument box will have a Jabiru stock number written on the top in marker pen. Take each instrument
out of its box, cut the tagged end of the box off and discard the box. Write the Jabiru stock number on the
tagged end and put it aside this information along with all other instrument serial numbers will be entered
on the Aircraft Identification form in this Manual.
Discard any O rings from around the instruments: these will not be required.
The Microair VHF radio and Transponder can be removed from their boxes at this time. Each unit is
wrapped in a silver electrostatic bag. Do not cut the bag open at the end, but rather cut the bag open along
the side of the bag and remove the unit. Cutting across the end of the silver bag risks cutting into the face of
the unit and must be avoided at all costs.
Unpack the Microair VHF radio/intercom and Transponder wiring harnesses.
If fitting a GPS unit you will need the appropriate mounting bracket and wiring harness.
If the GPS is a Garmin product the mounting bracket must
be removed from the end of the clamp assembly and
screwed to the Jabiru panel mount bracket as shown at
right.
180mm
To mount the Garmin 296/495 in a Standard panel, refer to

the photo at right for drilling dimensions:
If the GPS is an AvMap unit the supplied panel mount
bracket will be used.
If the GPS is any other brand or model refer to the
manufacturers literature for mounting instructions.
122mm
118mm
55mm
50mm
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Fit analogue instrumentation
Analogue
instrumentation (ASI, ALT, VSI, ETC, engine instruments) will require each individual wire to be
connected to the back of each instrument. There are 3 methods of fitting analogue instruments: screws
though the panel and into the instrument (flight instrumentation), or retaining brackets or retaining screw
rings (engine instrumentation).
The photo above shows the analogue instrumentation for a Standard panel. Note the Garmin GPS bracket
above the circuit breakers. The angle of the bracket faces the GPS unit towards the pilot: in the photo above
the bracket has been bent to face the GPS slightly upwards too.
When fitting the flight instruments the gold anodized captive nuts are first inserted into the rear of the screw
holes in the instrument and then held in place with a finger while the screw is fitted from the front, through
the panel and the instrument, and tightened.
There is not a lot of room around the instruments so the order of fitting is important.
Generally the approach is to start from the centre of the panel with the engine instruments: CHT, Oil
pressure and temperature and Voltmeter, and then move to the Tacho and then the VSI and ETC.
At this time the 2 points at the bottom of the panel should be placed on a known level surface and the
balance ball (circled above) should be checked to see if it is in the centre.
If it is not, remove the instrument and enlarge the mounting holes slightly (to about 3/16) then refit the
instrument and rotate it until the balance ball sits correctly when the panel is held level then tighten the
screws.
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Now the Altimeter and ASI can be fitted along with the wing tank fuel level digital gauges.
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Fit digital instrumentation
Digital instrumentation (EFIS, EMS, radio(s), transponder, intercom, GPS) will usually have a pre-wired
harness and a multi-pin connector fitting at the rear of the instrument.
The Dynon brand EFIS displays are supplied with mounting hardware and the fitting method is to fit the
instrument through the panel and lay the panel face down, then place the mounting bracket over the
instrument and carefully mark the position of the mounting holes on the panel with a sharp drill. Remove the
instrument, drill the holes through and fix the mounting bracket into place with M4 screws and Nyloc nuts
and then fit the instrument into the mount.
The
D100 EFIS
Mounting
brackets
D10 EMS
photo above shows a Dynon D100 EFIS (top) and a D10 EMS (bottom) fitted to a Jumbo panel. Note the
mounting brackets (arrowed) that attach each instrument to the panel.
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Finishing
For both the Standard and Jumbo panels you can now fit the intercom unit and faceplate or sticker, the VHF
radio(s) and the transponder to the panel. Each unit is retained by screws that are supplied with the unit. Any
blank spaces remaining in the panel can be covered with the supplied plate(s) or plugs.
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Wiring standards
Before you start wiring the panel we suggest that you follow a few wiring standards:
All wires and connectors will be identified by a colour coded heat-shrink tag or label,
Wiring insulation will be stripped back 4mm for all connectors,

All wires will be crimped into the appropriate connectors using a crimping tool,
No more than 2 wires will be crimped into any one connector.
Heat shrink tubing should be cut into short lengths (about 2 or 3mm) and used for tagging each electrical
connector or wire in the following manner:
Red = positive
Black = negative (earth)
White = signal
Cut about 20 of each colour to start with and cut more as needed.
Put a strip of masking tape along the bottom rear of the panel under the switches and circuit breakers and
label each one this will save you having to keep lifting the panel to read the labels on the front and that
will make the wiring a little bit easier.
Wiring the panel
This is a one-wire-at-a-time process that cannot be rushed.
The objective is to use lengths of wire that can later be zip-tied together to form a tidy wiring loom. The
before and after photos
below show how factory
wiring is arranged into a
loom:
From this:
(We use pre-cut wire lengths
for our standard panel layouts)
To this:
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The process is to put one wire on at a time, so if you were
to start with the wire from the Avionics circuit breaker to
the Avionics switch you would strip 4mm of insulation off
one end of the wire and crimp a red female spade connector
to it then heat shrink a red tag to the connector. Push that
connector onto the circuit breaker terminal and measure out
enough wire to reach the Avionics switch while allowing a
bit of height above the panel as shown in the photo at right.
Cut the wire, strip 4mm of insulation off, slip another red
tag on and crimp another red female spade connector in
place and heat shrink the tag on.
With that wire fitted in place you can then square off the
wire by bending it and then fit the next wire so that it would end up being the same height above the panel
and then keep adding one wire at a time until the panel is fully wired, then you can use zip ties to tidy up the
wiring into a loom as shown in the bottom photo on the previous page.
Note that there are 2 main wire sizes: 16 gauge, which is used for most of the wiring; and 10 gauge, which is
used for the main battery wiring, all shown on the electrical wiring diagrams.
Some wires will be common, such as the power supply to the engine instruments. In these cases the
suggested approach is to loop from instrument to instrument by crimping 2 wires into each blue connector.
Do not crimp more than 2 wires into a single connector or you run the risk of having some of the wires pull
out of the connector, so stay with 2 wires maximum.
Quite a lot of wires will go to other parts of the aircraft, and these wires are terminated into one of five
multi-pin connectors for ease of installation and maintenance. If one end of a wire will go to a multi-pin plug
then you must label that end clearly (use masking tape for the label) before going to the next wire. If you do
not label it you risk having a real problem later.
Multi-pin connectors are supplied in 2, 4, 6 and 8 pin types depending on the instrumentation options that
you have ordered with your kit. In all cases the pins are standard male and female spade connectors, just the
same as the normal wiring connectors except without the insulation, and each connector will be crimped on
to the wire in the same manner. The connectors will then be pushed into the respective half of a connector
body until they click into place.
With the male spade connectors (that fit into the female
connector body) care must be taken that the stripped end of
the wire does not extend beyond the end of the crimp area of
the connector, otherwise the connector will not be able to clip
into place in the connector body.
Wrong
The photo at right shows the wrong way and the right way to
crimp a wire into a male spade connector. Note that in the
Wrong example the bare wire has been pushed too far into
the crimp area of the connector, as indicated by the red
arrow, while in the Right example the wire stops at the end
of the crimp area of the connector, as indicated by the green
arrow.
Right
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Fitting the multi-pin connectors
What follows is the pin layout that is used in our factories. Some pins may not be used on your particular
panel in which case simply leave that pin unwired, and the connector layout here will be referred to again in
the Post-Paint>Fuselage>Install electrical wiring task.
Each connector is assigned a group of wires that go to a similar physical location.
The connector pairs should be marked from A, B, C, D or E as shown on the next page, and a mark should
be made on the corner beside pin #1 for each connector. If you have more than 1 QK6 connector you should
plan to fit 1 male and 1 female QK6 connector to the panel to lessen the possibility of plugging the wrong
pair of QK6s together.
The diagram below shows the pin numbering convention for each of the 4 connector types:
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Group the wires for each plug together and trim each group to an even length, then strip 4mm from the
insulation of each wire and fit the appropriate connector type to each wire: male spade connectors for a
female connector body and female spade connectors for a male connector body. References to male or
female will mean the connector body.
Hold the connector body in the correct orientation and insert each spade connector from the rear of the
connector body: push into place until a solid click is felt this indicates that the spade connector is correctly
seated in the connector body.
If a spade connector is not seated correctly it may be forced back and out of the connector body when the 2
halves are joined, so double check that each spade connector is fully seated.
The connector pin assignment shown below will be referred to again when the other side of each connector
is fitted in the Post-Paint>Fuselage>Install electrical wiring task:
Connector A: Engine instrumentation, QK8 connector, 16 gauge wire
1 CHT positive
5 CHT negative
2 Tacho positive
6 Tacho negative
3 Left MAG
7 Right MAG
4 Oil temperature
8 Oil pressure
Connector B: Electrical, QK6, 16 gauge wire

1 Starter
4 Regulator to main busbar
2 Starter pilot light
5 EFIS negative
3 Charge pilot light
6 Fuel pressure
Connector C: Main power, QL2 connector, 10 gauge wire

Note the use of the heavier 10 gauge wire to this connector.
1 Battery positive
2 Battery negative (earth)
Connector D: Wings 1, QK6 (or QK4 if no landing light) connector, 16 gauge wire
1 Fuel pump positive
4 Fuel pump negative (earth)
2 Flaps UP
5 Flaps DOWN
3 Landing light positive
6 Landing light negative
Connector E: Wings 2, QK6 connector, 16 gauge wire

1 Strobe positive
4 Strobe negative
2 Right wing fuel gauge positive
5 Right wing fuel gauge negative
3 Left wing fuel gauge positive
6 Left wing fuel gauge negative
You will have used one half of each connector by now. Because you will not be using the other halves until
the Post-Paint>Fuselage>Install electrical wiring task, store the remaining connector parts in the plastic
boxes that they came in until you need them. This simple action will make your life much easier when
wiring the rest of the aircraft so do it now: put all the boxes into a plastic bag, label it clearly and put it aside
where you can easily find it later.
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Fit the noise suppression filter into the power wire from the Avionics busbar to the VHF radio (use male and
female spade connectors) and zip tie the filter to the loom.
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Fit digital wiring harnesses
The digital wiring harnesses can now be fitted to the plugs at the rear of the digital instruments and the VHF
radio, transponder and intercom. Tighten the plug screws by hand.
There is an MP3 player input socket on the intercom harness and this may now be fitted to the panel if
desired. Select a location on the panel where the cable to the MP3 player will not obscure any instruments
and drill a 6mm hole through the panel and mount the socket.
Use zip ties to hold the digital harnesses to the wiring loom.
Tube up to the pressure instruments
Fit the nylon fittings to the rear of the pressure instruments decide first where the static tubing will run and
use elbows and tees to suit. Take care not to cross-thread the nylon fittings. Run the static tubing as required
and leave it about 200mm below the bottom of the panel. Run the pitot tubing from the ASI and trim to the
same length. Mark the pitot tubing clearly so that it will not be mistaken for the static line.
Zip tie the pressure tubes lightly (do not crush them) to the wiring loom.
Standard
Jumbo
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This completes the Post-Paint>Fuselage>Assemble instrument panel task.
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Post-Paint>Fuselage>Electrical wiring diagrams
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This completes the Post-Paint>Fuselage>Electrical wiring diagrams task.

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Post-Paint>Fuselage>Interior>Fit upholstery 1
To fit all of the stage 1 upholstery into the aircraft.
This task assumes that you will be using the Jabiru upholstery kit. If you are using the Jabiru kit it contains
extremely detailed instructions, however you may want to use your own materials in which case this task
can be used for more general guidance.
Materials required:
Jabiru upholstery kit or equivalent
High heat contact adhesive
Adhesive thinners and/or Acetone (for cleanup)
Dry fit
Start by cleaning your workshop floor and then lay out the contents of your upholstery kit and work out
what panel goes where. In general the unedged panels are fitted before the edged panels, so the unedged
panels will be for the larger areas: sidewalls and roof coverings and the like, while the edged panels will be
the finishing panels where the edges will be seen.
Take your time and test fit each panel it is much easier to do this now without adhesive! Consider labelling
the location of each panel with a sticky paper tag on the good side.
Adhesive
Each panel will be glued in place with contact adhesive the back of the panel and the surface to which it
will be attached are both coated and the adhesive is allowed to dry, then when both surfaces are pushed
together they are there to stay. Needless to say you want to be really sure of your positioning before pushing
the surfaces together.
In our factory we spray the adhesive onto the back of the fabric and use a brush to apply it to the fibreglass
but you can brush both surfaces. Do not apply too much adhesive if you do it can bleed though the fabric.
Just a thin coat is quite enough.
Sequence
1. Console fit the tailored console cover, taking care to align the seams correctly. Fit along the top first,
then carefully roll the cover down the console and fit along the sides, working on one side at a time,
until the cover is fitted.
1
1
6
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6
1
2. Firewall glue the 10mm foam layer to the firewall and then glue the fabric to the foam. Cut around the
ribs as required. Lower firewall fit the fabric down and back along the floor slightly and also over the
rudder pedal mounts.
3. Windscreen pillars and firewall surrounds. These areas are covered by several small pieces that each
cover a rib or brace. Note: the fuel tank wiring should be fitted inside the front pillars before covering
them. Refer to the Install electrical wiring task.
4. Front sidewalls cut out the vent openings after the panel has been fixed in place.
6
10
5
5
5
5. Crossbeam (front and back) and middle sidewalls behind the front doors.
6. Seat sides and base up to the bottom of the door sills.
7. Seat backs cut around the aileron cable brackets (circled in yellow) before fixing the panel in place.
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8a
8a
8
b
8. Front hood lining/roof: main panels (a) then the longitudinal rib (b)
9. Rear hood lining/roof as for the front (not applicable to J160/J170)
10. Rear sidewalls (not applicable to J160/J170)
11. Door panels
12. Door pockets attached with snap fasteners and Velcro
13. Instrument panel housing
14. Cable covers and all other small trim items.
Clean up any excess glue with adhesive thinners or Acetone. Do not get any adhesive thinners or Acetone on
vinyl or leather.
This completes the Post-Paint>Fuselage>Interior>Fit upholstery 1 task.
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Post-Paint>Fuselage>Install electrical wiring

To install all of the electrical wiring in the aircraft and connect to the multi-pin plugs.
Each wire will need to be cut from the supplied coils of aircraft grade wire. The length required will vary
depending on how you choose to route the wire and so it is difficult to give any exact lengths, but generally
you should allow a little extra length to be on the safe side.
Study the photos in this task to see how we route our factory wiring before starting work.
Materials required:
Wiring Kit, as well as both the Electrical wiring diagrams and Assemble instrument panel tasks for
reference and for pin assignment for the multi pin connectors.
Preparation
Before heading out to the aircraft there are a couple of things that need to be prepared:
The 2 tachometer (tacho) sender unit wires will need to be
soldered to 2 x 700mm lengths of 16 gauge wire as shown at
right.
Because soldering hardens the wire there is a risk of the wire
breaking just beyond the solder joint, so the wires are joined
by twisting the bare ends of the tacho wire around the bare
ends of the 16g wire and soldering them together and then
doubling the thinner wires back and covering each, and then
both, wires with heat shrink tubing, all as shown below.
This method provides a much safer joint that allows the wire to
flex without the danger of breaking near the solder joint. Label
each white wire as being positive (red) or negative (black).
The CHT sender plug halves can now be connected and then
the connector halves can be fixed together with 2 zip ties as
shown at right.
Cut off the ends of the zip ties.
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Engine wiring
All wires will need to be long enough to route from the respective sources, around the engine in the manner
shown, and either to a connection point on the firewall in some cases or through the firewall plus about
300mm for connection to a multi-pin plug for the majority of cases.
All wires to multi-pin plugs must be labeled (use masking tape) to avoid later confusion.
Refer to the Electrical wiring diagrams task (found immediately before this task) to see where each wire
will be connected to and plan the lengths accordingly.
Careful consideration must be given to the routing of wires around the engine. All wiring in the engine
compartment must be kept well away from all hot and/or moving parts.
The supplied white wire is all aircraft grade and has high temperature insulation but care must still be taken
to route away from obvious heat sources such as the exhaust system.
Wire the oil temperature and pressure senders
These senders are located on the left front of the engine and the single wire from each unit is routed back
under the cylinders to the rear of the engine and zip tied to the pushrod tubes.
Strip 4mm of insulation from each wire and crimp a red female spade
connector and a black heat shrink tag to each.
You will need to cut the insulation from the oil temperature connector as
shown at right to allow it to fit over the button pin on the oil temperature
sender. Note the black heat shrink tag this sender unit measures the
resistance to earth.
Connect to the oil temperature sender unit, which is located just above the
drain plug on the sump. Crimp over the end of the connector when it has been fitted to prevent it from
slipping off the sender unit. Label each wire.
Fit the other connector to the oil pressure sender unit, which is located above the oil filter. Note the black
heat shrink tag this sender unit also measures the resistance to earth.
Route both wires back under the cylinders and zip tie them to the pushrod tubes you will need to bend the
zip ties into a U shape first in order to fit them around the pushrod tubes.
In the photos above you can see the 2 wires running back under the pushrod tubes and then up behind the
rear cylinder. You can also see the earth wire from the left magneto (with a black tag again because it is used
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to earth the magneto to turn it off). These wires will all need to be long enough to be routed around the rear
of the engine and 300mm into the cabin.
Fit the tacho sender unit
For this step you will need to rotate the engine, which may
cause 1 or 2 of the sealing plugs to pop off of the exhaust
pipes and possibly some preserving oil may drip out, so
place some rag under the engine until this step is complete.
You will require a lever to turn the engine in our factory
we use a tool that fits onto the propeller flange.
Tacho timing
tag (on the
flywheel)
Rotate the engine until a tacho timing tag can be seen under
the tacho sender mount (the threaded fitting at the left rear
of the engine) - refer to the photo at right for detail.
Remove one lock nut from the sender unit and screw it into
the fitting, then carefully screw it down until it just touches
the timing tag. Unscrew the sender unit one full turn and
tighten the lock nut finger tight.
Tacho sender
mount
Front of
Now rotate the engine one half of a turn until the other
engine
timing tag is under the sender unit and screw the sender
down until it just touches that tag, which should be one full
turn. Back the sender unit out one half of one turn and firmly but carefully tighten the locking nut.
Wire the magnetos

Feed a plain length of 16 gauge wire through the hole in the side of each magneto, strip 4mm of insulation
off and crimp a red female spade connector to the wire with a black heat shrink tag. A black tag is used
because the magneto wire is used to earth the magneto to turn it off.
Left magneto
Right magneto
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Fit the CHT (Cylinder Head Temperature) plug and wiring
Zip tie the CHT connecting plug to the front of the left hand top engine mount with the high temperature
wire facing back. The sensor will be fitted to the left rear spark plug later in this task. The main photo on the
next page shows the CHT connecting plug fitted.
Engine wiring routing
Cut the zip ties that hold the alternator wires to the engine
and bend the wires to the right.
At this stage you will have wires at the top left rear of the
engine for oil pressure and temperature, left magneto, CHT
and tacho. Group these wires and zip tie them as shown at
right, so you will have 3 white 16 gauge wires (oil pressure,
oil temperature, left magneto) and 2 pairs of red and black
wires (CHT and tacho).
Now
run
the
CHT plug
Right
magneto
wire
Tacho sender
Left
magneto
wire
Alternator wires
wires across the machined aluminum beam behind the flywheel as shown above.
Add the alternator wire pair into the group as shown, but before you do, twist the wire pair several times so
that the there are no lengths where the wire pair is straight the full length of the alternator wires should be
twisted. This will help to minimize inducing noise into the wiring harness from the alternator.
From here the wiring bundle can be routed up to the top right engine mount and then back along the mount
tube to the firewall. Include the right magneto wire in the wiring bundle at this point.
The 16 gauge wires for oil pressure, oil temperature, left and right magnetos, CHT and Tacho can all be
passed through the right hand cable collar in the firewall and 300mm left free inside the cabin for later
fitting to Connector A.
If you are using the optional fuel pressure sensor it can be connected at this time and the wires included in
the wiring bundle for later fitting to Connector B.
The 2 wires from the alternator can be routed along the firewall and down to the regulator plug for
connection in the next step.
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Dont zip tie the wiring bundle to the engine mount just yet - there are some more wires to be added to the
bundle over the next few steps.
Wire the regulator connector

Power from the alternator will go to the regulator through the regulator connector, and power from the
regulator will go to the positive and negative sides of the battery as well as the power to the main bus and to
the optional low voltage warning light, also through the regulator connector.
Crimp a male spade connector to each of 2 x 1m lengths of 16 gauge wire and plug them into the female
connectors from the alternator. Cover each connector with heat shrink tubing. Route the wires into the
wiring bundle that runs along the top right-hand engine mount, around the firewall and down to the regulator
connector.
Alternator 16g
- Battery 10g
Alternator 16g
Low voltage
light 16g
+ Main bus 16g
+ Battery 10g
Wire the male half of a QK6 connector as shown above note that the positive and negative wires to the
battery are both 10 gauge (heavier) wire, shown above as light blue, while the rest are all 16 gauge (lighter)
wire, shown above as purple.
The colour coding of the pins in the diagram above indicates the colour of the wires coming from the
regulator to the connector.
Route the 10 gauge positive wire from the red pin to the front post on the starter solenoid.
Route the 10 gauge negative wire from the black pin to the earth terminal on the firewall.
Route the 16 gauge wires from the yellow pin to the main bus and from the green pin to the optional low
voltage warning light - pass both wires through the right hand cable collar in the firewall and leave 300mm
free inside the cabin for later fitting to Connector B. Carefully label each wire with masking tape.
Once you have allowed enough wire length to enable routing in a tidy manner, strip 4mm from the end of
each wire, carefully crimp a female spade connector to each wire, and then fit each connector carefully into
the connector housing.
Refer to the Engine bay wiring routing step later in this task for an example of how to route the wires from
the Regulator plug to the battery and the cable collar.
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Wire the starter solenoid
Route
short
orange
from
positive
the
to the
post of
starter
From battery
positive: heavy
orange cable
To main bus
bar 15A circuit
breaker 10g
Front
From regulator
plug 10g
To starter
button 16g
To starter pilot
light 16g
the
heavy
cable
the
side of
battery
front
the
To starter
motor: heavy
orange cable
solenoid. Fit an 8mm yellow ring terminal and a red heat shrink tag to each of 2 lengths of 10 gauge wire
(shown above as light blue) and route one wire to the red pin in the regulator plug and the other wire from
the front post to the main bus 15A circuit breaker: pass the wire through the right hand cable collar in the
firewall and leave 300mm free inside the cabin for fitting to Connector C.
Fit a red female spade connector and a red heat shrink tag to 2 x 1m lengths of 16 gauge wire (shown above
as purple) and route one wire from the left-hand middle connector on the solenoid to the starter button and
one wire from the right-hand middle connector to the starter pilot light - pass both wires through the right
hand cable collar in the firewall and leave 300mm free inside the cabin for fitting to Connector B.
The large and small spade terminals on the front post of the starter solenoid are not used.
Connect the starter motor
Earth the starter motor by fitting the long heavy orange cable under the top bolt that holds the front of the
starter motor housing in place this provides maximum current to the starter unit. Loosen both starter bolts
slightly and then remove the top bolt and fit the cable under it. Apply a drop of Loctite and retighten both
bolts firmly. Route both orange cables back along the top right engine mount strut.
The positive cable (the one that goes inside the starter motor) can be fitted to the rear post of the starter
solenoid and the earth cable can be fitted to the negative side of the battery.
Wire the firewall earth tag
The following 3 x 10 gauge wires are fitted to yellow 6mm ring terminals with black heat shrink tags and
connected to the firewall earth tag with a single AN3-5A bolt and Nyloc nut:
1. The negative wire from the black pin in the regulator plug;
2. The negative wire to the earth bus - pass this wire through the right hand cable collar in the firewall
and leave 300mm free inside the cabin for later fitting to Connector C;
3. The negative wire to the negative post of the battery. Do not connect this wire to the battery at this
time.
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Engine bay wiring routing
The engine wiring bundle can now be zip tied to the right top engine mount and then the starter cables and
the breather tube can be zip tied over top of those wires. Take some time to route all of the wires neatly and
zip tie any loose wires together. When all wires have been zip tied you can trim off the excess ends of the
zip ties.
In the
photos
above you
can see the
general
arrangement
of the
engine bay
wiring.
Solenoid
Earth tag
Cable
collar
Fuel
pressure
(optional)
Wire the
strobes
(optional)
Regulator
connector
Fit the
strobe unit
to the left
side step on the firewall and feed all of the strobe wiring through the left-hand cable collar in the firewall
this separates the high voltage strobe wiring from the low voltage signal wiring that passes through the right
hand cable collar.
Regulator
Connect the strobe power supply wiring to Connector E and connect the strobe output wiring to the strobe
wires that were fitted in the Pre-Paint>Fuselage>Fit control cables and lines task. Fit the strobe unit to the
top of the fin and connect the wiring.
Wingtip strobe units will be connected after the wings have been fitted to the fuselage.
Seal the cable collars
Once all wiring has been routed through the 2 cable collars, each collar must be sealed with automotive
exhaust sealer putty, which is available from any auto supply shop.
Push the putty into the cable collars from the firewall side until it can be seen inside the cabin and then
smooth both sides off with your thumb. This will provide a fire resistant plug seal that will delay an engine
fire from reaching the cabin through the cable collars.
Connect the high-tension leads and CHT sensor
Remove the ram air ducts from the cylinder heads. Remove the left rear spark plug and fit the CHT sensor
under the plug. Refit the spark plug.
The high-tension leads are zip tied in pairs and grouped for each side of the engine, and the lengths of the
leads are such that each pair will only fit properly to one cylinder. Test fit the leads with the ducts off, and
then feed them through the rubber grommet in the rear of each duct and push the spark plug leads firmly
onto the spark plugs. Replace the ram air ducts.
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Wire the fuel pump
Two fuel pump wires were fitted through the console to the fuel pump in the Pre-Paint> Fuselage>Fit
control cables and lines task: one wire will be the positive and one wire will be the negative or earth to the
fuel pump. Determine which wire will be the positive wire and which will be negative or earth wire and
label each end of each wire with masking tape. The forward or firewall end of both wires will be fitted to
Connector D.
Route the firewall end of both wires so that there is enough length for Connector D and then trim the rear
ends of both wires so that they end beside the fuel pump.
Fit a red female spade connector and a red heat shrink tag to the positive wire and a red male spade
connector and a red heat shrink tag to the red wire from the fuel pump. Connect the positive wire to the red
wire from the fuel pump.
Crimp one 4mm ring terminal with a black heat shrink tag to each of the following wires:
1. The negative or earth wire from Connector D;
2. The black wire from the fuel pump;
3. A 100mm length of 16 gauge wire this will earth the header tank quick drain:
4. 2 lengths of 16 gauge wire 100mm longer that the fuel lines these wires will earth the wing tank
quick drains. Crimp both wires into the one ring terminal.
Drill a 4mm hole through the floor near the fuel pump and fit a 4mm countersunk screw with a Tinnerman
washer from under the fuselage, then place all 4 ring terminals over the screw and secure them with an M4
Nyloc nut and washer. Tighten firmly. This will ensure a secure fixed earth point for the entire fuel system
that cannot accidentally become disconnected.
Feed the 100mm length of 16 gauge wire under the header
tank, out of the quick drain hole and through a small hole in
the side of the quick drain fairing, trim to length and fit a
4mm ring terminal with a black heat shrink tag and fix to
the side of the quick drain fairing with a stainless steel self
tapping screw as shown at right.
Run a length of twisted lock wire from the quick drain
fitting to the same point, fit a 4mm ring terminal with a black heat shrink tag and connect it under the same
self tapping screw as shown above. This will lock the quick drain fitting in place and also earth the header
tank.
Run the wing tank earth wires along the outside of the protective sheath with the fuel lines to the wing tanks
and zip tie the wires in place. These wires will be connected when the wings have been fitted. Label both
wires [Earth] with masking tape.
Wire the flaps and optional landing lights
Run a pair of 16 gauge wires from the firewall through the console, along the back of the front seats and up
behind the door to the flap motor. Fit male and female spade connectors to connect to the flap motor.
Landing light wires follow the same path through the console and are then routed out through the floor and
up inside the left hand wing strut.
Label each pair of wires for later fitting to Connector D.
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Fuel gauge wiring from the wing tank fuel gauges
Before completing the upholstery around the windscreen the 2 wires from the wing tank fuel gauges must be
routed down the windscreen pillars.
Drill a
5mm
(arrowed
above)
hole
slightly in
front of the forward wing mounting lug on each side and
feed 2 wires out of the hole and back towards the rear wing
mounting lug as shown above and tape them to the
fuselage.
Run the inside portion of the wires down the
windscreen pillar, holding them in place with
short lengths of cloth tape as shown above
right. The wires from both sides need to meet
slightly to the right of centre as shown above
left.
Leave the wires hanging down about 300mm
and make sure that the wires from each side
are clearly labeled [Left] and [Right] use
masking tape to label them. There is no
polarity requirement for these wires. These
wires will be fitted to Connector E.
Centre cowl
fastener
Note that these wires are quite separate from

the wing tank earth wires that were fitted
earlier.
The upholstery strips can now be glued into
place to cover the wires refer to the Post-Paint>Fuselage>Upholstery 1 task for detail. In the factory we
place these wires before the upholstery is fitted, which is shown in the photos above, however you could
equally install all of the upholstery apart from the windscreen strips and then fit them once the wires have
been placed.
The top ends of these wires will be connected to the wing tank fuel gauges when the wings have been fitted
to the fuselage. Leave them taped to the fuselage until then.
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Connect the multi pin connectors
Each wire inside the cabin has been labeled with masking tape as it was fitted in order to clearly identify
where it came from. If any wires have not been labeled then use a circuit tester to trace the wire to its source
and then label it clearly.
Use the multi pin connector diagrams from the Assemble instrument panel task to sort and group the wires
for each connector together. Trim each group to an even length, then strip 4mm from the insulation of each
wire and fit the appropriate connector type to each wire: male spade connectors for a female connector body
and female spade connectors for a male connector body.
The connector bodies that will be used are the matching halves of the connectors that were used in the
Assemble instrument panel task these were store at the completion of that task.
Use the connector diagrams and pin numbering assignments from the Assemble instrument panel task to
very carefully fit each spade connector into the connector body until it clicks into place in the same manner
as you did in the Assemble instrument panel task.
Take your time with this step the wiring to each pin must be absolutely correct!
RF Suppressor
Before
After
Notice the clear labeling of each connector in the photo above right.
Clip a ferrite RF Suppressor (shown opened at right) around each
wiring bundle as it exits from the cable collar in the firewall, taking
care not to crush any single wire when you clip it shut.
Use a zip tie around the wiring bundle to hold the RF Suppressor
from sliding down the wires.
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Fit the VHF radio wiring harness
The Aircraft Harness pack includes the wiring harness and all of
the necessary hardware: the Push To Talk (PTT) buttons for the
control stick and the headset jacks for the top of the cross beam
outboard of the seat backs. All wires are clearly labeled and the
headset jacks are colour coded as well for ease of installation.
The harness goes through the console and exits in 2 places: the
PTT wires exit under the control stick and the headset wires exit
each side of the console behind the seats. The multi-pin plug
connects to the digital harness behind the panel so leave the
plug about 400mm above the console. Note that in all cases the
grey wires are the earth wires.
Use a flexible rod inserted from the access hole behind the seats
to draw these wires back through the console, then work through the access hole in the side of the console to
feed the control stick PTT wires only around and out of the hole under control column as shown arrowed
below right. Fit a rubber grommet to the hole first to prevent chafing of the wires.
For a dual stick: feed both groups of PTT wires up and into the
left underside of the control stick, taking the Pilot group up the
left hand side and the Co-Pilot group up the right hand side.
For a single stick: feed the Pilot group up and into the stick and
route the Co-Pilot group into the right seat base. You will need
to cut an access hole under the right-hand seat in this case.
Both groups contain 2 pairs of wires: the blue and gray wires
are for the PTT button while the green and gray wires are for
the optional remote memory feature. Route the wires as shown
in the photo at right, leaving enough room for full and free
movement of the control stick.
Fit the wires to the PTT buttons and push the PTT buttons into
the top of the control stick, or in the case of a single stick fit the
Co-pilots PTT into the front of the right seat base.
Separate the pilot and co-pilot headset wires (both sets are labeled as shown
at right) and route them out of holes in either side of the console across
behind the seat back to the jack locations. Strip the ends of the wires and
solder them to the tags on the jacks, (the jacks are colour coded to match the
wiring) and then fit the jacks into place.
We suggest that you mount the jacks in the top of the beam between the seat
back and the side of the fuselage. This tends to keep the headset wires out of
the way in flight.
Zip tie the wires up under the rear lip of the beam drill 3 holes along the
bottom of each seat back for the zip ties.
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Connect the VHF antenna cable
The VHF coaxial antenna cable was installed in the Pre-Paint>Fuselage>Fit control cables and lines task
and connected to the VHF antenna in the Pre-Paint>Fuselage>Empennage> Fit vertical tail fin task. Trim
the cable off level with the top of the firewall and fit the BNC connector that is supplied with the wiring kit
(fitting instructions are included).
Fit the transponder encoder, antenna and cable
Start by mounting the encoder unit to the firewall with
the connecting plugs end facing downwards the
encoder unit attaches to a base (both shown at right)
with a thumbscrew so the base can be mounted to the
firewall with 3 stainless steel self-tapping screws and
then the box is fitted into it. Make sure that the encoder
will mount above the throttle shaft and not foul the back
of any instruments when the panel is fitted.
The static line up from the console will need to be
branched with a T piece to connect to the encoder
before connecting to the other static instruments.
Fit the supplied wiring harness plug to the encoder unit,
tighten the plug retaining screws by hand and leave the
other end free for later connection to the transponder unit when the instrument panel is fitted.
Mount the transponder antenna under the fuselage (shown fitted below right) you will need to drill a 22mm
hole through the floor of the aircraft on the centerline 415mm back from the base of the firewall. The
antenna must be mounted facing down with the ground plane (the large round plate) fitted against the
fuselage and held in place with the antenna flange. Smear the top of the ground plane with white silicone
sealer before fitting to seal it to the fuselage.
The retaining nut and washer can then be fitted from
inside the fuselage you will have to work inside the
front section of the console for this step.
Tighten the retaining nut firmly: do not over-tighten,
then wipe away any excess silicone sealer that may have
squeezed out from around the ground plane.
Connect the supplied coaxial antenna cable to the back
of the antenna and route the cable out of the console and
up the firewall for later connection to the transponder unit when the instrument panel is fitted. Route the
coaxial cable so that all bends are gentle and take care to avoid crushing the coaxial cable in any way.
This completes the Post-Paint>Fuselage>Install electrical wiring task.
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Post-Paint>Fuselage>Interior>Fit console controls

To fit all of the console controls: the control stick, elevator trim and brake system.
Materials required:
Card # 17J or 17T Elevator System and Control Stick
Card # 29JT Brakes
Card # 2J Trim System
Control stick
Fit the 2 eccentric aileron stops to the rear end plate with 2 Allen head
cap screws as shown at right.
The control stick should still be partly assembled from the PrePaint>Fuselage>Interior> Console>Fit Control Stick task. Clean any
debris from the front and rear bushes and apply a small amount of
lubricant to the bushes. Fit the control shaft into the console from the
front, wipe away any lubricant from the rear of the control shaft and fit
the aileron bellcrank to the rear of the shaft with an AN3-16A bolt and
Nyloc nut, with the bolt fed up through the bellcrank.
Fit the control stick to the pivot plate with an AN3-13A bolt, taking
care
a flat
to fit
nylon washer on each side between the stick and the plate. Connect the elevator cable rod end to the control
stick with an AN3-21A bolt, spacer, 1/4 flat washer and a Nyloc nut as shown in the photo above and in the
drawing on the next page.
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Check for full and free movement of the control stick.
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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
by 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.
Fit the master cylinder to the front of the
x by UNC Allen head cap bolts and fit
bottom of the lever with an AN5-11 bolt and
tighten the castle nut firmly and lock in place
console with 2
the clevis to the
castle nut,
with a split pin.
Drill a hole near the top left of the front face

and feed the brake hose into the console then
of the hole behind the top of the main
legs. Fit a rubber grommet over the brake hose
the console, blow the hose clear and fit it to the
the master cylinder. Tighten the fitting firmly.
hose about 50mm below the fuselage and trim
of the console
down and out
undercarriage
at the front of
brass fitting on
Leave the brake
off.
Fit a brass T connection to the hose, then run

brake hose down each main undercarriage leg
level with the top of the wheel rim, trim to
brass T connection to the hose. Zip tie the
way down the leg.
a length of
to a position
length and fit a
brake hose half
Run a short length of brake hose from the T

each brake assembly as shown in the photo at
length of PVC tubing over the brake hose is to
chafing from the wheel spat. Zip tie the brake
connector to
right. The short
protect against
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.
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Elevator trim lever assembly
Connect the trim cable rod end to the left-hand trim lever
with an AN3-10A bolt, 3/16 and 1/4 flat washers and a
Nyloc nut. Clean any debris away from the trim bush and
fit the trim shaft and levers, with soft washers under the
levers, and secure the levers to the shaft with an AN3-35
bolt and castle nut. The castle nut should be fitted to the
left-hand side of the console, tightened firmly and locked in
place with a split pin as shown in the photo at right.
Check for full fore and aft stop-to-stop movement of the
trim levers.
Pitot tubing
Use a flexible rod to draw a length of ID PVC tubing
through from the wiring access hole in the lower front of the console, through the console and out of the
hole under fuselage where the brake line exits.
Leave enough length so that the top of the tubing is just below the bottom of the windscreen and so that the
bottom of the tubing reaches across to the right-hand strut bushing.
The top end of the pitot tubing will be connected in Post-Paint>Fuselage>Interior>Fit the instrument panel
and the bottom end will be connected once the wings have been fitted.
Fuel tap
Fit the red fuel tap handle to the fuel tap shaft as shown in
the photo at right.
Position the L shaped plastic guard in front of and below
the tap, drill holes for the end pegs and Araldite the guard
into place.
Placards
Place the fuel tap placard behind the fuel tap.
Place the trim placard above the trim lever on top of the
console with the front of the placard level with the front of
the brake lever slot.
Place the brake lever placard behind the brake lever slot
with the rear of the placard level with the rear of the trim
placard.
This completes the Post-Paint>Fuselage>Interior>Fit

console controls task.
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Post-Paint>Fuselage>Interior>Controls>Fit rudder pedals

To fit the rudder pedals and steering links to the aircraft, and fit the rudder cable to the rudder pedals and set
the deflection of the rudder.
Materials required:
Card # 3J Rudder
Card # 19J Noseleg for the steering yoke
Fit the pedals
The rudder pedal assembly will be fitted to 3 sets of bearing blocks, 2 on the moulded floor mounts and 1 on
the lower front of the console. Sit the pedals in the lower mounting blocks on the mounts and clean the front
and back holes in the mounts with a 3/16 drill. There are captive nuts in the centre holes in each mount so
do not drill any centre holes.
Apply a thin layer of grease to the half-round cutouts in the upper and lower rudder pedal blocks and then fit
the rudder pedals into place in the lower blocks. Seat the pedal assemblies in the blocks and fit the upper
blocks and clamp plates and secure with an AN4-25A centre bolt to each block to hold it in place. Check for
minimal side-to-side movement.
Place a flat washer under the head of each bolt.
Now
the
fit
Blocks
Stops
Detail shown
below
Floor mounts
bottom clamp plates in place inside the floor mounts one at a time: start with the front AN3-25A bolt and
Nyloc nut the front nut can be awkward to fit but if it is super
glued to the
plate then the plate can be held in place and the bolt can be
threaded
down into it.
Fit the rear AN3-25A bolt and Nyloc nut all as shown at right.
When all bolts and nuts have been fitted, tighten each nut to
then tighten the centre bolts down firmly.
safety and
Check for free fore and aft movement of the rudder pedals.
It may be necessary to adjust the tension on the bolts slightly if
are binding.
the pedals
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Fit the UNF Allen head cap screws through the pedal travel stops beside the pilots side right rudder
pedal on the rear bar and fit UNF plain nuts behind. These will be set later in this task.
Assemble and fit the steering yoke
Trim off the moulding lip from around the hole in the rubber bush
with a sharp knife if required. Press the rubber bush into the
smaller hole in the steering yoke as shown and apply a smear of
grease to the mating surfaces between the soft connection link and
the steering link. Press the spacer tube into the rubber bush.
Rubber bush
and spacer
Fit the steering assembly to the noseleg: have someone hold the
tail of the aircraft down and lower the nose leg until the steering
yoke and soft link can be fitted between the upper and lower
bushes with the arms of the yoke facing rearwards. Lightly grease
the top and bottom of the nose leg and then push the nose leg back
up and lower the nose of the aircraft. Refer to the drawing below
and the photos on the next page for detail.
Steering
yoke
Soft
link
Connect the soft link to the steering yoke with an AN4-16A bolt
and large flat washer and secure with a washer and Nyloc nut and
tighten the nut to safety. If nose leg is not drilled, then centre the
front wheel so that it is pointed exactly straight ahead, move the
steering yoke assembly so that both arms are an equal distance
from the firewall and then drill a 3/16 hole through the hole in
the soft link and all the way through the noseleg and fix the soft
link in place with an AN3-22A bolt, washer and Nyloc nut and
tighten the nut to safety.
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Fit the steering yoke and pushrods
Fit the retaining collar to the top of the nose leg with an AN3-22A bolt, washer and Nyloc nut and tighten
the nut to safety. The nose leg is now final fitted as shown below.
Assemble the pushrods: thread a rod end with a plain nut to
each end of each pushrod.
Retaining collar
Do not tighten the nuts until the pushrod lengths have been
adjusted.
Cut 2 rectangles of rubber sheet to approximately 30 x
50mm and punch a hole in the centre of each just big
enough to pass the pushrod through. These are dust covers
and they will be fixed to the firewall at the end of this task.
Slip one over each pushrod for now.
The pushrods are different lengths: the longer pushrod fits
to the right-hand side of the steering yoke and the shorter
pushrod fits to the left-hand side of the steering yoke.
Soft
link
Fit the pushrods though the holes in the firewall and then
connect them to the steering yoke with AN4-13A bolts.
Steering yoke
Each bolt is fed down from the top of the yoke with an
AN960-516 flat washer fitted under the head of the bolt,
then the rod end and then a AN960-416L flat washer fitted
between the rod end and the yoke and a regular AN960-416
flat washer and Nyloc nut fitted below the yoke as shown at
right.
Tighten all of the Nyloc nuts to safety and mark each with
TorqueSeal.
The dust cover is shown fitted in the lower photo, however
it will not be final fitted until the end of this task, which is
when this photo was taken.
Pushrod and
rod end with
plain nut
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Adjust the push rod lengths and connect
Now the pushrods can be adjusted to length and connected to the rudder pedals.
Set the nose wheel so that it is facing straight ahead move the aircraft back a few meters and then move it
forward in a straight line so that the nose wheel will align correctly.
Set the rudder pedals so that the tops of the pedals are all in line when viewed from the side, as shown in the
lower left of the drawing at the end of this task.
Adjust the length of the left-hand pushrod by screwing the rod ends in or out an equal amount at each end of
the pushrod until the rod end lines up with the hole in the pilots side right rudder pedal arm without altering
the position of the nose wheel and then fit the rod end to the outside of the rudder pedal arm with an AN414A bolt through the pedal arm then an AN960-416L flat washer and then the rod end followed by an
AN960-516 flat washer and Nyloc nut.
Repeat the length adjustment procedure for the right-hand pushrod, still keeping the tops of the rudder
pedals all in line, then fit the rod end to the outside of the co-pilots side left rudder pedal arm with an AN414A bolt through the pedal arm then an AN960-416L flat washer and then the rod end followed by an
AN960-516 flat washer and Nyloc nut.
Pushrod and
rod end
with plain
nut
Rudder
cable tab
Rudder
travel stop
Check that the rudder pedals can move the nose wheel freely from side to side and make any fine
adjustments that may be needed to have the tops of the rudder pedals all in line with the nose wheel tracking
straight ahead.
When the final adjustments have been made then all the plain nuts on the rod ends can be locked off, all the
Nyloc nuts can be tightened to safety and all nuts can be marked with TorqueSeal.
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Connect the rudder cable
Clamp the outer cable to the inside front of the cable housing with the notched saddle clamp and backing
plate and secure the clamp in place with 2 x AN3 bolts fitted from the outside of the cable housing and
Nyloc nuts with flat washers under them. Tighten the nuts to safety.
Connect the rudder cable rod end to the right of the tab at the top of the pilots side right rudder pedal
(circled in yellow below) and secure with an AN4-6A bolt through the pedal tab then an AN960-416L flat
washer and then the rod end followed by an AN960-516 flat washer and Nyloc nut. Tighten the Nyloc nut to
safety and mark with TorqueSeal.
Move the rudder cable to half travel and then set the rear of the rudder to a position 5mm to the right of the
aircraft centreline (refer to the photos at the bottom of this page that show a rudder position/deflection jig in
place under the rudder) and hold it in that position with some cloth tape or have someone hold it in place for
you.
Set the rudder pedals to the neutral position,
with the nose wheel facing straight ahead and
the pedals all lined up along the tops.
Position the outer cable so that it runs in as
smooth a line as possible from the cable entry
cut-out in the console to the rudder pedal tab
and then mark and drill the 5 x 7/32 holes
through the cable housing and into the console
and rivet the cable housing (circled in green at
right) to the console with 5 x 7/32 TLR rivets.
Adjust the rudder deflection

The rear of the rudder should be able to be move 78mm to the left and 78mm to the right from a neutral
position that is defined as being 5mm to the right of the aircraft centreline.
This range of movement is controlled and limited by movement of the rudder pedals.
The
photos above show a rudder position/deflection jig in place under the rudder.
The limits are adjusted by the rudder stop screws beside the pilots side right rudder pedal: adjust the pedal
travel by using the Allen head cap screws until the rudder deflection is correct. Lock off the Allen head cap
screws with the plain nuts, recheck all deflections and mark the lock nuts with TorqueSeal.
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Fit the centring springs
The
centring
springs are
attached by
Anchor bolts
links of
chain bolted
to the top of
the centre
rudder
pedals with
Rudder
AN3-11A
travel stop
bolts and
then
anchored to
the firewall
by means of
anchor bolts
refer to
the drawing
at the end of
this task for
detail.
Position the
anchor bolts so that they are evenly spaced and then mark and drill 3/16 holes and fit the anchor bolts
through the firewall with a flat penny washer each side and a Nyloc nut tightened to safety.
Fit the centring springs into place and use pliers to bend the hooked ends of the springs so that the springs
cannot easily or accidentally be removed.
Adjust the spring tension by altering the length of the anchor bolts so that the nose wheel will return to
centre when there is no weight on the nose wheel (hold the tail down to do this check). When adjustments
are complete tighten the anchor bolt nuts.
Fit the dust covers
The last step is to fit the rubber dust covers into place hold
so that it is square and level and fix it in place by means of
contact adhesive or small screws and washers.
each cover
either
The photo at right shows a dust cover fixed in place with

sealer and 4 small stainless steel self-tapping screws and flat
silicone
washers.
The next page of this task shows a drawing of the rudder

steering assembly.
pedal and
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This completes the Post-Paint>Fuselage>Interior>Fit rudder pedals task.

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Post-Paint>Fuselage>Interior>Fit flap drive motor

To fit the flap drive motor and actuating assembly.
Materials required:
Card 16J or #16T Electric Flaps
Fit the flap shaft
Remove the inner flap drive arm from the flap drive shaft by removing the 2 x AN3 bolts and pulling the
flap drive arm completely off of the shaft.
Feed the bare shaft into the cabin through the flap shaft
the top right of the cabin, first taking care that the bolt
flap drive arm will end up on the left-hand side of the
slip the inner flap drive arm over the shaft before the
the cabin through the left side flap shaft mount.
mount in
holes for the
cabin, and
shaft exits
Ensure that the inner flap drive arm will be 180 away
from the
outer flap
drive arms
as shown
above in
red.
Refit the
inner flap
drive arm
with the
AN3 bolts,
flat washers
and Nyloc
nuts and
tighten the
nuts to
safety as
shown in
the photo at
above right.
Fit the outer flap drive arms to each end of the flap
secure each with an AN3 bolt and Nyloc nut as shown at right. Tighten the nuts to safety.
shaft and
Prepare the flap drive motor assembly

Bolt the mounting bracket to the post on the gear case of the flap motor assembly by placing a Bundy tube
through the post and then an AN3-12A through the bracket and the post. Fit a flat washer and a Nyloc nut
with the nut facing into the cabin and tighten the nut to safety.
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Refer to the photo on the next page for detail.
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Fit the flap drive motor assembly
Mounting
bracket
Flap shaft and

flap drive arm
Rod end
Actuating shaft
Flap motor
assembly
Pilots door
Bolt the rod

end of the
flap drive
motor
assembly to
the flap
drive arm
with an
AN4-10A
bolt through
an AN960516 flat
washer, the
rod end, an
AN960-416
flat washer,
the drive
arm, an
AN960-416 flat washer and a Nyloc nut.

Tighten the nut to safety and then swing the motor assembly forwards and up until the mounting bracket sits
on top of the door jamb as shown above. Align the flap drive arm to be completely vertical (i.e. directly
under the flap shaft) as pictured above.
Measure forwards from the vertical centre of the flap
shaft 272mm and mark the front of the mounting
bracket as shown at right. Drill and countersink the 2
x 3/16 mounting holes through the door jamb and
mark the location of the mounting bracket.
Cut away any upholstery and peel cloth from the
where the bracket will be mounted and roughen the
bracket and the door jamb surface where the bracket will be bonded into place.
Note that the flap drive motor will sit at a slight angle to the vertical due to the profile of the fuselage skin,
so it may be necessary to make the mounting bolt holes slightly oversize to accommodate the mounting
angle. It is very important that the flap drive motor actuating shaft can be extended and retracted with no
binding at any point in its travel. In the factory we fit the flap drive motor in place with packing underneath
and power up the motor (12v) and then run the actuating shaft through its full range of travel to check for
any binding before flocking the bracket into place.
Flock the mounting bracket into place on an 8mm bed of flock and fix it loosely in place with 2 x 3/16
waxed countersunk screws and Nyloc nuts and leave overnight to cure.
Tighten the nuts to safety the next day.
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Fit the flap indicator
Assemble the flap indicator: paint the outside of the indicator washer red and
mark the 3 flap positions in a dark colour. Push the inner cable through the
indicator body and through the indicator washer and then all the way into the
long end of the indicator body. Slide the washer to the last mark at the long
end of the indicator body as circled above right and crimp it to the inner cable.
Using the supplied crimping tool, crimp the indicator body to the outer cable.
Crimp tool
Screw the L shaped bracket to the bottom of the motor assembly with a countersunk screw (circled in
yellow above), then drop the AN3-16A bolt down through the actuating shaft and add the 3 spacers and the
2 retaining nuts (circled in green above).
Position the flap indicator on the left-hand windscreen pillar
so that the cable follows the line of the door opening and
remains clear of the opening and screw the flap indicator and
cable into place with the supplied nylon clips as shown at
right.
Check the outer cable for length and trim as required then
crimp the threaded end in place. Fit the threaded cable end to
the L bracket on the motor with 2 thin nuts and fit the
inner cable to the long bolt through the actuating shaft, all as
shown in the photo on the bottom of the previous page.
Check that all bolts and nuts are tightened, route the power
lead behind the motor assembly and down behind the door opening for later connection in the PostPaint>Fuselage> Interior>Install electrical wiring task. Adjustment of the flap motor and indicator will be
done in the Post-Paint>Wings>Fit flaps task.
This completes the Post-Paint>Fuselage>Interior>Fit flap drive motor task.
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Post-Paint>Fuselage>Interior>Fit instrument panel housing

To fit the instrument panel housing to the aircraft. This task will require 2 people.
Materials required:
Card #4J or 4T: Panel mount throttle
Prepare the panel housing
Standard panel
Jumbo panel
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Instrument panel housings come in 2 sizes: Standard and Jumbo. The Standard housing is mounted with 5
mounting bolts while the Jumbo housing uses 7 mounting bolts.
Refer to the photos above for mount positioning (arrowed in yellow).
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 5Minute 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.
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Locate and fit the throttle cable
The last step is to drill through the firewall for the throttle cable.
The positioning of the hole is important to minimise the chance of the throttle cable binding in the full
forward/full throttle position: start by positioning the throttle linkage almost fully forward until the input
lever is about 10mm away from the front of the panel housing the thickness of the tip of your index finger
is about 10mm.
With
the
linkage in that position, make a mark (circled above) directly ahead of the output lever (which must face as
shown) and then drill a pilot hole at that mark rotate the throttle linkage backwards to allow access for the
drill and hold the drill firmly against the firewall to make sure that it does not move about while drilling.
As before, have the other person check that the drill will not cause any damage as it comes through the
firewall and move any wiring out of the way if needed.
Rotate the throttle linkage forwards and check that the pilot hole is precisely in front of the output lever and
correct if necessary.
You can now work from the front of the firewall and expand the pilot hole until the throttle cable (complete
with the adjustment nuts) can just pass though the hole.
Drill out 2 flat penny washers to fit over the outer cable and then cut a slot in each so that they can be fitted
over the throttle cable. One will fit to the cable on each side of the firewall.
You will need to carefully grind both ends of the throttle cable to size the manufacturing process often
leaves some excess solder on both fittings and sometimes the ball end may have the inner cable standing
slightly proud, which will need to be ground back a little.
Fit the throttle cable into place through the firewall. Connection and adjustment of all cabling will be
addressed in the task Post-Paint>Firewall forward>Engine control cabling.
Fit the throttle input shafts through the pivot blocks and fully onto the rod ends on the input levers and
Loctite each input shaft into place with a drop of Loctite 620. The pilots side input shaft will require a
machined collar to be fitted on the shaft on each side of the pivot block.
This completes the Post-Paint>Fuselage>Interior>Fit instrument panel housing task.
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Post-Paint> Fuselage>Interior>Engine control cabling

To fit all engine control cabling from the instrument panel to the engine.
Materials required:
Cables: Throttle, Carb Heat, Choke, Cabin Heat (optional
see Card #25JT)
Throttle
Choke
Carb heat
Size the outer cables

The Carb Heat, Choke and the optional Cabin Heat outer cables will need to be cut to
length. This is done by removing the inner cables completely and then fitting the
outer cables through the panel and routing them through the firewall to the
appropriate locations and then trimming each outer cable to length. The Choke and
the optional Cabin Heat cables will then need to have allowance made for the
threaded end section, which is then crimped onto the cut end (use the crimping tool,
shown at right). The throttle cable is supplied ready to use.
Fit the
cables to
the
instrume
nt panel
Fit the
Carb Heat,
Throttle
Choke and
the
optional
Cabin
Heat
cables to
Choke
Cabin heat
the lower
centre of
the
instrument
panel
through
the
nameplate
and secure
each to the panel with a serrated washer and lock nut and then route the cables through the firewall as shown
above.
Carb heat
Fit the throttle cable through the firewall from the engine side with the ball end inside the cabin and secure
with a slotted flat washer and nut on each side of the firewall as shown.
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Fit the ball end of the throttle cable into the drive arm on the throttle shaft.Throttle and choke
Note the cable routing shown above this photo was taken looking straight down.
Fit the
throttle
cable first:
undo the
Throttle
front nut
cable
completel
y until it is
Carburettor
resting on
bracket
the inner
cable and
then fit the
inner cable
through
the slotted
top hole in
Choke
the bracket
cable
and fit the
threaded
cable end
into the bracket. Fit the lock nut onto the threaded cable end and tighten so that the lock nuts are in the
centre of the threaded cable end.
Fit the barrel end of the cable into the throttle linkage on
the carburettor with a washer each side and a split pin
through the hole in the barrel end of the cable.
Adjust the throttle cable until at full throttle (with the panel
mounted throttle shafts fully forward) the throttle linkage is
just touching the front stop on the carburettor. Tighten all 4
lock nuts firmly for the moment fine adjustments will be
made later.
Put 1 lock nut on the threaded end of the choke cable and
fit it through the bottom hole in the bracket. Fit the other
lock nut, centering the threaded end in the bracket.
Throttle
Choke
Make sure that the choke drive arm is fully forward and slip
Right hand side view of carburettor body showing cables
the brass ferrule over the inner cable then fit the ferrule into
the hole in the drive arm. Bend the inner cable at right
angles in front of the ferrule. Cut the excess inner cable off. Slip the ferrule through
the retaining collar and fit to the to the drive arm with a washer and split pin fitted
to the brass ferrule on the underside of the drive arm. Refer the photos and drawing
on the next page for detail.
Adjust the choke cable until with the choke all the way in the choke arm just
touches the stop on the carburettor body. Tighten the lock nuts firmly.
Carb heat
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Run the outer cable through the clamp and secure by tightening the clamp, then slip the brass ferrule over
the inner cable.
Make sure that the air valve drive arm is fully forward and then fit the ferrule into the hole in the drive arm.
Bend the inner cable at right angles in front of the ferrule. Cut the excess inner cable off. Slip the ferrule
through the retaining collar and fit to the to the drive arm with a washer and split pin fitted to the brass
ferrule on the underside of the drive arm.
Adjust the Carb Heat cable with the clamp until with the Carb Heat T handle all the way in the air valve
drive arm is fully forward as shown above. Tighten the clamp bolts firmly.
Cabin heat
Put 1 lock nut on the threaded end of the Cabin Heat cable and fit it up through the hole in the firewall
beside the Cabin Heat valve. Fit the other lock nut, fixing the threaded cable end through the firewall.
Make sure that the Cabin Heat valve drive arm is fully forward and then fit the ferrule into the hole in the
drive arm. Bend the inner cable at right angles in front of the ferrule. Cut the excess inner cable off. Slip the
ferrule through the retaining collar and fit to the to the drive arm with a washer and split pin fitted to the
brass ferrule on the underside of the drive arm.
Adjust the Cabin Heat cable until with the Cabin Heat knob all the way in the Cabin Heat valve is fully
closed. Tighten the lock nuts firmly.
This completes the Post-Paint>Fuselage>Interior>Engine control cabling task
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Post-Paint>Fuselage>Interior>Fit the instrument panel
Post-Paint>Fuselage>Interior>Fit the instrument panel

To pre- and final fit the instrument panel to the panel housing. This task will require 2 people so have a
friend come over and help you for an hour or so.
Pre-fit the panel
Remove the throttle knobs from the throttle input shafts.
Both people should sit in the aircraft with the panel held between them. The person in the right-hand seat
should reach over the top of the panel and push all of the multi-pin connectors, instrument tubing, radio and
GPS wiring from the panel back inside the
panel
housing.
Working together, offer the panel up to the
Lift the bottom of the panel over the
heat and choke knobs, then carefully ease the
place. You may need to grind small amounts
housing to clear items such as the mag
use a pen to mark what needs trimming and
panel. Trim away the marked areas, vacuum
debris from the grinding process and refit the
it slips neatly into place.
housing.
carburettor
top into
out of the
switches, so
remove the
away any
panel until
Fit the panel

Refit the panel as before, but this time the
person in
the right-hand seat should reach over the top and connect the panel. Each multi-pin connector should have
been clearly marked (A, B, C, D or E): join each connector pair by pushing them together firmly
until the safety clip clicks into place. Connect the VHF antenna cable and transponder cable.
Fit the panel into the housing and secure it in place with machine screws.
Now you will need to work from under the panel: connect the static line and pitot line with brass tube joiners
and plug in the radio wiring plug.
If you are using a panel mounted GPS, lower the antenna to the floor and then route the antenna and cable
out the bottom right of the panel and back up until the antenna can be velcroed to the top right of the panel
housing near the right corner of the windscreen. The antenna wire can be tucked back into the small gap
between the housing and the firewall and the excess cable length can be coiled up and zip tied up inside the
housing.
Refit the throttle knobs and tighten them firmly.
At this point there will be a large amount of wiring and tubing emerging from the access hole in the lower
front of the console and going up into the panel. In the upholstery kit there is a piece of upholstery fabric
with a Velcro strip at each end: hold the wiring bundle together and wrap this fabric around it and let the
Velcro strip hold it in place: this will tidy things up.
Ideally no loose wiring should hang down under the panel housing, so tuck up any wires that need tidying
and zip tie them into place.
This completes the Post-Paint>Fuselage>Interior>Fit the instrument panel task.
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Fit the remaining interior trim to the aircraft, completing the interior fit out.
Materials required:
Jabiru upholstery kit or equivalent
High heat contact adhesive
Card 9J or 9TSeatbelts
Flap drive shaft and flap drive motor cover
Flap drive
shaft
Headset
bracket
Wrap the flap drive shaft in upholstery fabric and fix into place with contact adhesive. The join line should
be at the top rear of the shaft.
Use Velcro tabs to hold the drive motor cover into place.
Headset bracket
Position the headset bracket on the top longitudinal rib and fix in place with 2 TLR rivets as shown arrowed
in yellow in the photo above.
Floor coverings
Test fit the floor coverings first you will
carefully cut the front covering to fit around
the rudder pedal mounts.
need to
and under
The floor coverings should overlap the

and console fabric slightly so that no
can be seen.
sidewall
fibreglass
Fix the floor coverings into place with contact
adhesive.
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Fuel line covering
Wrap both sheathed fuel lines with the supplied lengths of
Velcro-edged fabric position the Velcro join line so that it
faces towards the outside of the aircraft. Use zip ties to
secure the sheathed fuel lines to the rear of the fuselage rib
as shown at right.
Rear bulkhead sound curtain
Glue 8 evenly spaced Velcro strips around the rear
bulkhead and attach the sound curtain by pressing it onto
them.
Seat
covers
Identify the
left and
right side
seat covers.
Slip each
seat cover
over the
correct seat
back and
pull the
cover as far
down as you can, then roll the lower part of the cover over
the seat base and press the Velcro strip along the front edge into place.
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Seatbelts
Bolt
the
Aileron
bellcrank cover
seatbelts to the seatbelt fittings the shoulder harness fits to the outside of each seat while the lap part of the
harness fits beside the console.
Each seatbelt fitting is fitted to the outside of the mounting bracket (away from the seat) with an AN3 bolt
with one washer under the head, through the mounting bracket, the seatbelt fitting, then the heavy flat
washer (from the Seatbelts card) and a plain washer then the Nyloc nut, all as shown in the photo above.
Tighten the Nyloc nuts to safety.
Aileron bellcrank cover
Note that this cover is fitted after the wings have been fitted and the aileron cables have been connected and
adjusted. It is included in this Upholstery 2 task for convenience.
Slip the cover over the rear of the console as shown in the photo above: check that the aileron cables slots
are correctly positioned and they do not cause any restriction to the aileron cables and fit the cover in place
with 3 x 6G stainless self tapping screws: 1 each side at the front of the cover and 1 at the rear of the cover.
This completes the Post-Paint>Fuselage>Interior>Fit upholstery 2 task.
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Post-Paint>Fuselage>Fit rudder, elevator and elevator trim

To fit the rudder, and elevator and elevator trim assembly to
empennage.
the
Fit the rudder

Hold the rudder up to the vertical fin and fit it into place with
pins: the top pin will be fitted up through the hinge from the
while the 2 lower pins will be fitted down from the top.
free movement of the rudder from stop to stop.
the hinge
bottom
Check for
Locate the ends of the hinge pins in the retaining slots and
each pin in place with pin retainers the locations are
right.
secure
arrowed at
Each pin retainer will be held in place with a 5/32 machine

screw. Mark each retainer screw with TorqueSeal.
thread
Connect the rudder cable

Withdraw the rudder cable from the slot at the base of the
vertical fin and pull it out until the locating groove in the
outer cable is level with the 2 mounting bolt holes in the
side of the fin.
Clamp the outer cable to the fin with 2 x AN3-6A bolts fed
from inside the fin, then the angled aluminium plate with
the narrow side facing the front of the aircraft, the clamp
backing plate, the saddle clamp (taking care to locate the
locating key on the saddle clamp in the locating groove in
the outer cable), then flat washers and Nyloc nuts, all as
shown in the photo below.
Rudder cable hardware
Fit
rod
to
Rudder cable fitted
the
end
the
rudder drive arm with an AN3-8A bolt fitted from the top and down through the drive arm, then an AN960416 (3/16) flat washer, then the rod end followed by an AN960-515 (1/4) flat washer and a Nyloc nut as
shown above.
Tighten each Nyloc nut to safety and mark the end of each nut with TorqueSeal.
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Adjust the rudder travel
Make a template that will sit over the rear of the empennage and tape it in place. Find the centreline of the
fuselage and mark a 5mm offset to the right of the centreline onto the template, then mark 98mm each side
of that offset mark as shown in the photos above.
Place a saw stool under the front of the fuselage to lift the nose wheel
off the ground and then adjust the rudder cable length so that the rudder
sits on the 5mm right mark with the rudder pedals centred, with the
pedals all level.
Lock both rod end lock nuts firmly and mark each one with TorqueSeal.
Now use the rudder pedal adjustment set screws (shown arrowed at
right) to adjust the rudder travel so that the rudder deflects exactly
98mm to each side of the offset centre mark as shown in the photos
above.
When this has been done tighten up both of the lock nuts firmly and
mark each one with TorqueSeal.
The rudder is now adjusted.
Rudder pedal adjustment detail
Fit the elevator
Hold the elevator up to the horizontal stabiliser and fit the hinge pins in place: all pins are fitted by pushing
them in from the outside of the hinge and towards the rudder.
Check for free movement of the elevator from stop to stop.
Locate the ends of the hinge pins in the retaining slots, push the
trim lever on the console fully forward and then apply a length of
Wotan cloth tape to the top of the gap between the elevator and the
horizontal stabiliser as shown at right, pressing the tape over the
top of the hinge pins so that they break through the tape surface.
Use one length of tape on each side of the tailplane, make sure that
there are no wrinkles and press the tape firmly down.
Secure each hinge pin in place with pin retainers.
Each pin retainer will be held in place with a 5/32 machine thread
screw.
Mark each retainer screw with TorqueSeal.
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Connect the elevator cable
Fit the drive arm extension to the elevator drive arm: secure with an M4
x 25 bolt, washer and Nyloc nut through the top hole. Tighten firmly
and trim off any excess bolt length.
Elevator
drive arm
Fit the elevator cable rod end to the elevator drive arm with an AN310A bolt fitted through the lower hole in the elevator drive arm and the
centre hole in the drive arm extension. Fit an AN960-416 (3/16) flat
washer, then the rod end followed by an AN960-515 (1/4) flat washer
and a Nyloc nut.
Elevator
cable rod
end
Do not tighten the Nyloc nut or the rod end lock nut until the cable
length has been adjusted in the next step.
Drive arm
extension
Adjust the elevator travel

Use the supplied deflection templates to check the up and down travel
of the elevator.
Elevator drive arm detail
DOWN elevator template
Hold the
control stick all the way forward (have someone help you) and check the amount of down deflection and
adjust the cable length (by screwing the rod ends in or out an equal amount at each end of the cable) until the
down deflection is correct.
UP elevator template
Now have
your helper hold full back stick and check the amount of up deflection: it should be very close to correct if
the down deflection is OK, however you may need to make some fine adjustments to equalise elevator travel
until both up and down deflections are correct.
The elevator must clear the rudder and the down stop by 2mm at full deflection.
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Recheck the up and down deflections and then lock the rod end lock nuts at each end of the cable and mark
each rod end lock nut with TorqueSeal. The elevator is now adjusted.
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Assemble and fit the elevator trim assembly
Refer to the drawing on the next page: Assemble the trim pivot: press the 2 sealed bearings into the hub and
then pop rivet the assembly together. Assemble the trim spring unit, adjust the rod end to almost full thread
depth and tighten the lock nut.
Connect the trim spring unit to the trim pivot with an AN3-13A bolt through the black pivot block in the
middle of the spring assembly and the top hole in the trim pivot arm, taking careful note of the arrangement
of the washers and the sleeve between the two items.
Connect the trim cable rod end to the trim pivot with an AN3-12A bolt through lower hole in the trim pivot
arm. Fit the trim pivot to the trim horn with an AN4-14A bolt.
Fit the rod end of the trim spring unit to the bottom hole in the elevator drive arm extension with an AN307A bolt.
Push the trim lever on the console fully forward, hold the
trim pivot arm fully forward as shown at right, align the
trim cable as shown, then drill the 2 x 3/16 trim cable
clamp holes through the trim horn.
If you are working alone you can wedge the trim pivot into
position for this step.
Elevator
cable
Trim cable
Elevator
drive arm
extension
Trim horn
Trim pivot
Trim
spring unit
Trim horn
Trim cable
clamp
Trim pivot
block
Trim pivot
Attach the outer trim cable to the right hand side of the trim horn with 2 x AN3-06A bolts fitted through trim
horn, the clamp backing plate and then the saddle clamp and securing with flat washers and Nyloc nuts,
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taking care to locate the locating key on the saddle clamp in the locating groove in the outer cable before
tightening the Nyloc nuts to safety.
Use the supplied deflection templates to re-check the up and down travel of the elevator.
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Fit static line Water Trap.

While you are working in this area, this is a good time to fit the water trap for the static line. Install as
shown below.
Water trap
The little clip that holds the static line is found on the Card with the fuel system components.
Make sure the o-ring is fitted inside the water trap and it is tightened to prevent air leaks.
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This completes the Post-Paint>Fuselage>Fit rudder, elevator and elevator trim task.
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Post-Paint>Fuselage>Fit doors
At this stage the doors have been painted and now they can be refitted to the aircraft.
Materials required:
Door hardware from Card # 1J or # 1T Doors
Fit the door seals
Clean the inside of the door lip and fit the white door seal rubber around the entire outer edge of the door.
The door seal is adhesive backed: peel the backing paper back as you stick the seal into place. Start and
finish at the top hinge.
Refit the doors
Fit the hinges to the door pivot arms using the screws and nuts that were used in the PrePaint>Fuselage>Pre-fit doors task and tighten the nuts to safety.
Fit each
door to the
fuselage.
Apply a
single drop
of Loctite
242 to each
screw, then
fit the top
screw first
to hold the
top of the
door, then
fit the
bottom
screw and
check that
the door
closes in
the centre
of the door
opening
there will
be enough
movement
in the hinge screw holes to allow the door to be centred very accurately.
Tighten both screws firmly while the door is shut and both latches are closed.
Check that the door can be opened and closed easily and make any minor adjustments that may be required.
Remove the masking
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Both sides of the window will still be masked at this stage carefully
remove all of the masking until you only have the blue Fine Line masking
tape left around the window and then very carefully peel the Fine Line
tape from the window by pulling the tape back over itself and in towards the
centre of the window as shown in the photo at right.
This will allow the edge of the tape to cut the paint to a nice clean edge,
which is the reason for using the tape.
Never pull any masking tape towards the painted surface, always pull away
from the painted surface.
Pull
Window
Painted surface
Fit the door swing straps

These straps prevent the doors from swinging too far
forward in windy conditions.
Loop a length of black webbing through the bracket at the
front of each door and measure out enough webbing so that
the door can be opened to no more than 90 to the fuselage
and the webbing can be wrapped around the inside the front
of the door jamb.
Cut the webbing to length and secure to the back of the
door jamb with a countersunk screw.
Use your soldering iron to burn the bolt hole through the
fabric this will seal the edges of the hole.
Seal the cut ends of the webbing with a flame.
Fit the screw through the door frame: countersink the hole and fit the screw with a
Tinnerman washer under the head then place a penny washer over the webbing as
shown at right and secure with a Nyloc nut tightened firmly.
Fit the striker plate

Place the striker plate on the door jamb and align the latch pin hole. Hold the
striker plate in place with some tape and check that the door can be closed
and that the latch pin will fit though the striker plate make any required
adjustments and then rivet the plate in place with 2 x 5/32 rivets as shown
in the photo at right.
Repeat for the other door.
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Fit the door locks
Fit the door locks though the lock holes in the fuselage behind each door and
fix in place with the retaining nuts. Tighten each retaining nut firmly.
Fit the locking arm to the end of the shaft with the supplied screw: apply a
drop of Loctite 242 to each screw.
Check that the locking arm works in the correct sense and that the key can
be removed at both the locked and unlocked positions. It may be necessary
to lengthen the slot slightly if the key cannot be removed in the locked
position.
Clean the windows

Now you can clean the windows: start with a small amount of
methylated spirits on a clean cloth and carefully remove any dust and
debris from the painting process then, using a clean soft cotton cloth,
polish both sides of each window with a good quality cleaner such as
Novus Plastic Polish: start with Novus #2 and then finish with Novus
#1. Novus #3 should only be used for buffing out extremely heavy
scratches.
Support an open door with one hand while you polish the window.
Any cleaner/polish used must be safe to use on acrylic and must not
contain any silicon.
This completes the Post-Paint>Fuselage>Fit doors task.
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Post-Paint>Fuselage>Firewall forward>Final assembly

To complete all of the remaining firewall forward assembly work.
Materials required:
Card #15J or # 15T Spares
Card #22J or # 22T Hot air mixer box
Card #23T Oil bottle
Card #25JT Cabin heater
Prepare the muffler

Fit the inlet air heat shroud to the muffler with 2 large hose
clamps: align the shroud as pictured with the cutaway in
the shroud just touching the exhaust pipe.
Tighten the hose clamps firmly.
Fit the cabin heater heat exchanger to the exhaust pipe and
push up until it touches the muffler and tighten the Allen
head cap screws.
Shroud
Heat
exchanger
Fit the muffler

Remove the red sealing caps from the ends of the exhaust
pipes and fit the pipes into the inlet holes in the front of the
muffler.
Hose
clamps
Springs
Hold the muffler in place by fitting the supplied springs

from the tags on the muffler to the tags on the exhaust
pipes as shown arrowed in the photo at right.
Set
Check if the muffler is touching on the set screws (arrowed
screw
in purple at right) that hold the cover directly above the
muffler: if the muffler is touching these screws it could
eventually wear a hole in the muffler, so mark any spots
where the set screws are touching, remove the muffler and use a hammer to tap a small indent into the top of
the muffler. Refit the muffler and recheck.
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Connect the inlet air scat hoses
Flow
Carb inlet
Heated air
Cold air
Engine bay viewed from above showing the inlet air hose arrangement
the carburettor from 2 sources, cold and heated, through

the air mixer box on the firewall and then into the
carburettor air inlet. In each case a scat hose is used to duct
the air and each scat hose is held in place with hose
clamps.
Air is fed into
Inlet air horn
Start by connecting the air box outlet to the carburettor air

inlet: remove the red sealing plug from the carburettor and
connect the curved air inlet horn to the mouth of the
carburettor and secure with a hose clamp, then cut a short
length of scat hose to fit between the horn and the air mixer
box outlet and fit it into place. The scat hose should be
routed in a smooth curve between the 2 fittings as shown in
the photo at right.
Fit a length of scat hose to the lower air inlet fitting on the
air box, then hold the lower cowl in position and cut the
scat hose to length to fit the cold air inlet fitting on the lefthand side of the cowl. Remove the cowl and set aside for
later fitting.
Run a length of scat hose from the fitting on the left rear of
the muffler to the front fitting on the air box.
Heated air
Muffler
Fit the equalising tube
Carb inlet
Inlet air ducting as viewed from the right hand side
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Air mixer box

Eq tube
Eq tube
Carburettor
Route a length of 4mm clear tube from the fitting on the right of the air mixer box to the compensator fitting
on the right rear of the carburettor as shown in the photos above.
Fit the oil overflow bottle

Clip the oil bottle into the bracket on the lower right of
the firewall.
Fit the oil tube from the engine oil filler fitting, along the
top engine mount and curve it down to the inlet. Cut the
tube to length so that it will not rub on the inside of the
lower cowling and fit to the oil bottle with a hose clamp.
Cut a short length of oil tube as shown at right, so that it
can be routed over the lower engine mount and down. Fit
the short length of alloy tube into the bottom of the outlet
tube with a hose clamp then fit the outlet tube to the oil
bottle with a hose clamp.
Use the supplied saddle clamp to fit the outlet hose to the
firewall as shown at right.
Route the 2 x 4mm clear drain hoses from the fuel pump
breather and drain along the lower engine mount and
down through the saddle clamp as shown and trim to the same length as the oil outlet tube.
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Connect the cabin heater
Route a length of the smaller size scat hose (Card #25JT)
from the top fitting on the heat exchanger to the cabin
heat valve on the firewall.
Route a length of scat hose from the cold air inlet in the
front left of the lower cowling to the bottom of the heat
exchanger unit.
Cold air inlet
Fit the lower engine cowling into place.

Route the hose along the cowling and secure with zip ties
through flocked-on holders as shown in the photo at
lower right.
Cold air
inlet hose
Connect the air inlet hose

Fit the inlet air hose from the NACA duct on the left side
of the lower cowling to the air mixer box and secure with
a hose clamp.
Inlet air
hose
This completes the Post-Paint>Fuselage>Firewall forward>Final assembly task.
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Post-Paint>Fuselage>Engine>Fit Jabiru wood propeller and spinner

In this task the propeller will be fitted to the engine and the spinner will be mounted.
The propeller must be fitted before the engine can be rotated or run.
This task covers the fitting of either the Jabiru or Sensenich propeller.
The cylinder compression can cause the propeller to move unexpectedly when rotating the engine and so for
safety reasons all spark plugs should be removed and set aside and the spark plug holes should be covered
with a clean cloth during this task.
Card # 23 Spinner hardware, Torque Seal inspection putty, small torque wrench
Fit the propeller
Sand both sides of each spinner mounting plate flat in the flange/propeller mounting area.
Turn the engine so that one set of flywheel magnets are at the top (circled above left). This will ensure that
the propeller will stop in a horizontal position. Fit the guide bushes from the back of the propeller flange and
fit the rear spinner mounting plate over them with the cupped face towards the rear. Fit the propeller so that
the upper blade is closest to the 11 oclock position when viewed from the front of the engine. Tap the bolts
through with a soft hammer.
Fit the front spinner mounting plate with the cupped face towards the front, followed by the machined
aluminium mounting plate.
On each bolt place pairs of Belleville washers in a cup to cup arrangement: ( ) ( ) (Jabiru prop: 4 pairs,
Sensenich prop: 3 pairs) followed by a single flat washer and a Nyloc nut. Tighten the nuts until they are just
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firm and then torque each nut (Jabiru: 7 ft/lbs or 9.5 Nm, Sensenich: 12ft/lbs or 16.25 Nm) working in a
diagonal or criss-cross pattern.
There must be more than 1 and less that 3 threads showing. Pack behind the Nyloc nuts with flat washers
as required in order to achieve this. Recheck the torque settings, applying a slow, steady pressure on the
torque wrench until the correct torque value is reached.
Add engine oil
At this time the engine should have oil of the recommended grade and quantity added refer to the engine
manual for specific detail. Pour slowly to minimize the chance of spillage and refit the dipstick. Remove the
Do Not Run: Contains No Oil tag from the engine.
Check and set the propeller blade tracking
It is important that the tips of both propeller blades track exactly in line with each other as the propeller
rotates tracking must be adjusted to very close tolerances,
preferably less than 0.25mm, in order to minimize engine
and/or airframe vibration.
To check the tracking you will need to make up an adjustable
pointer (example shown arrowed at right) that can be clamped
to the nose gear and placed against the tip of the propeller blade
as a reference point (shown circled at right).
Rotate the propeller and check that each tip is just touching the
pointer. If there is any variation then the technique to be used is
as follows:
Coarse adjustment: if the difference between blades is greater
than 1 to 1.5mm then a shim will need to be made and placed
between the propeller and the propeller flange.
Remove the propeller. Cut a shim from a sheet of standard
80gsm paper (photocopier paper) as shown at right (use the
discarded universal propeller flange as a pattern) and fit on the
propeller flange on the side of rearmost blade.
Re-fit the propeller and re-torque all the nuts to the correct
values, working in a diagonal or criss-cross pattern, and check
the tracking.
Add more shims if required. Note that a shim cut from a manila
folder will correct a 2.5-3mm tracking error. Make fine adjustments as described next:
Fine adjustment: if the variation between blades is 1mm or less then apply additional torque of no more
than 2 ft/lbs to the 3 nuts on the side of the front-most blade and check the tracking.
When the blade tracking is less than 0.25mm, loosen off all of
the nuts and then re-torque them all to the correct values,
working in a diagonal or criss-cross pattern.
When blade tracking is correct and all the nuts have been set to
correct torque, apply a dab of Torque Seal inspection putty to
the top of each nut as shown at right. This gives a clear visual
indication that no further work is required.
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Pre-fit the spinner
Test fit the spinner it can be fitted in 2 positions, so try it each way and use the position where the holes all
line up the best while giving an even gap around the base of the propeller.
When the mounting position has been decided, mark each component with a permanent marker as shown
above so that if there is any need to remove the spinner or propeller all the parts can be refitted in the same
position relative to each other.
Fit the spinner in place and line it up with the back of the rear mounting plate and then push a 5/32 pop
rivet though all of the holes that line up. Working on one remaining hole at a time, drill a 5/32 hole through
the spinner and the rear mounting plate and temporarily place a 5/32 pop rivet in each hole to keep the
spinner and the mounting plate in alignment.
Work your way around all 6 holes in this manner. Repeat the process for the 6 holes in the front mounting
plate. The spinner should resemble a porcupine at this stage, with pop rivets protruding from the 12
mounting holes. Remove the pop rivets and the spinner and drill all the holes in the spinner out to 3/16 to
provide clearance for the screw threads.
Countersink each hole so that the Tinneman washers will sit flush against the spinner.
Fit the captive nuts to the inside of the spinner mounting plates - use the captive nut itself
(a complete captive nut assembly is shown below left) as a jig (below right) to drill the rivet holes thread
the screw part way through the captive nut from the back and fit the exposed end of the thread into the hole,
then drill the 2 x 3/32 rivet holes.
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Countersink the rivet holes just enough to make a countersunk 3/32 rivet sit flush and fix the captive nuts in
place and then enlarge the 5/32 holes in the mounting plates to 3/16 to provide clearance for the screw
threads.Fit the spinner
Fit the spinner using 5/32 countersunk screws and Tinneman washers.
Use a long sanding block to sand the rear mounting plate flush with the rear of the spinner.
Refit the spark plugs refer to the engine manual for the torque settings.
This completes the Post-Paint>Fuselage>Engine>Fit Jabiru wood propeller and spinner task.
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Post-Paint>Fuselage>Engine>Fit Jabiru composite propeller and spinner

In this task the propeller will be fitted to the engine and the spinner will be mounted.
The propeller must be fitted before the engine can be rotated or run.
This task covers the fitting of either the Jabiru composite propeller only.
The cylinder compression can cause the propeller to move unexpectedly when rotating the engine and so for
safety reasons all spark plugs should be removed and set aside and the spark plug holes should be covered
with a clean cloth during this task.
Card # 23 Spinner hardware, Torque Seal inspection putty, small torque wrench
Fit the propeller
1.
Figure 3 shows typical propeller installation details.
2.
Ensure that Propeller drive bushes 6 off, are in place in the Crankshaft Propeller Flange (note that
two are special, short parts and face backwards compared to the others see Figure 4). Sand both
sides of each spinner mounting plate flat in the flange/propeller mounting area. Fit the rear spinner
backing plate to the flange.
3.
When fitting a propeller turn the crank of the engine by hand until the magnets are aligned vertically
and then fit the propeller with the blades close to horizontal. This method makes it likely that when
the engine is turned off the propeller will naturally tend to come to rest with the blades close to
horizontal. Note that this procedure does not apply to 3300 engines as they may stop in any position.
4.
Fit propeller to flange.
5.
Fit Propeller Bolts - 4 off. The bolts must be oriented with the nuts positioned furthest from the
propeller flange (nuts forward for a standard tractor installation).
6.
Fit front spinner plate and penny washers to front of propeller. Note the use of AN970 Penny
Washers this is required to distribute the load applied by the bolts.
7.
Ensure that both spinner plates are locating correctly on the spigots of the propeller hub. The rear
spinner plate is drilled to allow the rear hub bolt spigots to pass through and mate directly against the
propeller flange. There must be nothing between these mating faces.
Progressively tighten bolts ensuring equal distribution of load and in a normal criss-cross torque
sequence. Ensure that the hub is tightened evenly: check that the gap between the front and rear hub
plates is the same on both sides of the propeller.
Using Torque Wrench, tighten propeller mounting bolts to the value given in Error! Reference
source not found..
8.
9.
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10.
Using Torque Wrench, tighten the outer blade clamp bolts to the value given in Error! Reference
source not found..
Check tracking of Propeller as detailed below.
Locate Spinner on Spinner Flange and fix with Machine Screws through tinnerman Washers.
Check Spinner tracking as detailed below in this section.
After the first 5 hours following the propeller installation or adjustment of the hub mounting bolts the
spinner must be removed and the propeller bolts checked for correct tension per Table 5 in the
propeller technical manual JPM0001-3.
11.
12.
13.
14.
Figure 3 Typical Propeller Installation
Figure 4 Propeller Hub Assembly (Spinner and blades not shown)

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IMPORTANT
For all Jabiru Aircraft the spinner is an important and integral part of the propeller Assembly. It is
essential to ensure adequate engine cooling. The aircraft must not be flown with the spinner removed.
Procedure Propeller Tracking
1.
Locate a fixed object on a flat floor so that it clears the Propeller tips by a small margin 1-3mm.
2.
Rotate the Propeller by hand.
3.
Check that each blade clears the object by the same amount. Measure the clearance for each blade.
4.
Maximum Tracking Error Tolerance is +/- 2mm.
5.
If the Propeller is outside the approved tolerance, refer to JABIRU Aircraft Pty Ltd or a JABIRU
Approved Service Centre for rectification instructions.
.Engine oil.
At this time the engine should have oil of the recommended grade and quantity added refer to the engine
manual for specific detail. Pour slowly to minimize the chance of spillage and refit the dipstick. Remove the
Do Not Run: Contains No Oil tag from the engine.
Pre-fit the spinner
Test fit the spinner it can be fitted in 2 positions, so try it each way and use the position where the holes all
line up the best while giving an even gap around the base of the propeller.
When the mounting position has been decided, mark each component with a permanent marker as shown
above so that if there is any need to remove the spinner or propeller all the parts can be refitted in the same
position relative to each other.
Fit the
spinner in
place and
line it up
with the
back of the
rear
mounting
plate and
then push a
5/32 pop
rivet though
all of the
holes that line up. Working on one remaining hole at a time, drill a 5/32 hole through the spinner and the
rear mounting plate and temporarily place a 5/32 pop rivet in each hole to keep the spinner and the
mounting plate in alignment.
Work your way around all 6 holes in this manner. Repeat the process for the 6 holes in the front mounting
plate. The spinner should resemble a porcupine at this stage, with pop rivets protruding from the 12
mounting holes. Remove the pop rivets and the spinner and drill all the holes in the spinner out to 3/16 to
provide clearance for the screw threads.
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Countersink each hole so that the Tinneman washers will sit flush against the spinner.
Fit the captive nuts to the inside of the spinner mounting plates - use the captive nut itself
(a complete captive nut assembly is shown below left) as a jig (below right) to drill the rivet holes thread
the screw
part way
through
the captive
nut from
the back
and fit the
exposed
end of the
thread into the hole, then drill the 2 x 3/32 rivet holes.
Countersink the rivet holes just enough to make a countersunk 3/32 rivet sit flush and fix the captive nuts in
place and then enlarge the 5/32 holes in the mounting plates to 3/16 to provide clearance for the screw
threads.
Fit the spinner
Fit the spinner using 5/32 countersunk screws and Tinneman washers.
Use a long sanding block to sand the rear mounting plate flush with the rear of the spinner.
Refit the spark plugs refer to the engine manual for the torque settings.
Spinner Tracking
1.
Locate a fixed object on a flat floor to just clear the lower edge of the tip of the Spinner.
2.
Rotate the propeller by hand and check that the Spinner runs true.
3.
Correct any run-out by loosening machine screws, realigning spinner then retightening machine
screws.
This completes the Post-Paint>Fuselage>Engine>Fit Jabiru composite propeller and spinner task.
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Post-Paint>Fuselage>Fit wheel spats
Post-Paint>Fuselage>Fit wheel spats

To final fit the spats or wheel fairings to the main wheels and the nose wheel.
Main wheel spats
Each main
wheel spat is held in place by a single bolt on the outside of the spat that fits into the axle
extension and 4 screws on the inside that fit to the spat mounting plate.
Fit
spat
each
into
position over the wheel and secure with an axle bolt and a flat washer and then fit the inside 3/32 machine
screws and Tinnerman washers to the backing plate.
Fit the rubber blanking plug to the tire pressure inspection hole on the outside of each spat.
Nose wheel spat
Support the front of the aircraft so that the nose wheel is off the ground and remove the front axle and wheel.
Fit the front of the spat over the yoke and refit the front wheel and the axle, passing the axle through the
spat, yoke and wheel as shown below. Fit a flat washer to each side of the axle. Lower the nose wheel back
to the ground.
Fit the castellated axle nut and tighten to safety then secure the nut with a lock pin. Screw the spat to the
yoke with a short 3/32 machine screw and Tinnerman washer to each side of the spat (arrowed in red in the
photo below left).
Fit
rear
the
section of the spat to the front section with 8 x 3/32 machine screws and Tinnerman washers as shown in
the photo above right. Fit the rubber blanking plug to the tire pressure inspection hole on the left hand side
of the spat.
This completes the Post-Paint>Fuselage>Fit wheel spats task.
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Post-Paint>Wings>Install aileron cables

To install the aileron cables in the wings. The cable is tied to a pre-installed drawstring and carefully drawn
through the wing ribs. This task requires two people: one person to pull the drawstring and a helper to feed
the cable into the wing.
Place the cable
The labelled end of the cable is the end that goes inside the cabin, so the unlabelled end is the end that goes
out through the wing to the aileron. The cable may be fed from either the wing root or the aileron cable
inspection hole. This task will describe feeding from the wing root.
Fit a rod end to the unlabelled end of the cable the rounded end will aid the passage of the cable through
the high-density foam ribs and push the inner cable all the way in towards the labelled end of the cable.
This will make the pulled end of the cable shorter and thus it will be more flexible to follow the curved path
inside the wing (refer to the second photo below).
There is a drawstring inside in the wing with extra string coiled around a stick at the aileron end that will be
visible through the aileron cable inspection opening. Loosen the drawstring and check that it can be moved
freely, then pull a short length out of the wing root (circled above) and tie it firmly through the rod end.
Wrap cloth tape around the cable end from the rod end all the way back to the outer cable: this will ease the
cable through the wing ribs.
The aileron cable runs in front of the spar and then
curves around through the spar and emerges at the
aileron drive arm position as shown at right (photo
taken during wing manufacture).
Have your helper feed the cable into the wing while
you pull gently on the drawstring through the aileron
cable inspection opening. Work slowly and do not
apply too much pressure but rather move the cable
carefully and shake it if it seems to catch at any time.
It will help if your helper can slowly rotate the outer
cable while you ease the cable around the curve at
the outboard end of the wing. Do not pull strongly
on the drawstring: if you do you will only succeed in cutting the string into the foam ribs and wedging the
cable, which will make it extremely difficult to complete the task.
Feed the cable through the wing until it can be pulled through the aileron cable inspection opening, then
discard the cloth tape and string and remove the rod end. Push the cable back into the aileron cable
inspection opening and pull the end of it out of the aileron cable slot in the upper surface of the wing.
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Connect the aileron cable
The cable is held to a strengthened rib inside the wing by a saddle clamp and 2 x AN3 bolts and Nyloc nuts.
Access is from the aileron cable inspection opening and the 38mm hole beside it: the bolts are fed through
from the back of the rib (through the 38mm hole) and then the clamp backing plate goes against the rib, then
the cable and then the saddle bracket with the aligning indentation fitting into the slot on the outer cable and
the assembly is held in place with Nyloc nuts. Check that the cable is correctly positioned and tighten both
nuts firmly. Mark each nut with TorqueSeal or similar.
Fit the inspection cover
At this time
you can fit the clear acrylic inspection cover to the inspection opening.
Fit the threaded fairing sockets to the inspection cover and then position the cover inside the wing and fix in
place with 8-32 button head screws, all as shown in the drawing above.
This completes the Pre-Paint>Wings>Install aileron cables task.
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Post-Paint>Wings>Fit stall warning

To fit the stall warning device to the left wing.
Materials required:
Card #6J or #6T: Stall warning
Mark and drill the wing root
Mark a position in the left-hand wing root 75mm back from the leading edge and drill a 10mm hole at that
location in line with the wing attach bolt hole in the front lug.
The clear plastic stall warning tube will enter the wing here.
Assemble the stall warning
Use 5-Minute Araldite and flock to fix the aluminium stall
funnel to the plate, about 4mm back from the front edge, and
the stainless steel gauze to size and flock it by the edges to
of the funnel as shown at right. Leave to cure, then round the
edges of the plate carefully. Roughen the sides and bottom of
assembly.
warning
then cut
the front
front
the
Mark and cut the leading edge

Measure out 1195mm from the wing root of the left-hand
and mark the location. Use cloth tape to protect the paint on
leading edge of the wing during this step.
wing
the
Using the drawing on the next page, locate the vertical centre
stall warning aperture and mark the location. Recheck your
measurements carefully and drill a pilot hole, then widen the
10mm and file carefully out to a rectangle 12mm high and
wide. The top of the opening should be precisely on the
edge of the wing. Final size the hole to fit the stall warning
assembly.
of the
Hold the lip at the bottom of the assembly with pliers while
be careful not to drop it inside the wing.
fitting
hole to
19mm
leading
Fit the stall warning assembly

Use a steel rod to feed the plastic tube in from the wing root
through the wing ribs until it can be seen though the hole in
leading edge, then pull the tube through using a wire hook
superglue and lock wire the tube to the rear of the stall
funnel.
and
the
and
warning
Apply 5-Minute Araldite and flock to the bottom and sides of

warning assembly and carefully slide it back into the wing
gauze is flush with the leading edge of the wing and leave to
Remove the protective cloth tape.
the stall
until the
cure.
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This completes the Post-Paint>Wings>Fit stall warning task.
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Post-Paint>Wings>Prepare wings for fitting

To prepare the wings prior to fitting them to the fuselage.
This is a 2 day task, where the flap bushes are flocked in and left overnight to cure overnight, then the
ailerons and fuel gauge are fitted the next day.
Materials required:
Resin and flock
Card #16J Flaps
Fit the flap hanger bushes
Start by placing the wings upside down on padded trestles.
The flap hanger closest to the wing root on each wing will have a pair of machined bushes (part # 3106094,
on the card) fitted to it to better spread the load from the flap drive arm.
Drill the bolt hole in the flap hanger out to accommodate the step in the bush and test fit the bushes, making
sure that they seat snugly into each side of the flap hanger the hole may need to be slightly countersunk to
get the fit exactly right.
Test fit the bushes and check that you can fit an AN3 bolt cleanly though both bushes, which indicates that
the alignment is correct, then mix up a small batch of flock and flock the bushes into place. Do both wings at
the same time with the same batch of flock.
Keep
flock
from
bolt
the
away
the
Bushes
Flap hanger
Packer
holes, fit a flap pivot bolt though the bushes and then fit and tighten a plain nut just enough to hold the
bushes firmly in place. A packer should be used to avoid the flap hanger flexing in when the bolt is
tightened. Smooth the flock carefully with a clean mixing stick dipped in resin and leave overnight to cure.
Prepare the flaps
Next day remove the bolt and clean any excess flock away from the area. Run a 3/16 drill though the bolt
hole in each flap hanger to clear any paint and debris out of the holes.
Clean out the 1/4 holes in the flap pivot arms in a similar manner.
The flaps will be fitted to the wings after the wings have been fitted to the fuselage.
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Fit the ailerons
Hold the aileron in place and slide the hinge pins though each hinge, starting from the side of the hinge
where the pin retaining slot was filed in the Pre-Paint>Wings>Fit ailerons task.
Fit the pin retainers and hold each one in place with a 5/32 machine thread screw.
Place the ailerons in the neutral position and place a length of cloth tape over the top surface of the wing and
the aileron. This will prevent the ailerons from dropping when the wing is turned right way up. Turn the
wings over so that they are right way up.
Fit the aileron cable rod end to the aileron drive arm with an AN3 bolt fitted through the drive arm, then an
AN960-416 (3/16) flat washer, then the rod end followed by an AN960-515 (1/4) flat washer and a Nyloc
nut as shown in the photos above.
Tighten the Nyloc nuts to safety and mark with Torqueseal.
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Fit the inspection cover
At this time you can fit the clear acrylic cover to the aileron cable inspection opening.
Fit the threaded fairing sockets to the inspection cover and then position the cover inside the wing and fix in
place with 8-32 button head screws, all as shown in the drawing above.
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Fit the fuel gauges
Remove the masking tape from over the fuel gauge boss in the wing root and
clean the area.
Test fit each fuel gauge feed the float unit into the wing tank and hold the
gauge in place with 2 screws. Check the empty indication the needle should
sit slightly below the E or Empty mark as shown in the photo at top right.
If it does not then the gauge will need to be adjusted.
The gauge needle is driven by a magnet that is turned by the action of a float
that sits inside the fuel tank. The gauge can be disassembled by pulling the
black nylon float drive out of the aluminium gauge body and the magnet can
be twisted slightly by hand. See the photos below for detail of the gauge unit.
Gauge unit assembled
Float
drive
Magnet
Gauge
body
The gauge can then be reassembled and rechecked (and readjusted if necessary) until it reads correctly.
The nylon drive unit barrel should be a firm fit into the gauge body: if the fit is
not entirely to your satisfaction then a smear of Loctite 577 Sealant should be
applied to the barrel.
When the gauges are fitted each of the 4 retaining screws and the top and
bottom gauge face screws should have a small drop of Loctite 242
Threadlocker applied before fitting.
Carefully bend the electrical spade terminals out so that they are parallel to the
face of the gauge as shown circled at right.
Fit the fuel tank connector blocks

Fit the tank connector blocks through the slots in each side of the fuselage and push each connector block
fully forward in the slot.
Use the supplied layer plate as shown in the photo at right
to hold the connector blocks in the fully forward position
and fix to the fuselage with 2 x 8G stainless steel selftapping screws.
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Fuel lines and fittings
There are 3 fuel lines that need to be connected in the wing root: the bottom 2 carry fuel to the header tank
while the top line is the breather for the header tank. These fuel lines each need to be fitted and then cut to
an approximate length of 300mm behind the rear of the wing.
All 3 lines exit the wing root towards the rear and both of the
fuel lines will have a spring fitted to prevent any chance of a
kink developing when the lines are bent to the rear, while the
breather line faces rearwards already.
Fit each fuel line to the tank fitting and secure with a hose
clamp. Slide a 100mm length of spring over each fuel line,
push all the way up to the hose clamp and fix in place with
silicone sealer at the hose clamp end as shown in the photo at
right.
Label the other end of each fuel line with tape as shown at
right. This is essential because once the wing has been fitted
it will be very difficult to determine which line is which if it
has not been labelled.
B = breather line
F = front fuel pickup
R = rear fuel pickup
Fit the fuel gauge windows

Locate the clear, round fuel gauge windows and Superglue them over the outside of the fuel gauge holes in
the wing root area of the fuselage.
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Fit the vent tubes to the fuel filler caps
The fuel filler caps came partly assembled on the card and were fitted to the fuel filler opening on the wing
in the Pre-Paint>Wings>Prepare wing root task to keep dirt out of the wing tanks, all that remains now is
for you to fit the vent tubes to the fuel caps.
Fuel cap
Vent tube
Vent ball
Vent cap
Working on one wing at a time, remove the fuel cap and place a clean cloth or a piece of tape over the fuel
filler opening so that no dirt or debris can fall into the tank during this process. Start by carefully cleaning
away any paint from the top of the fuel cap and in particular from the vent tube hole in the top of the cap.
Use a file to cut 4 notches each 1mm deep into the top of the vent tube. Remove all burrs.
Fit the notched end of the vent tube to the vent cap the vent tube should be a snug fit into the vent cap, use
fine sandpaper if required to size the tube to a good fit. Now, working upside down, drop the small white
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vent ball into the vent cap and use a smear of Loctite 620 to fix the vent tube into the vent cap. Make sure
that nothing has caught the vent ball the ball should still rattle in the vent cap when the assembled tube and
cap is shaken.
Fit the vent tube to the hole in the top of the cap the vent tube should be a snug fit into the hole, use fine
sandpaper if required to size the tube and then fix it in place with Loctite 620 with the breather holes in the
vent cap facing towards the outside of the fuel cap.
This completes the Post-Paint>Wings>Prepare wings for fitting task.
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Post-Paint>Wings>Fit wings
To final fit the wings to the fuselage. This is a repeat of the Pre-Paint task but because you have already prefitted the wings they can now be fitted into place more easily. This task will discuss the fitting of one wing
at a time.
In our factory we use 3 people for this task, so ask 2
friends over to help you.
Do not try to do this task with less than 3 people or you
risk dropping the wing.
Preparation
Place 2 trestles beside the fuselage and lay the wings on
them.
Fit the bottom of the strut to the lower fuselage mount and
secure with an AN175-15A bolt inserted from the front
and an AN960-516 washer MS20365-528 nut. Rest the
outboard end of the strut against a saw stool as shown at
right.
Lay the AN4-14A wing attach bolts and some AN960-416 washers on top of the fuselage where you can
easily reach them.
Fit the wing
One person holds the outboard end of the wing while the other 2 hold the front and back of the wing root as
shown in the photo above.
Carefully walk the wing in to the fuselage, feeding the aileron cables through the fuselage holes and feeding
the fuel lines, stall warning tube and any electrical wiring, and guide the wing attach lugs on the wing into
the aluminium wing attach brackets on the fuselage.
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The fit between the wing attach lugs on the wing into the aluminium wing attach brackets will be tight and it
may take some careful positioning of the wing to get them to fit the outboard end of the wing may need to
be moved forward or backwards to get the correct alignment.
Each AN4-14A wing attach bolt should be fitted with one AN960-416 washer under the head of the bolt and
one AN960-416 washer under the nut.
It will be necessary to gently tap the AN4-14A bolts into place tap in until the head of the bolt is seated
hard against the aluminium wing attach bracket and then put an AN960-416 washer and a MS20365-428 nut
and tighten up until the nut is in safety: there should be at least 1 threads showing though the nut but not
more than 3 threads showing.
DO NOT OVERTIGHTEN THESE BOLTS. They should be just tight enough to prevent rotation. Over
tightening
may result
in failure of
the wing
attach lugs.
Fit the
strut
When both
wing attach
bolts are in
place, lift
the strut up
to the
underside of
the wing
and fit the
strut to the
wing with
an AN17515A bolt
inserted
from the
front and an AN960-516 washer MS20365-528 nut and tighten up until the nut is in safety: there should be
at least 1 threads showing though the nut but not more than 3 threads showing.
tightening may result in failure of the strut attach lugs.
Repeat the fitting process for the other wing.
Fit the stall warning horn
Trim the stall warning tube to length and fit the stall warning horn to the end of the tube.
Hold the stall warning horn to the cabin upholstery with Velcro strips.
Test by sucking on the stall warning in the leading edge of the wing until you hear the horn.
This completes the Post-Paint>Wings>Fit wings task.
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Post-Paint>Wings>Connect ailerons
To connect the aileron cables and set the aileron deflections. One person can do this task but it is much
easier with 2 people: one to position the ailerons and one to make the adjustments.
Aileron cables
Wedge pins
R clips
Aileron brackets
Fit the outer cables

Feed each aileron cable through the same side bracket in the seat back: the left-hand cable though the lefthand bracket and the right-hand cable through the right-hand bracket.
Fit the groove in the outer cable into the shaped hole and push the cable forward so that the cable seats into
the bracket, then fit the retaining wedge pin in behind the cable, push the wedge pin firmly down and secure
it in the bracket with the retaining spring clip as shown at right.
Set the ailerons to the neutral position
Set the ailerons to the neutral position: a straightedge held

under the wing must touch the front and back of the wing
and the back of the aileron as shown arrowed in the photo
above.
Keep the straightedge handy this setting will need
rechecking several times.
Aileron cable
Wedge pin
R clip
Detail view of the aileron cable in the bracket

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Set the aileron cable lengths
Loosen off the lock nuts on the rod ends at both ends of each aileron cable.
Set the control stick so that it is centred laterally/from side to side.
Check that both ailerons are still set to the neutral position and then carefully adjust the rod ends on each
aileron cable by hand so that an AN3 bolt can be fitted though the rod end and the aileron bellcrank on each
side.
Aileron cable
rod ends
Aileron
bellcrank
Aileron
stop bolt
Rear of
console
It may be necessary to adjust the cable length at both ends of the cable, and ideally the rod ends should be
adjusted to be close to equal with the same amount of thread showing at each end of the cable. Work on one
side at a time and check that the aileron is still neutral and the stick is still centred, then move to the other
side.
Take your time with this step: it is easy to bump the control stick slightly while testing cable lengths and it
may be necessary to repeat the process several times until both ailerons are set to neutral and the cable
lengths are both correct.
Ensure that the inboard end of the aileron cables are connected to the same side of the aileron bellcrank at
the rear of the control column: the left wing cable must connect to the left side of the bellcrank and the right
wing cable must connect to the right side of the bellcrank.
When both aileron cable lengths have been set with the ailerons in the neutral position and the stick
centered, fit the rod ends to the aileron bellcrank with an AN3 bolt. Fit an AN960-515 (1/4) flat washer,
then the rod end followed by an AN960-416 (3/16) flat washer, then the bellcrank, another AN960-416
(3/16) flat washer and a Nyloc nut.
Tighten the Nyloc nuts to safety and mark each nut with a dab of TorqueSeal.
Tighten the rod end locknuts at each end of each aileron cable firmly and mark each locknut with a dab of
TorqueSeal.
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Set the aileron deflections
Once the aileron cables have been adjusted to length with the ailerons in the neutral position and the stick
centred, the full travel deflections can be set.
In the kit there is an aileron deflection template. Place this template on top of the wing and set the aileron to
the full UP travel deflection as shown in the photo above (note the 3 arrowed points where the template
touches) and then adjust the stop bolt on the aileron bellcrank so that the bolt just touches the eccentric stop
at full deflection.
The eccentric stop that you fitted in the Post-Paint>Fuselage>Interior>Fit console controls task can be
rotated if required to give an equal length to the stop bolts.
Repeat the process for the other aileron and tighten the stop bolt locknuts.
Final check
Recheck each step:
Check that the outer cables are firmly fixed into the brackets by the wedge pins and that the wedge pins are
held by the R clips;
Centre the control stick and check that both ailerons are in the neutral position. Make minor adjustments as
required;
Check that the aileron stops are set correctly for full deflection: when the control stick is at full left
deflection the left aileron should touch the aileron deflection template at all 3 points and when the control
stick is at full right deflection the right aileron should touch the aileron deflection template at all 3 points.
Make minor adjustments as required;
When all of the settings are correct check all 4 rod end lock nuts (2 on each cable) and the 2 aileron stop
lock nuts for tightness and mark each one with a dab of Torqueseal.
This completes the Post-Paint>Wings>Connect ailerons task.
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Post-Paint>Wings>Connect wing tanks
Post-Paint>Wings>Connect wing tanks

Breather
Front pickup
Back pickup
To connect the fuel lines and earth the wing tanks to the fuel system.
Size and connect the fuel lines
Hold the fuel lines under the connector block and cut each line to length so that they can be fitted to the
connector block as shown above. There must be no kinks in any fuel line.
As you can see from the photos above and at right (taken
from the Pre-Paint>Fuselage> Interior>Fuel system task)
the back fuel pickup goes to the inside ferrule, the front fuel
pickup goes to the middle ferrule and the breather goes to
the outside ferrule.
Left
Right
Back
Working from the inside line to the outside, hold each fuel
line in place with a hose clamp and tighten each clamp
firmly.
Front
Route the earth wires

Breather
Run a length of white aviation wire from the front of each

wing, through the aileron hole in the fuselage and into the
top of the fuel line sheathing from each wing tank. Run the
wire all the way down into the header tank enclosure and
leave enough length to connect to the common earth post in
the floor of the enclosure.
Crimp a red ring terminal to the bottom of each wire and fit
to the common earth post in the header tank enclosure
(arrowed at right) the same earth post that connects the
earth from the fuel pump and the quick-drain fitting on the
header tank. The top of each earth wire will be connected to
the quick-drain fittings on each wing after the wing root
fairings have been fitted in the Post-Paint>Wings>Fit
fairings task.
Common
earth post
This completes the Post-Paint>Wings>Connect wing tanks

task.
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Post-Paint>Wings>Fit flaps
To fit the wing flaps to the wings and adjust their deflection. We use 2 people in the factory to carry out this
task and we recommend that you do the same as the flap is too long for one person to handle and there is a
risk of damaging the painted surface of the flap and the wing.
Materials required:
Wotan cloth tape to hold the flaps up while adjusting the flap push rod lengths.
Fit the flap push rods to the flaps
Fit a rod end and plain locking nut to one end of each flap
push rod and tighten the lock nuts firmly. Lay the flaps
upside down on trestles and fit the flap push rods to the
inboard end of each flap.
Working through the access hole in the flap, feed an AN313A bolt with an AN960-416 (3/16) flat washer under the
head from the inside of the flap through the drive post.
Drive
post
Access
hole
Fit 3 x AN960-416 (3/16) flat washers, then the rod end

and an AN960-515 (1/4) flat washer and a Nyloc nut as
shown in the photo at right. Tighten the nut to safety.
The flap push rods should now be centred in the slot in the
leading edge of the flap.
Flap
push rod
Fit the flaps to the wings

Inboard end of inverted flap showing push rod attachment
Each flap post bolt hole has a short length of Bundy tube
spacer fitted inside (tip: a smear of grease will hold the
spacer in place while fitting) and the flap post fits into the flap hanger and is then secured with an AN3-8A
bolt.
Gap equal to 2
mixing sticks here
Touching
here
Touching
here
Working on one flap at a time, fit the flap to the wing with the AN3 bolts with a 3/16 flat washer under the
head of each bolt. Fit a 3/16 flat washer and Nyloc nut and tighten each nut to safety. Check that the flap
can be extended and retracted by hand, taking care not to scratch the fuselage or the side window when the
flap is near full deflection.
Hold a straightedge under the wing and flap with a gap equal to 2 mixing sticks at the rear of the wing and
touching at the front and back, all as shown in the photo above.
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Tape the flap into position with a length of cloth tape as
shown arrowed in the photo at right.
Fit and set the other flap in the same manner.
The flaps are now in the fully retracted position and are
ready for the flap push rods to be connected to the flap
drive arms in the next step.
Connect and adjust the flaps

Apply power to the flap motor and extend the actuating
shaft fully as shown at right.
Fit a rod end with a plain locking nut to the free end of the
flap push rods and screw the rod end into the flap push rods
until the hole in the rod end lines up with the hole in the
flap drive arm, then fit the rod end into the clevis in the flap
drive arm as shown below right with an AN3-10A bolt with
a 3/16 washer under the head of the bolt and another 3/16
flat washer and a Nyloc nut and tighten the nut to safety.
Tighten the plain locking nut firmly.
Repeat the process for the other flap. At this point the flaps
have been fitted and adjusted.
Apply power to the flap motor and extend the flap to the
first position and check both flaps for clearance from the
fuselage.
Have someone watch each flap as you continue to extend
the flaps to the second full flap position and check each
flap for clearance from the fuselage until the full flap
position is reached.
If you set your flap end clearances correctly in the PrePaint>Wings>Test fit wings task there should be no
problems, but if the flaps do touch the fuselage then you
will need to remove the flap and cut the end of the flap
away to maintain a 5mm clearance from the fuselage.
This completes the Post-Paint>Wings>Fit flaps task.
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Post-Paint>Wings>Fit fairings
To fit the final trim: specifically the wing root fairings, the upper strut fairings, the lower strut/main gear
recess fairings and the wheel spats.
Wing root fairing
The wing root fairing comes in 2 parts: upper and lower. Fit
the lower fairing first tape the fairing into place with the
fairing just touching the fuselage and then screw the fairing
to the wing with 5 x evenly-spaced 6G stainless steel selftapping screws.
Fit the fuel block fairing to the lower fairing with 2 x 6G
stainless steel self-tapping screws.
Quick-drain
fitting
Fit the top fairing with the front return overlapping the
lower fairing and screw in place in the same manner.
Earthing
connection
Repeat the process for the other wing.

Refer to the photos at right for details of placement and
screw spacing.
Fuel block
fairing
Wing tank earth

Fit a length of lock wire to the quick-drain fitting under the
wing and long enough to reach the rear fairing screw and
twist it.
Crimp a red ring connector to the lock wire.
Trim the white earth wire that you fitted in the PostPaint>Wings>Connect wing tanks task so that it reaches
the rear fairing screw and crimp a red ring connector to it.
Fit both ring connectors under the rear fairing screw and
tighten the screw firmly.
Earth
connection
Repeat the process for the other wing.

Strut to wing fairing
Fit the front section of the fairing into place with 6G
stainless steel self-tapping screws as shown in the photos
above. Repeat the process for the other wing.
Lock wire
earth
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Lower strut/main gear fairing
Start
by
Right hand side strut/main gear fairing from below (top photo) and side on (above)
tucking the brake lines up into the main gear recess and zip tying them to the top rear of the main gear legs.
Connect the pitot line from the right hand strut to the instrument panel line with a blue water trap connector
and tuck the pitot line up into the main gear recess.
Fit the right hand section first: tuck the blue water trap connector into the fairing and then fit the fairing into
place and hold it there temporarily with some cloth tape while you fit the 5/32 machine screws and
washers, then fit the left hand section in the same manner.
This completes the Post-Paint>Wings>Fit fairings task.
CONGRATULATIONS, you have completed construction!!
Now, on to Testing.
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Testing>General
Testing>General
Here we are: the Construction phase has been completed and the task in hand is to thoroughly check the
aircraft in preparation for flight and then, finally, test fly the aircraft for first time.
Many tasks need to be completed prior to the first flight:
The aircraft must be carefully Weighed and Balanced and, if necessary, rebalanced to suit your
intended loadings and the information recorded in the Owners Manual;
The Rigging (the deflection of the control surfaces) must be rechecked each deflection was set as
part of the relevant Post-Paint tasks so this is essentially confirming your earlier work and making
minor adjustments if required;
The Fuel Gauges will need to be calibrated so that you will have an accurate indication of fuel
quantity;
You will need to affix the required placards and decals as listed in Section 2.8 of the Owners
Manual;
You will need to fit the Registration Markings required by your countrys aviation authority;
An extensive Pre-Flight Checklist must be completed: this checklist runs to 15 pages and to complete
it correctly will take you several days;
And finally the Test Flight, which will require a disciplined approach and which should be conducted
by a suitably experienced pilot.
Resist any temptation to rush these final tasks; it is extremely important that all checks be completed
correctly before flight is attempted. Failure to do so could have severe consequences, so take your time and
be very thorough!
So there is still quite a bit of work to do, but you are within a week or 2 of finishing your build, depending of
course on how much time you can devote to these tasks.
This would be a good time to have a clean-up of both the aircraft and your workshop:
Clean the aircraft interior: remove anything that is not part of the aircraft (tools, rags, sandpaper, etc)
and vacuum out any dust and dirt.
Wash the exterior with clean water with a little soap (most car washing products are suitable) and
chamois dry.
Clean the windscreen and windows carefully and if necessary use some Novus products (refer to
Post-Paint>Fuselage>Fit doors for details) to clear any minor marks or scratching.
Clean your work area thoroughly and organise your tools.
Locate your deflection templates: you will need them shortly.
OK, lets get on with it the end is in sight!
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Testing>Weight and balance

To calculate the Empty Weight and the balance point or Centre of Gravity of the aircraft.
The Empty Weight Trim Index is calculated from these values and then various loading scenarios are be
tested to see if any rebalancing of the aircraft is required. Finally all values are entered into the Aircraft
Empty Weight Record in Section 6.2 of the Owners Manual.
Equipment required:
3 bathroom scales capable of weighing up to 150Kg
Plumb bob and string line, set square
Builders type spirit level
Chalk and a builders chalk line to mark the reference positions onto the hangar floor
Prepare the equipment
Before you do anything else, check your scales for accuracy: use some objects of a known weight, such as a
few 20Kg bags of cement to see if your scales are reading correctly at around the 100Kg range of the scale.
If there is a problem then either adjust the scale or, if this is not possible, note how much the scale
over/under reads and apply this as a correction to the weight displayed.
Prepare the aircraft
Remove all surplus items from the cockpit: tools, clothing, etc. and clean the interior of the aircraft with a
vacuum cleaner. Clean the exterior of the aircraft: remove all dust and dirt with a damp cloth. Check that the
engine oil is full to the bottom of the hatched marking on the dipstick. Turn the fuel tap on the console to the
OFF position (lever facing up).
Fill the header tank with fuel but leave zero fuel remaining in the wing tanks.
The aircraft should contain everything required for flight except fuel in the wing tanks.
Reference points
In this task you will be measuring the horizontal distances from the Datum, which is the leading edge of the
wing, to the main wheel axles and the front wheel axle.
Each reference point will be marked onto the hangar floor and then measured.
Mark and measure
Refer to the drawing on the next page for colour-coded details of the line markings.
Use a chalk line to mark 2 lines at least as long as the aircraft on the hangar floor in a right angle cross. Roll
the aircraft directly along one line (coloured blue in the drawing) until the main wheels are directly over the
second line (coloured green in the drawing).
The main wheel axles must be directly over the second (green) line: use a square or a plumb line from the
axle bolt centres in the main wheel spats to check this and move the aircraft as required. Leave the brakes
off and chock the main wheels when the position is correct.
Mark the Datum line (coloured purple in the drawing) on the floor by means of a plumb line hung from the
leading edge of each wing, using a point about 300mm outboard of each main wheel. Join both Datum line
marks and mark a line across the floor with your chalk line.
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Mark a point on the floor directly under the centre of the front axle bolt on each side: use a square or a
plumb line from the axle bolts in the front wheel spat to check this.
Now measure the distance from each side of the front axle (the red line above) to the Datum line: these are
distances A and B. add them both together and divide by 2 to get the average distance this will compensate
if the front wheel is not set exactly straight ahead. Enter the distance as a negative value in the Distance to
Datum column on the chart on the next page.
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Measure the distance from the left main wheel axle to the Datum line and enter the value at distance C in the
chart on the next page. Do the same for the right main wheel (distance D).
Weigh the aircraft
The weighing part of this procedure should be conducted in a closed hangar with a level floor. Because the
aircraft is very light any wind will adversely affect the weights, so a closed building, without any doors
being opened during the procedure, is required.
Place a set of scales under each wheel and level the aircraft: use a builders level across the lower door sills
to check for lateral level, and along each lower door sill to check for longitudinal level. Pack under wheels
as required to level the aircraft.
Record the weight of each wheel under the Weight column in the chart below.
Note: if you have access to only 1 set of scales you may weigh each wheel individually, however you will
need to pack under the other wheels to level the aircraft before each weight is recorded.
Calculate the Empty Weight and Centre of Gravity
Sum all of the items in the Weight column and put the total at the bottom of the column.
All distances aft of the Datum are considered positive and all distances forward of the Datum are considered
negative in the calculation that we are about to do in this step.
Calculate the Moment of each wheel: starting with the nose wheel, multiply the Weight by the Distance to
Datum and record the result in the Moment column. Note that the Distance to Datum value for the nose
wheel will be a negative value and the result will also be negative.
Multiply the Weight by the Distance to Datum and record the result in the Moment column for each main
wheel. These results will both be positive values.
Sum all of the items in the Moment column and put the total at the bottom of the column.
Divide the total Moment by the total Weight and record the result in the red box at the bottom of the chart
this is the distance aft of the leading edge where the empty aircraft will balance and is referred to as the
Empty Aircraft Arm.
Item
Weight
(kg)
Nose wheel
Left main wheel
Right main wheel
Distance to Datum
(mm)
(A+B)/2 -
Moment
(kg/mm)
=
-
(C) +
(D) +
Moment / Weight
Column totals:
Empty Aircraft Arm:
mm aft of Datum
Calculate the Empty Weight Trim Index

Multiply the Empty Aircraft Weight by the Empty Aircraft Arm and divide the result by 1000 to arrive at the
Empty Weight Trim Index.
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This value can be used in the Load and Balance Worksheets in Section 6 of the Owners Manual.
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Examples of calculation
Below is an example calculation showing typical values:
Item
Weight
(kg)
75
Nose wheel
Left main wheel
Distance to Datum
(mm)
- 780
Moment
(kg/mm)
- 58,500
108
+ 475
+ 51,300
Right main wheel
108
+ 475
+ 51,300
Column totals:
291
Moment / Weight
44,100
Empty Aircraft Arm
151.55
mm aft of Datum
Empty Weight Trim Index: [(291 x 151.55) / 1000] = 44.1.
Rebalancing the aircraft

You must now use the Load and Balance Worksheets in Section 6 of the Owners Manual to test all of the
likely loading scenarios for your intended operations and see if any fall outside of the envelope.
For factory built aircraft we are required to use the CASA-approved standard passenger weight (currently
86kg) to calculate loadings, but as you are the builder you may choose to use the actual weights of yourself
and your regular passenger(s) along with items that you intend to carry with you, such as tie downs, toolkit,
suitcases, camping equipment and so on.
If it seems possible that an intended loading could exceed, for example, the forward limit, then you would
need to consider adding some ballast to the rear of the aircraft.
If any rear ballast is required the preferred method is to add it in the form of lead shot mixed with resin to
the ventral fin. (Note: It is unusual to need forward ballast if there is an intended loading that would
require forward ballast it will usually be very close to MTOW anyway and should very probably be avoided
all together.)
Assuming that rear ballast is required you would measure the arm of the ballast station/ location from the
Datum and calculate the weight of ballast required, adjust the calculations to obtain a revised Empty Aircraft
Weight, Empty Aircraft Arm and Empty Weight Trim Index and then retest all of the likely loading scenarios
for your intended operations and see if any still fall outside of the envelope.
Once you are satisfied that the majority of the likely loading scenarios for your intended operations will fall
inside of the envelope, you may physically add the ballast and repeat the weighing procedure and then
record the revised values in the Aircraft Empty Weight Record in Section 6.2 of the Owners Manual.
This completes the Testing>Weight and balance task.
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Testing>Rigging check
To perform a final check of all control surface deflections and make any adjustments that may be required
prior to the first flight.
Each control surface has had its deflections set as part of the appropriate fitting task, so this final check is
just to verify that nothing was missed during assembly.
Materials required:
Deflection templates for all control surfaces
Straightedge 1 metre long
Rudder
Check the rudder travel

Tape the rudder template over the rear of the empennage.
Place a saw stool under the front of the fuselage to lift the nose wheel off
the ground and then adjust the rudder cable length so that the rudder sits
on the centre mark with the rudder pedals centred and all level.
Use the rudder pedal adjustment set screws (shown arrowed at right) if
required to adjust the rudder travel so that the rudder deflects to each full
travel mark as shown in the photos above and mark each with TorqueSeal.
Flaps
Hold a straightedge under the wing and flap with a gap equal to 2 mixing
sticks at the rear of the wing and touching at the front and back, all as
shown in the photo below. Adjust the flap pushrods if required until all 3
positions are touching on each wing. Tighten the pushrod locknuts and
mark each with TorqueSeal.
Rudder pedal adjustment detail
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Gap equal to 2
mixing sticks here
Touching
here
Touching
here
Ailerons
Check the control stick with the ailerons in the neutral position
Set the ailerons to the neutral position: a straightedge held under the wing must touch the front and back of
the wing and the back of the aileron as shown arrowed in the photo above.
The control stick should be centred left to right at this position.
Adjust the aileron cable lengths as required to centre the control stick.
Check that all rod end jam nuts are tight and mark each with TorqueSeal.
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Check the aileron deflections
Place the aileron deflection template on top of the wing and set the aileron to the full UP travel deflection as
shown in the photo above (note the 3 arrowed points where the template touches) and then check and adjust
the stop bolt on the aileron bellcrank so that the bolt just touches the eccentric stop at full deflection.
The eccentric stop that you fitted in the Post-Paint>Fuselage>Interior>Fit console controls task can be
rotated if required to give an equal length to the stop bolts.
Repeat the process for the other aileron, tighten the stop bolt locknuts and mark each with TorqueSeal.
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Elevator
Check the elevator travel
Use the supplied deflection templates to check the up and down travel of the elevator.
DOWN elevator template
Hold the control stick all the way forward (have someone help you) and check the amount of down
deflection and adjust the cable length (by screwing the rod ends in or out an equal amount at each end of the
cable) until the down deflection is correct.
UP elevator template
Now have your helper hold full back stick and check the amount of up deflection: it should be very close to
correct if the down deflection is OK, however you may need to make some fine adjustments to equalise
elevator travel until both up and down deflections are correct.
The elevator must clear the rudder and the down stop by 2mm at full deflection.
Recheck the up and down deflections and then lock the rod end lock nuts at each end of the cable and mark
each rod end lock nut with TorqueSeal.
This completes the Testing>Rigging check task.
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Testing>Calibrate fuel gauges

To calibrate the fuel gauges so that they show the amount of fuel remaining correctly and to mark a fuel
dipstick at the same time.
In this task you will be working with flammable fuel and you should take precautions such as having a
suitable fuel extinguisher close to hand and no naked lights of any kind nearby.
In the task Post-Paint>Wings>Prepare wings for fitting you set the empty indication of the fuel gauges,
now you must check the other indications: , , and full.
To do this you must have the following:
A fuel supply of at least 135 litres of clean aviation fuel (AVGAS)
An accurate means of measuring the fuel as it is dispensed
Clean, sealable fuel container(s) capable of holding around 135 litres

2 metres of fuel grade tubing and a 1 litre container
A length of clean wood or aluminium about 300mm long to use as a fuel dipstick
Some aircraft refuellers may allow you to use a part of their ramp area for this test provided that you
purchase your fuel from them. The calibration process should take less than an hour.
Level the aircraft
Park the aircraft on the level surface and chock the main wheels.
Use a spirit level to check the aircraft for level: laterally level across the bottom of door sills; longitudinally
level along the door sills. Pack under the wheels if and as required to level the aircraft. If the surface is
exactly level you can measure the distance from each wingtip to the ground as a final check of lateral level,
but the spirit level is the best reference.
The rest of this task depends on the aircraft remaining level throughout, so chock it carefully.
Find the zero fuel level
Remove the upper engine cowling.
Disconnect the fuel line in the engine bay at the firewall fitting and run a length of fuel line from the firewall
fitting, down and out of the lower cowling and into a clean fuel container.
Turn the fuel tap on the console to the ON position, with the lever facing forwards.
Remove both fuel caps and pour a small amount of fuel into each wing tank. Allow the fuel levels to settle
until some fuel runs out into the container. When the fuel no longer runs out of the line the header tank will
be full and the wing tanks empty: this is your zero fuel level.
Lock off the fuel lines
Now that you are at the zero fuel level the fuel lines from each wing tank must be locked off be clamping
both the front and back fuel pickup lines. Remove the lock wire around the fuel sheathing at the rear of the
wing root to expose the fuel lines as they enter the cabin.
Clamping of the fuel lines must be done carefully so as not to stress the fuel line, so use a rounded surface
with no sharp edges to bear against the fuel lines and apply just enough clamp pressure to close the line, no
more. Medium size spring clamps will excerpt enough pressure to clamp the lines shut.
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Calibrate the fuel gauges
Fit the fuel gauge calibration decal around each wing tank gauge opening in the wing root with the Zero
indication on the decal placed against the fuel gauge needle at this point there is no usable fuel in either
wing tank.
The process now is to add 10 litres of fuel at a time to each tank in turn and mark carefully what each gauge
needle indicates on each decal (use a pencil initially), and at the same time dip your fuel dipstick into each
tank and mark carefully where the fuel level is on the dipstick.
If you have installed an engine management EFIS please refer to the documentation supplied with the unit
for details of how to calibrate the equipment during this task.
If any fuel runs out of the temporary line from the firewall it indicates that there is not enough clamping
pressure on a fuel line, so check carefully for any dribbling when the first fuel is added to each wing tank
and make sure that it is corrected before proceeding.
Continue adding fuel in 10 litre increments until each tank is full, noting at each stage the gauge needle
position for each tank each and marking the appropriate end and side of the fuel dipstick. Each wing tank
will hold approximately 60 litres of fuel.
Once both tanks are full and each decal and each end of the dipstick have all been marked, remove the
clamps from the fuel lines and check very carefully for any sign of weeping or leaking from the part of the
fuel lines where the clamps were applied.
Any sign of a leak will require that the fuel be drained from both tanks (otherwise it will cross feed from the
full tank to the empty tank) and complete replacement of the leaking fuel line.
Note that fracturing of the fuel lines after clamping is a rare occurrence that is only likely to happen if the
fuel lines are very old, for example in a long-delayed build that has sat for many years. If this is the case we
strongly recommend that all fuel lines be replaced before flight if one fuel line is weak then the others are
very probably in a similar state.
Even if your fuel lines are new you must check each line carefully for leaks after clamping.
Once all of the fuel lines have been checked and there are no leaks the protective sheathing can be refitted
and lock wired back into place.
Flush all of the quick drains thoroughly drain at least 500ml of fuel out of each one, more if there is any
sign of dirt or debris: flush until the fuel runs clean from each drain.
Now you must drain all but 20 litres from each wing tank in preparation for test flying: use the temporary
line from the firewall fitting and let both tank drain down to the 20 litre mark you can use your new
calibrated fuel dipstick to check the fuel level.
If you are using ramp space at the refuellers you may wish to push the aircraft back out of the way for the
draining process, which can take some time. You may use the electric fuel pump to speed the draining
process up. Record the time taken to fill a 1-litre container both with and without the use of the electric fuel
pump and save the result for the Final inspection checklist.
Once the draining process is complete, reattach the fuel line from the carburettor to the firewall fitting and
tighten the hose clamp and then refit and lock wire the fireproof sheath.
Mark the fuel gauge decals in a permanent manner. Keep your calibrated fuel dipstick in a handy location
such as a door pocket and consider making a spare copy, just in case.
This completes the Testing>Calibrate fuel gauges task.
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Testing>Registration markings
To fit complying registration markings to the aircraft.
You will need to determine the requirements of the aviation authority in your own country.
In Australia either the Recreational Aircraft Association (RAA) for recreational registration or the Civil
Aviation Safety Authority (CASA) for general aviation registration controls the allocation of aviation
registration markings.
Registration markings should be made from vinyl by a specialist sign-writing company and applied by them,
usually under the left wing and on each side of the empennage.
The drawings above show the RAA requirements as an example.

This completes the Testing>Registration markings task.
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Testing>Final inspection checklist

This is the checklist that we use in the factory: it covers every part of the aircraft and it must be completed
before your first flight.
Time to complete properly: at least one full day, probably more. Do not rush these checks!
Aircraft Registration:
Jabiru Model:
Firewall forward components
Propeller: Jabiru / Sensenich
Propeller Size:
Propeller Serial No:
Propeller Bolts
1
Check torque (Jabiru prop 7 ft/lbs, Senenich prop 12ft/lbs)
Check tip tracking is accurate to < 2mm, adjust if required
TorqueSeal the propeller nuts
Visually check propeller for serviceability
Spinner
1
Spinner screws secure
Check that the spinner and spinner backing plate has been indexed
correctly and marked on the spinner and spinner flange
Visually check spinner tracking with the engine running
Engine
1 Engine Serial Number: ___________________
2
Engine mount bolts secure:

a) firewall
b) engine
Thrust washers in place and correct
Fuel hose secure:
a) bulkhead to fuel pump
b) fuel pump to carburettor
c) fuel lines all clamped and tied
d) fire sleeve covering clamps and lock wired in place
Breather hose from fuel pump: drain line routed correctly
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6
Drip tray under fuel pump: drain line routed correctly
Spark Plugs/Coil leads

1
Spark plugs are secure in cylinder heads
Spark plug leads are secure on spark plugs
Spark plug leads not rubbing (on air ducts, cylinder heads)
Terminal nuts are secure
CHT sender (12mm terminal) secure
Spark plug leads secure in distributor caps
16 gauge earth wire secure and clipped to each coil
Ram Air Ducts

1
Baffles in place
Cap screws secure through ducts to cylinder heads
Springs in place inboard side of ducts
Spring lock-wire correct and secure
Check alignment of rubber front lip with the top cowl
Air ducts not touching the underside of the top cowl or oil door hinge
Cooling tubes directed onto coils
Engine Oil
1
Oil level correct (capacity: 2200 = 2.3 litres, 3300 = 3.5 litres)
Sump plug tightened and lock wired
Oil filter secure (spin on filter, hand pressure only)
Oil cooler bracket secured to engine
Oil cooler secured to bracket
Oil cooler hose clamps secure x 4
Check oil hose routing
Fire sleeve secure and lock wired over hose clamps
Oil breather hose and oil bottle secure
Throttle cable
1
Cable lock nuts secure on both ends of cable
Cable end free in carburettor link
Split pins secure
2 x 5/16 washers between cable and carburettor link
Cable alignment correct with outer at both ends
Cable adjustment
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a) full throttle
b) idle
Choke Cable
1
Lock nuts secure both ends of cable
Split pin secure
Cable alignment correct with outer
Operational
Carburettor Heat Cable

1 Lock nuts secure both ends
Split pin secure
Cable alignment correct with outer
Operational
Cabin Heat Cable

1 Lock nuts secure both ends
Butterfly sealing in ON and OFF positions
Over-centre spring fitted properly and working
SCAT hoses routing nothing rubbing, etc
Scat Hoses
1
Hot air mixer box to carburettor

a) hose clamps secure
b) hose not bunched up under carburettor
c) cobra head fitted and aligned properly
d) smooth routing
NACA duct in cowl to hot air mixer box cold air inlet
b) smooth routing and secure
Heat shroud on muffler to hot air mixer box hot air inlet
b) smooth routing
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Nose leg and housing
1
Front tyre pressure checked: 34 psi
[Tyre Pressure] decal in place on spat above grommet
Nose wheel - ease of rotation
Nose leg lubricated and ease of rotation left to right
Assembly all bolts secure in nose leg
Housing bolts secure
Rod ends secure both sides
Safety hole in rod ends within limits
Jam nuts on rod ends secure
10 Air valve grommet in place
11 Spat retaining screws secure
12 Centring springs do not become coil bound full deflection
Electrical
1
Battery tie down secure
Battery terminals secure
Battery earth secure on firewall
Starter solenoid locknuts and wires secure
Regulator wires secure and correct
Temp sender wires secure (EOT and CHT) plus EGT if fitted
All wiring cable tied and secure
Oil pressure wire correct and secure (G terminal)
Cowls
1
Top and bottom cowl alignment correct (no gaps)
Retained nuts secure and correct
Oil door operational
Spinner not touching front of cowl and Propeller
Oil cooler not touching bottom cowling
Cylinder heads not touching top or bottom cowling
NACA duct secure with no sharp edges
Cam locks secure and operational
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Interior
Fuel system
1
Fuel filter secure and flow direction correct
Fuel pump (electronic) secure and flow direction correct
Fuel lines secure:

a) fuel pickups and breather lines from wing roots to header tank inlets
b) header tank outlet to fuel filter
c) fuel filter to electric fuel pump
d) electric fuel pump to fuel tap on console
e) fuel tap on console to bulkhead fitting
Fuel line sheathing in place and secure
Check fuel valve mounting and lever secure to console
Fuel Breather:
a) check breather hose clamps and breather route
b) wing breather tube to wing root secure
c) check ball in breather in wing tank cap is free
d) check fuel breather tube is secure to body fuel filler
e) fuel breather check has been conducted:
Note: you must be able to hear air in all outlets independently by:
i)
Removing filler cap in left wing and blow into tank
ii) Removing filler cap in right wing and blow into tank
Fuel gauges
LEFT
RIGHT
Window fitted in fuselage opposite wing roots
Calibration decal in place left and right
Wires connected to left and right senders
Left sender drives left gauge and vice versa
No leaks from sender boss
Fuel flow test
20 litres of fuel in each wing tank
Check fuel tap has been correctly indexed i.e. ON is on OFF is off
Select fuel tap on and measure the fuel flow (recorded in Calibrate fuel gauges task)
a) electric fuel pump OFF ____________ litres per minute
b) electric fuel pump ON ____________ litres per minute
There should be around 1 litre per minute flow with the electric fuel pump ON
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Controls
Rudder pedals
1
Rudder springs installed properly
Rudder stops lining up properly
2 x Pedal mount bolts secure (pushrod to pedals)
Rudder pedal keepers secure and correct
2 x and 4 x 3/16 bolts secure in bearing blocks
2 x bolts secure in pushrods (pushrod to nose leg yoke)
Check jam nuts on rod ends secure x 5
Check safety hole is within limits on rod ends x 5
Check rod end free play at full deflection, both directions
10 Rudder clear of fin channel. Rudder cannot bind on channel
Rudder cable
1
Anchor secure and correct position in clamp
Rod end secure in pedal with washer outside
Safety hole is within limits on rod ends
Jam nuts on rod ends secured
Rod end free play at full deflections, in both directions
Rudder pedal stops adjusted and secure:

rudder should move 98mm left and right from the 5mm offset centre mark
Trim
1
Trim levers (left and right) are secure
Lever pivot secure and split pin fitted through nut
Free play between left and right side levers not excessive
Friction correct and secure
Rod end secure
Cable position in clamp correct and anchor secure
Operation full forward and full back trim
10 Spring not coil bound with elevator fully deflected up

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11 Placard fitted to console top in correct sense
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Brake
1
Handle assembly correct and secure
Check safety hole within limits
Operation
Free play
Fluid level full
Stainless striker in place
Handbrake correct and operational
Throttle
1
Cable anchor secure
Cable alignment correct
Cable end free in output lever
Output lever secure
Input lever x 2 secure
Throttle lock hole in pilots input lever
Bearing blocks x 2 secure
Throttle stops correct and secure
Main control shaft

1
Control stick pivot secure
Yoke secure (no free play)
Rod end secure
Elevator cable anchor secure and correct position in clamp
Elevator cable clear of centre console in all positions

(particularly elevator UP and aileron to left hand side)
Rod end free at full deflections
Aileron bell crank lines up properly with stops and is not binding
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Aileron Cable
LEFT
RIGHT
Cable anchor wedges in place
R clips in place
Rivets x 3 TLR through each bracket and seat back
Rod end secure
6
7
Aileron stoppers secure x 2 (cannot over centre aileron bellcrank)
Seat belts
1 Check bolts are through Nyloc and buckle has free play
LEFT
RIGHT
Operation of buckle and length adjustments play
Belts not twisted play
Seat belt anchor secure (lower and upper) play
Door frame compression struts in place, no sharp edges
Headsets
1 Hook secure
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Instrument panel
1 Secure and level
Instruments square (check that the slip/skid ball is centred).
Slip/skid ball air bubble not visible
Circuit breakers secure and correctly labelled
Switches secure and correctly labelled
Registration number displayed on panel
Mag switch guard in place and square with rounded edges
All instruments fitted and operational *
Instrument markings correct
10 Altimeter QNH correct
11 All avionics installed and operational
12 Cigarette lighter / 12v power fitting installed
* Fit 1 metre of rolled up surgical tubing to the brass static tube connector under the panel.
Watch the pressure instruments while slowly unrolling the tubing. The altimeter should start to show an
increase in altitude. The vertical speed indicator should start to show a positive rate of climb and the
airspeed indicator may show a small positive indication.
When the altimeter shows 2000 feet pinch off the tubing. There will be some initial decrease in altitude and
the vertical speed indicator will read zero. The altimeter should then hold the indicated altitude for at least
one minute. If altitude is lost then look for leaks.
Note: NEVER apply suction orally or mechanically to a static line - it can damage the instruments.
Flaps
1
Mounting bolts secure
Rod end bolt secure: motor end and flap shaft ends
Rod end not binding in any position
Safety hole is within limits on rod end
Jam nut on rod end secured
Visual on input switch (knob shape, operation and decal)
Visual on bearing blocks
Check all nuts are in safety
Flap indicator
1
Secure and correct indication:

a) Flaps up
b) First stage: half flap
c) Second stage: full flap
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Upholstery:
1 Fitted and clean
Seat covers
Map pockets
Flap shaft upholstered
Centre console upholstered
Fuel line covers in place
Placards and decals:

1
[No Smoking] on panel
[No Intentional Spins] on panel
[Voltage must be displayed at all times] above EMS (if applicable)
[Transponder not calibrated] (if applicable)
Switches labelled (label above switch, [OFF] below switch)
[Aircraft built to LSA standards] decal beside main placard
Warning placard above windscreen. Weight entered
Baggage (Limit, loading rules, seat backs)
Loading stations
Doors:
1 Operation: open and shut, latches working
LEFT
RIGHT
Restraining straps secure and correct length
Hinge and pin secure
Catches secure and freely operating (main plus top latch)
Visual on door jamb
Visual on door seal
Visual on handle
Visual on top catch
Decals
a) [Do Not Lean On Door]
b) [Exit]
c) [Open]
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Exterior
Wings:
LEFT
RIGHT
Root bolts inspected (correct tension) x 2
Strut bolts x 2 inspected, correct tension
Warning decals in wing roots x 2 [Do Not Tighten]
Wing root cover strips secure
Upper strut fairing secure and clear of strut
Lower wing strut/belly fairings secure
Flaps
1
Hinge points secure with pivot bolts in safety
Pushrod rod ends secure and not binding in any position
Safety hole in rod ends is within limits
Pushrods not fouling on cover strips
Drive shaft output secure
Drain holes have been drilled
Flap operation:
a) flaps up
b) first stage half flap
c) second stage full flap, not fouling fuselage
Flap slot gap even, smooth and the same size on both wings
Fuel caps
1
Filler caps secure in fuel filler body
Earth wires secure from caps to breather fitting in tank
Quick drain: operation and lock wired
Decals in place and correct
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Ailerons
LEFT
RIGHT
a) Neutral (level with lower wing skin) with stick centred
b) UP
c) DOWN ________degrees
Hinge pins and pin retainers secure
Rod ends secure
Safety hole on rod ends within limits
Cable anchor secure and correct position in clamp
Drain holes
a) Wing drain hole in trailing edge
b) Aileron cable inspection windows secure
Deflections
________degrees, or touches template
Pitot
1
Secure
ASI operation (see * below)
Cover present
Pressure Test with no leaks (see * below)
* Slip 1 metre of surgical tubing over the pitot tube. Have one person watch the airspeed indicator while the
other person very slowly rolls up the tubing. This will apply pressure to the instrument in a gentle and
controllable manner. When the ASI needle reaches cruising speed pinch the tube shut the ASI should hold
that reading for at least one minute. A fast drop off will indicate a leak in the instrument, fitting, lines or the
test hose attachment.
Note: NEVER blow into a pitot tube it can damage the ASI.
Stall warning:
1
Stall warning horn secured in cabin
Operation correct (suck to ensure reed is working)
Gauze and lip installed correctly and clear
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Main Undercarriage
LEFT
RIGHT
Main gear legs secure
Stub axle secure
Hubs secure
Stub axle extension is secure
Calliper secure
Discs secure
Ease of rotation
Tyre pressure 45 psi
[Tyre Pressure] decal in place
10 Brake line not rubbing on spat
a) screws secure
b) clear of tyre
c) retain nuts
d) outer edge nothing rubs
e) air valve grommet in place
f) [No Step] decal in place
11 Spats
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Empennage
Elevator Deflections
UP
________ degrees, or touches the UP template
DOWN ________ degrees, or touches the DOWN template
2mm clearance to the stop on fuselage at full DOWN deflection
Elevator
1
Hinge pins and retainers secure
Rod ends secure
Safety in rod ends within limits
Drive plate secure
Rod end free play at full deflections
End-plug not touching end-cap full deflection down
Elevator min 2mm clear of stabiliser channel
10 Elevator cannot bind on horizontal stabiliser channel

Trim
1
Pivots secure
Spring rod
a) split pins secure
b) springs lubricated
c) black block secure and free
d) rod ends secure
e) safety hole within limit
f) jam nuts secure
g) rod end free at full deflections
Trim cable
a) cable anchor secure and correct position in clamp
b) rod ends secure
c) safety hole in rod ends within limits
d) jam nuts on rod ends secure
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e) rod end free at full deflections

Ventral Fin:
1
Retained nuts in fuselage secure
Elevator horn not hitting cut-out in ventral fin at full up deflection
Inspection holes drilled
Drain holes drilled out
Ventral fin secure onto fuselage
Rudder:
1
Centre 5mm offset to right when pedals level
Deflection
a) Left
the offset centre mark
_________mm from
b) Right
the offset centre mark
_________mm from
2mm clearance to the stops on fuselage at full deflection
Hinge pin and pin retainers secure
Rod end secure
Safety in rod end within limits
Jam nut on rod end secure
Rod end free at full deflections
Static Vent:
1
Tip secure
Holes clear
Decal in place
Note that leak testing of the static system has been performed as part of the instrument checklist.
I hereby certify that I have completed this Final Inspection Checklist:
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Owner / Builder / Engineer
Date
(strike out any that do not apply)
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Testing>Flight testing
To safely and successfully test fly the aircraft, record information resulting from the flight test sequence and
use that information to fine tune the flying characteristics of the aircraft.
Well, this is what it all comes down to: you have built your own Jabiru, you have painted it and assembled it
and checked and tested every part of it to your satisfaction and now it is time to finish the project and
actually fly the machine for the first time!
This is no small undertaking, and you must ask yourself if you are capable of performing the flight test on
your own, or, perhaps, if your experience level or recency is low, you may wish to hire a more experienced
pilot to conduct some or all of the flight testing for you.
This task will step you through each of the flight testing stages that we employ here in our factory testing
program, along with the appropriate forms to record the results of each stage.
The correct sequence for rectifying any out of rig conditions will be explained along the way.
Reference documentation
The Australian Civil Aviation Safety Authority (CASA) produces a Flight Test Guide for Certification of
CAO 101.28 Category Airplanes. This document is required to be completed as part of the approval
process for Australian-built aircraft.
In countries other than Australia, the amateur builder should seek advice from the appropriate Airworthiness
Authority and/or the relevant amateur building association (EAA Chapter or equivalent) as regards their
requirements.
In the USA the FAA publishes the Amateur-Built Aircraft and Ultralight Flight Testing Handbook
(publication AC90-89A), which addresses the topic in considerable detail and which may be obtained here:
www.faa.gov/library/manuals/
Sequence
This task will address the following steps:
Preliminary work
o Airport selection
o Emergency plans and equipment
o The test pilot
Sequence #1: Ground runs

o Engine parameters
o Taxi testing
Sequence #2: Initial flight and function testing

o First flight, rigging checks
o Rigging corrections
Sequence #3: Performance flight testing
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Airfield selection
Airfield selection will play a very important role in your testing and you should approach your choice of
airfield with considerable care. The nearest flat piece of land may not necessarily be the best or safest place
and you may have to consider transporting your new Jabiru by road to a suitable airfield for the flight testing
sequence.
The ideal airfield would be at or near sea level with a runway of at least 1000 metres length (for every 1000
feet increase in elevation add 200 metres to the length required) in an area that is relatively flat with few
obstructions near the airfield. Ideally there should not be many buildings surrounding the airfield and there
should be enough open space around the airfield to allow for the possibility of an out landing.
The test pilot should familiarise himself with the surrounding area from the air with particular regard to
suitable landing areas for emergency use before starting the testing sequence.
Emergency plans and equipment
Before any testing can begin you must have a plan in place to deal with emergency situations. You must
address what actions to take if it all goes badly and an accident happens and know the local emergency
telephone numbers.
A support crew of 2 suitably experienced people will be required to support the flight testing sequences and
assist the test pilot with refuelling and checking the aircraft.
The following details the bare minimum requirements, to which you may wish to add your own items:
The GROUND emergency plan
All crew (pilot and ground crew) should know how to:
Open the cabin doors
Release the pilots harness/seat belt
Locate and turn off the fuel valve
Locate and turn off the Master switch and the magneto switches
Remove the cowling and disconnect the battery for fire fighting purposes
The IN-FLIGHT emergency plan

The pilot will need to consider his response to the following:
Complete or partial engine failure, particularly shortly after takeoff
Flight control problems including severe out of rig conditions
Fire in the engine compartment or cockpit
Equipment
The pilot should carry a CO2 detector in the cockpit at all times during all flight testing.
The crew should have access to a dry powder fire extinguisher.
There should be 2-way radio communication between the pilot and the support crew at all times as well as
any radio communication required by local regulations. Most Jabiru aircraft will have a VHF radio installed,
and if the support crew have a hand-held VHF radio then a discreet frequency can be used to communicate
during the test flight sequence.
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The test pilot
Flight testing must only be carried out by a suitably qualified and experienced test pilot.
Test flying any newly built aircraft is risky. For example, minor changes to aircraft rigging can significantly
alter stall behaviour, leading to extreme wing drops or spinning. Test pilots must be aware of this and all
other potential risks and be suitably skilled to recover control of the aircraft from extreme and unusual
attitudes.
The Test Sequence in this task is based on the Test Schedule used by Jabiru Aircraft on factory-built models
and is supplied as reference material as a part of the construction data for this kit. Several of the manoeuvres
required by this schedule will result in extreme aircraft attitudes and carry an increased risk of spinning or
other undesirable aircraft behaviour.
Pilots choosing to follow the Jabiru Aircraft Test Sequence do so at their own risk.
Recency
In particular, the test pilot should have a recently demonstrated ability to:
Deal with an engine failure at low altitude (~200ft) after takeoff
Recover from stalls in level flight and in banked turns
Recover from a spin
Recover from unusual attitudes (including a spiral dive)
Carry out a flapless landing
Carry out a glide approach and landing
Medical considerations
The test pilot should be in good health and should abide by the following conditions:
Should not have a head cold or any current sinus problems
Have had no local or dental anaesthetics for at least 48 hours prior to test flying
Alcohol: an absolute minimum of 24 hours, preferably longer, must have elapsed between the last
consumption of alcohol and any test flying
Should not have donated blood for at least 3 weeks prior to test flying
Clothing
The test pilot should consider the possibility of an in-flight fire and dress accordingly:
Dress ONLY in natural fibres and do NOT wear any synthetic materials
Long pants and long sleeves no bare skin should be exposed
Nomex gloves for hand protection (most pilot supplies shops carry these)
Checklists
The test pilot should be completely familiar with the normal and emergency checklists in the Owners
Manual and should commit to memory the critical airspeeds that are specified in the Owners Manual.
It may be useful to write these speeds down and tape them to the instrument panel for ease of reference in
flight.
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Sequence #1 First start, ground run and taxi
Print and use the Flight Testing form Sequence #1 for this sequence.
Locate the aircraft on a suitable run-up area with no gravel or small stones in the area under the propeller,
point the nose of the aircraft into wind and chock the main wheels.
Pre start
Remove the upper cowling and set it aside. Remove the spark plugs, turn the Master switch ON and leave
both magneto switches OFF. Press the starter button and allow the engine to crank over. Watch the Engine
Oil Pressure (EOP) gauge for the first indication of oil pressure. Stop cranking once oil pressure is seen.
Refit the spark plugs and upper cowling.
Start
Turn both magneto switches ON and pull the choke ON. Turn the fuel tap ON, turn the fuel pump ON and
listen for its operation for 10 seconds. Turn the fuel pump OFF.
Press the starter button; listen for the click of the solenoid, and the winding of the starter motor. The engine
should start within a few revolutions, usually as soon as fuel reaches the carburettor. Listen for the sound of
the starter motor disengaging after engine start.
Watch the EOP and if it does not rise in the first 10 seconds after starting shut the engine down and call the
mechanic. The EOP range should be from 220 to 525 kPa.
Idle condition
The idle should be smooth and may be up to 1400 rpm with the choke on, and up to 900-950 rpm with the
choke off. Note that the requirement for choke will vary with OAT. Check the Engine Oil Temperature
(EOT), it should rise slowly and steadily to 50 60 C, and the Cylinder Head Temperature (CHT) should
rise to 85 105 C. The Exhaust Gas Temperature (EGT) gauge (if fitted) should read between 425 485
C.
Once the engine has warmed (EOT 50C or more) then you may proceed, but before you do the idle speed
must be adjusted correctly in accordance with the procedure in the next step.
Idle speed adjustment
Once the engine has been warmed to operating temperature then the idle speed must be adjusted before
proceeding. This idle speed adjustment procedure will require 2 people: one inside the cabin operating the
engine and one adjusting the idle stop on the carburettor.
Stop the engine by turning both Mag switches to the OFF position. If the engine will not stop it means that a
Mag earth wire is not correctly connected in this event stop the engine by turning the fuel tap OFF and
waiting until the engine stops. Connect the earth wire before
re-starting the engine.
Remove the upper cowling and set it aside. The Pilot side throttle input shaft has 2 alloy collars while the
Co-Pilot side has 1 collar. Loosen all 3 collars with an Allen key, working through the holes in each side of
the instrument panel housing. Start the engine and adjust the idle stop on the carburettor until the engine
idles at 900 rpm. Stay well clear of the propeller!
Adjust the collars on the input shafts so that when the engine is at idle the collars on each input shaft are just
touching the back of the input shaft pivot block. Lock each idle collar in place. With the engine turned OFF
push both input shafts to full throttle and adjust the Pilot side collar so that it is just touching the other side
of the pivot block and lock it in place.
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Re-test the idle and make any further adjustments required. Replace the upper cowling.
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Run up and full power check
Re-start the engine and smoothly increase the engine speed to 2000 rpm. Check that all temperatures and
pressures are in the green part of the range.
Check each magneto individually: the maximum permissible rpm drop is 200 rpm but it is typically much
less. If an rpm drop of more than 100 rpm occurs on either magneto, shut the engine down and call for the
mechanic.
Still at 2000 rpm apply carburettor heat: the maximum permissible rpm drop is 100 rpm but it is typically
much less. Check that all temperatures and pressures are still in the green.
Advance the throttle until it is fully open: the engine should not falter or surge during this operation. Record
the maximum sustained static speed (2975 3050 rpm); wait for 60 seconds and then record the EOP, EOT,
CHT and EGT (if fitted). Limit the full power segment of the ground run to less than 2 minutes total time.
Bring the engine smoothly back 1200 rpm for a minute or 2 and then back to idle.
Engine shutdown
Allow the engine to return to idle: the idle should be smooth at 900 rpm. Turn both magneto switches OFF
and the engine should stop smoothly.
Turn the Master switch OFF.
Remove the cowling and check for any leaks of oil or fuel. Correct as required before proceeding with the
testing sequence.
Taxi tests
Re-start the engine and taxi to the movement area or ramp with your headset off.
Listen for and note:
Airframe sounds
Electric fuel pump functioning
Suspension movement
Doors and windscreen structure movement
Wheel bearings and brakes
Tyres rubbing on the wheel spats (if fitted)
Steering: should steer positively
Approaching the movement area or ramp cut the engine.

Check that the aircraft rolls freely without brake drag. At a slow speed and without your feet on the rudder
pedals apply the brakes firmly, the brakes should pull straight and the aircraft should stop abruptly.
Any brake binding or wheel rubbing issues should be rectified before the first flight.
Restart the engine.
On the movement area or ramp check the turning circle (left and right turns). The radius of the left and right
turns should be the same.
Face into and taxi into wind. The aircraft should track straight with feet off the rudder pedals.
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Compass swing
While you are out in the run-up area and provided that the ground run has gone well, this would be a good
time for a compass swing before you start the actual test flying.
You will need assistance to turn the aircraft accurately onto headings and your ground crew can help you
with this. You'll need a small, brass, non-magnetic screwdriver and ideally an airport with a compass rose: a
compass rose is a pattern painted on the ground, which accurately depicts magnetic headings. If your local
airport doesnt have one you can make your own using the known magnetic orientation of the runways at an
airport or a known good hand held reference compass with an alignment sight.
Be careful with this approach though, just because a runway is marked "14" doesnt mean it is oriented at
140, it might actually be oriented 144 or 138. Check with your local airport operator to get the precise
orientation. A hand held reference compass is usually preferable.
Remove all metal objects from your person and the aircraft before you start and make sure that the selected
area has no nearby metal structures that could affect the magnetic compass.
For the test the aircraft should be configured as it would be for flight, with the engine running and all
avionics and Nav and strobe lights turned on. Try some test transmissions with your VHF comms to see if
transmissions affect the compass in any way.
Under the compass display window are 2 screws that are used to compensate for instrument errors, one for
North South adjustments and the other for East West adjustments.
Position the aircraft at a known North heading using a compass rose or a reference compass.
1. With the aircraft oriented North, the engine running, and all radios switched on, adjust the N-S
adjusting screw until the compass reads due North, or 0.
2. Rotate the aircraft to a known East heading, and use the E-W adjusting screw to make the compass
read due East, or 90.
3. Rotate the aircraft to a known South heading. Note how many degrees off South the compass reads.
Turn the N-S adjusting screw to remove one half of the error.
4. Rotate the aircraft to a known West heading. Note how many degrees off West the compass reads.
Adjust the E-W adjusting screw to remove one half of the error.
5. Rotate the aircraft through the N, E, S and W headings again, confirming that the errors for North
and South are the same, and the errors for East and West are the same.
You may want to repeat steps 1-4 to fine-tune the corrections.
6. Now rotate the aircraft from North, stopping at each 30 point on the compass rose or reference
compass (e.g., 030, 060, 090, 120, 150, 180, 210, 240, 270, 300, and 330 degrees) and make a note
of the actual aircraft compass reading compared to the compass rose or reference compass at each
point, then complete the compass calibration card that was packed with your compass, which you
should then mount in the holder on the front of the compass for reference.
If you cannot get a usable set of readings you will need to locate any sources of magnetic interference. Look
for steel screws, washers or other components near the compass. You should also experiment with aircraft
electrical systems (lights, for example), to see whether activation of that equipment causes the compass to
misbehave.
The compass should be re-swung after any significant changes to the panel or engine bay and at least once
every 2 years.
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Sequence #2 First flight and rigging tests
Pre-flight
Print and use the Flight Testing form Sequence #2 for each test flight in this sequence.
Recording
Use a kneeboard or clipboard to hold the Flight Test forms and record details of each test flight, however the
first priority must always be to fly the aircraft so write things down only when it is safe to do so.
Loading
Load the aircraft with the test pilot and 20 litres of fuel in each wing tank.
If you have followed the instructions in the Testing>Calibrate fuel gauges task you should already have 20
litres per side at this point, if not then drain or add fuel as required.
Engine Start and Run-up
Start the engine normally, taxi to the run-up area and perform an engine run-up.
Check temperatures and pressures and make sure that the idle is correct when the engine is warm it should
idle at around 900 rpm.
Pre-take off Checks
Record the date and engine hours as well as the wind direction and strength, the OAT, the Runway in use
and the Pressure Altitude. Set the altimeter back to the local QNH.
Check controls for full and free movement and correct sense see each control surface movement. Any
sense of controls binding must be addressed before proceeding.
Listen for traffic and wait for the traffic to clear for first flight. Carry out the pre-takeoff checks specified in
the Owners Manual.
Advise all traffic that a first flight is to be conducted.
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Flight testing
Takeoff and climb
Use the full length of the available runway, which should be into wind.
Apply full power in a positive manner over a count of 4.
Check engine rpm indication and ASI function on the roll and abort if either is incorrect.
Immediately after takeoff check instruments and LISTEN, FEEL and SMELL and if in any doubt abort and
land on the remaining runway, otherwise proceed.
Climb at full power at 80 KIAS while remaining over the airfield: remain within gliding distance of the
airfield at all times on the first flight: plan your climb carefully so that you are always within reach of the
field should the engine fail. This may require an initial turn at less than 500 ft AGL depending on the layout
of the airfield.
Monitor the engine gauges carefully while climbing and note any tendency towards overheating. If
temperatures get near to the top of the green range, increase airspeed to 90 KIAS to improve the cooling
airflow. If the temperatures are still too high, reduce power slightly. Be particularly alert when you reduce
the power for the first time.
At 3,000 ft above the airfield reduce the power to 2800 rpm, trim the aircraft for straight and level flight and
check the rigging of the aircraft.
Rigging tests
If the aircraft flies straight with the ball in the centre and the rudder pedals are level the rigging is correct.
There are 4 steps or tests that must be made:
1. If the aircraft flies straight with the ball in the centre but with the rudder pedals displaced then the
pushrods that connect the rudder pedals to the steering yoke need adjusting.
2. If the aircraft flies straight but requires pressure on one rudder pedal to keep the ball in the centre then the
rudder cable needs adjusting.
If the ball is centred and the rudder pedals are level but the aircraft tends to roll or turn then the flaps may
need adjustment. Check the stall before making any changes to the flaps.
Slow the aircraft to near the point of stall in a clean configuration at idle power with the ball centred and
note any tendency to roll just before the point of stall. If this happens then slow the aircraft to near the
point of stall in a clean configuration several more times and note which wing drops just before the point
of stall.
3. If the aircraft rolls just before the point of stall then the angle of incidence will need to be adjusted by
means of the eccentric wing root bushes that are supplied with your kit.
The correct installation procedure is explained later in this task.
4. If all flight up to the stall is wings level then the angle of incidence can be considered to be correct and
any roll corrections can be made by individual adjustment of the flaps.
Slow the aircraft to VFE, test the flaps at both half and full settings and then retract them.
Descent and landing
Descend to circuit height and conduct a normal approach and landing.
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During the landing roll check that the undercarriage does not have any unusual noises, that the aircraft is
easily controlled and that the brakes work evenly when applied.
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Rigging corrective actions
It is particularly important that any rigging problems are dealt with in the correct sequence.
Use the flowchart below to work your way through any rigging problems: it may be necessary to step
through the flowchart more than once, but the sequence is very important so work through each line one at a
time, making corrections as indicated and retesting each time until the rigging is correct.
No
Does the aircraft fly

straight and level
with the ball centred?
Yes
Are the rudder

pedals displaced?
Yes
Adjust the rudder

pedal pushrods
Adjust the rudder

cable length
Adjust the Angle

of Incidence
Adjust the
flaps individually
No
Is rudder pressure
needed to keep
the ball centred?
Yes
No
Is there any
tendency to roll
or turn?
No
Rigging is
correct
Yes
Does the aircraft

roll just before
the stall?
Yes
No
Retest the aircraft after each adjustment has been made and keep working through the flowchart from line #1
all the way to line #4 until you reach the Rigging is correct box at the bottom left of the chart.
The Flight Testing form Sequence #2 should be printed out and used to record information while in flight.
Print one form per test flight and retain each as a permanent record.
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1. Adjusting the Rudder Pedal Pushrods
If the rudder pedals are displaced fore and aft when the aircraft is in straight and level flight, adjust the
rudder pedal pushrods that connect the rudder pedals to the steering yoke until the pedals sit level. Retest
and adjust as required.
2. Adjusting the Rudder Cable
If pressure is required on one rudder pedal to keep the aircraft straight in straight and level flight: if pressure
is required on the right pedal then the rudder cable must be shortened, while if pressure is required on the
left pedal then the rudder cable must be lengthened.
To alter the length of the rudder cable the rod ends must be removed from the connecting bolts, the lock nuts
must be loosened and each rod end must be moved and equal amount, either in or out. Note that the rudder
pedal stops must be readjusted at the same time.
It is not possible to predict the amount of adjustment required as each case will be different, but as a general
guide try moving each rod end one full turn for a total of 2 full turns (1 at each end of the cable) and then
test fly that configuration to see if more or less adjustment is required. Take careful note of each change and
the effect on the flying qualities of the aircraft.
Care must be taken: the threaded end of the rudder cable must always be visible through the safety hole in
each rod end, the lock nuts must be tightened against each rod end and the Nyloc nuts on the connecting
bolts should be replaced before each test flight.
3. Adjusting the Angle of Incidence (AoI)
Use this procedure only if the aircraft repeatedly rolls towards the same wing just before the point of stall in
a clean configuration as explained earlier in this task. The wing that drops is stalling slightly ahead of the
other wing and it will need to have its angle of incidence reduced by a small amount. You will need to fit the
eccentric bushes to the wing that drops to decrease the Angle of Incidence by 0.4, which will entail placing
the offset hole in the front bush UP and the offset hole in the rear bush DOWN. This very small change will
be all that is required.
This procedure can be carried out without removing the wing from the aircraft.
Remove the wing root fairings. Chock the main wheels and support the outboard end of the wing. Remove
the nuts from the wing root bolts and then very carefully tap each bolt out: as each bolt is removed, replace it
with a length of stout wire of approximately 5mm thickness so that the wing root will not drop and damage
the fuel lines or the side of the fuselage. Note carefully the position of the flat washers for reassembly.
Now the front wire can be removed and the wing can be slightly lifted so that the front bush is raised above
the mounting lugs on the fuselage and the wing must then be held in this position by placing a bolt back
through the front wing lug on the fuselage so that the wing lug can sit on the bolt. Take your time and make
sure that the wing is unable to move or fall from this position by making sure that the outboard end of the
wing is firmly supported fore and aft as well as underneath.
Heat the front bush with a soldering iron and remove it completely from the lug and clean away all of the
flock from the bush mounting hole in the lug then tap the hole to 5/8 UNC in preparation for screwing in
the eccentric bush.
It is very important that the tap be exactly square on to the lug and not angled in any way.
It may be necessary to remove a small amount of material from the leading edge at the wing root to allow a
straight approach to the hole in the front lug when tapping the thread.
The wing root fairing will cover a small cutout here if it is required.
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Test fit the eccentric bush into the wing lug dry, using a gently tapered object such as an old round file
through the centre of the bush to screw the bush into the lug, ending when the bush is centred in the lug with
offset hole facing UP to test the threads. Remove the bush.
Mix a very small batch of resin and separate it into 2 portions and then use one portion to coat the thread in
the bush mounting hole in the wing lug and then coat the outside of the eccentric bush. Add flock to the
other portion and apply a small amount to the bush and then screw the bush back into the lug, ending when
the bush is centred in the lug with offset hole facing UP.
Wipe away all excess flock and lower the wing lug and bush back into the fuselage lugs and place the length
of wire through the holes in the lugs and the bush.
Repeat the process for the rear bush, first test fitting the bush dry and then fitting it with resin and flock, but
this time end with the offset hole in the bush facing DOWN.
Wipe away all excess flock and lower the wing lug and bush back into the fuselage lugs and hold in place
with the wire. Leave the flock overnight to cure.
The next day fit the wing bolt though the lugs and the new bush. Refit the flat washers to the bolts as before.
Remove the wire from the front bush and refit the wing bolt and flat washers.
Fit new Nyloc nuts to each wing bolt and tighten to safety. Do not reuse these nuts.
tightening may result in failure of the wing attach lugs.
Refit the wing root fairings. Retest the aircraft and, if required, make any small roll corrections by adjusting
each flap individually.
4. Adjusting the Flaps
Use this procedure if the aircraft shows a tendency to roll in straight and level flight and not just before the
point of stall in a clean configuration as mentioned in the previous step then minor adjustments may be made
to each flap individually.
If the aircraft rolls to the left then the left flap may be lowered slightly, or the right flap may be raised
slightly. If the aircraft rolls to the right then the right flap may be lowered slightly, or the left flap may be
raised slightly.
Remove the wing root fairings as required to gain access to the flap pushrods. Remove the rod end
connecting bolt from the drive yoke, loosen the lock nut and move the top rod end in or out and then refit the
rod end to the drive yoke, tighten the lock nut. Refit the wing root fairings before each test flight.
It is not possible to predict the amount of adjustment required as each case will be different, but as a general
guide try moving a rod end one full turn and then test fly that configuration to see if more or less adjustment
is required. Take careful note of each change and the effect on the flying qualities of the aircraft.
If, for example, down adjustment becomes a problem on one flap then adjust the other flap up. If it becomes
necessary to adjust the flap end of the pushrod, remove the flap to do so.
Care must be taken: the threaded end of the rod end must always be visible through the safety holes in each
end of the pushrod, the rod end lock nuts must be tightened against each end of the pushrod and the Nyloc
nut on the connecting bolt through the drive yoke should be replaced before each test flight.
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Sequence #3 Performance and handling
Print and use the Flight Testing form Sequence #3 for each test flight in this sequence.
If all of the rigging corrections in Sequence #2 have been done correctly and all equipment performs
correctly then this sequence will usually only require one flight.
Record the date and engine hours as well as the wind direction and strength, the OAT, the Runway in use
and the local QNH.
Loading rules
This Sequence is performed with either:
Pilot weighing 100 Kg or less and 100 litres of fuel; or
Pilot and 1 passenger for a combined weight of 172Kg or less and 50 litres of fuel.
Stalls
Climb at 80 KIAS using full power to 3000 feet AGL or higher, watching the engine instrumentation for any
tendency towards overheating. If temperatures get near to the top of the green range increase airspeed to 90
KIAS improve the cooling airflow, and if temperatures are still too high then reduce power as required.
Once established in a suitable test area, perhaps directly over the airfield, stall testing can start. During the
course of the stall testing it will be necessary to climb back to the starting altitude from time to time.
The stalls are performed in the configurations listed on page 1 of the Flight Testing form Sequence #3.
Each stall is started from 60 KIAS and the aircraft is decelerated at a constant rate of 1 knot per second until
the wing is fully stalled, which will require an increasing rearward rate of movement of the control stick.
Record the Indicated Airspeed (IAS) at which each stall occurs.
If anything out of the ordinary occurs during the stall testing phase record it in the Notes section at the end
of the form.
Trim Speed Range
In the cruise configuration (2800-2900 rpm) record the trim speeds achieved at the full aft and full forward
trim lever positions. Trim speed limitations are 50-65 KIAS in the aft trim position and 90-140 KIAS for the
forward trim position.
In the approach configuration (full flap, engine at idle: 1000-1200 rpm) record the trim speeds achieved at
the full aft and full forward trim lever positions. Trim speed limitations are: 60-70 KIAS in the aft trim
position, and then trim forward until the airspeed reaches the end of the white arc (VFE) on the ASI.
Glide at 62 KIAS
Retract the flaps, reduce the power to idle and trim the aircraft for a 62 KIAS glide.
Note the controllability and if the controls are rigged properly.
VNE
Descend under power, typically 2700-2900 rpm, and approach VNE in small speed increases. Note any
vibration or buffeting as well as the overall controllability of the aircraft.
Do not exceed VNE under any circumstances.
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Maximum Power Flight
Descend to 1000 feet AGL, set the altimeter subscale to 1013.2 hPa and record the Pressure Altitude and
OAT.
With the engine at wide open throttle and the aircraft in straight and level flight, record the indicated
airspeed and engine rpm and the EOP, EOT, CHT and EGT (if fitted).
Timed Climb
Set the aircraft up in the cruise configuration at 2800-2900 rpm. Record the Pressure Altitude, which will
also be the start height, and the OAT.
With the engine at wide open throttle and the aircraft trimmed to 80 KIAS, record the time taken to climb
1000 ft, the indicated rate of climb, the engine rpm and the EOP, EOT, CHT and EGT (if fitted).
Set the altimeter subscale back to the local QNH that you recorded before takeoff.
General
Record your observations of the following:
Lateral & Directional Control Rigging
Lateral & Directional Rigging and Trim
Lateral & Directional Stability and Control
Longitudinal Static Stability
Equipment
Test and record the operation and performance of the VHF comm(s), the transponder (if fitted), the GPS (if
fitted), all flight and engine instrumentation and any other fitted equipment such as strobe and Nav lighting
or UHF comm.
Ground handling during and after landing
When landing check that the undercarriage does not have any unusual noises, that the aircraft is easily
controlled on the runway and that the brakes work evenly when applied.
Post flight
Immediately after landing and securing the aircraft record your observations of the overall characteristics of
the aircraft and its systems as well as calculating the total engine hours and the fuel consumption rate.
When you are satisfied that the aircraft performs satisfactorily then this completes the Testing>Flight testing
task and signals the end of this Manual as well.
The future
Congratulations, you have achieved something that most people can only dream about: you have built and
flown your very own aircraft! This is a significant achievement and one that you can be justifiably proud of.
Well done!
Please drop us a line here at Jabiru and tell us all about it, we would love to know.
We are sure that you will have many enjoyable hours of flying your very own Jabiru aircraft and we are
equally sure that you will enjoy the low operating costs as well as the pleasurable flying characteristics that
all Jabirus share.
Issue:
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2015

Testing>Forms
Testing>Forms
This final task of the Constructors Manual contains a set of forms that are intended be used to record the
details of your new Jabiru aircraft and all of the flight testing sequences.
The first form, Aircraft Identification, should be used to record the serial numbers of all components: the kit
number, engine serial number, propeller details and all instrumentation.
The other forms should be used in conjunction with the preceding task Flight Testing.
Taken as a group these forms should be kept as a permanent record.
Abbreviations
Here is a listing of common abbreviations that are used throughout these forms:
AGL
Above Ground Level
AH
Artificial Horizon
ALT
Altimeter
CHT
Cylinder Head Temperature
EFIS
Electronic Flight Information System
EGT
Exhaust Gas Temperature
EMS
Engine Management System
EOP
Engine Oil Pressure
EOT
Engine Oil Temperature
ETC
Electric Turn Co-ordinator
GPS
Global Positioning System
IAS
Indicated Air Speed
ISA
International Standard Atmosphere: 1013.2 hPa, 15C
KIAS
Knots Indicated Air Speed
MAG
Magneto - engine ignition system
OAT
Outside Air Temperature
P. ALT
Pressure Altitude: the indicated ALT at ISA conditions
RPM
Revolutions Per Minute - engine speed
RWY
Runway
UHF
Ultra High Frequency - sometimes used for remote area comms
VHF
Very High Frequency - standard aircraft comms
VSI
Vertical Speed Indicator
Issue:
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2015

Testing>Forms
Aircraft Identification
Owner
Phone
Address
Mobile
Fax
Model
Registration
Kit #
Engine Serial number
Propeller: Jabiru / Sensenich
Size x Pitch
(Cross out one)
Serial Number
Flight instrumentation
Make/Serial number
Serial number
ASI
EFIS
/AH
ALT
VSI
GPS
ETC
Engine instrumentation
Jabiru #
Make/Serial number
EMS
Serial number
TACH
EOP
EOT
CHT
EGT
VOLT
Issue:
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Page: 372 of
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2015

Testing>Forms
Sequence #1 Ground run

WIND
Date
Engine hours start
OAT
Pilot
Run up - 2000 rpm

rpm drop
Engine parameters
(200rpm max)
Left MAG
EOP
CHT
Right MAG
EOT
EGT
All in the green range
Carb Heat
Full power check

Engine parameters
Maximum sustained rpm

2975 3050 rpm
EOP
CHT
EOT
EGT
Restrict the full power run to less than 2

minutes total time
Idle check
Engine parameters
Idle rpm
800 - 900 rpm
Allow the engine to run at 1200 rpm for

2 minutes and then check the idle
Taxi tests
EOP
CHT
EOT
EGT
Notes
Brakes both pull evenly

and release with no drag
Steering: tracks straight
into wind with feet off
Steering: left and right
turns are equal radius
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Testing>Forms
Sequence #2 Rigging
Date
WIND
Engine hours start
OAT
P. ALT
RWY
Loading
1013.2 hPa
Full power climb at 80 KIAS
Pilot
Engine RPM
2900 3050 rpm
Pilot only, no PAX,

20 litres of fuel per side
No
Does the aircraft fly

straight and level
with the ball centred?
EOP
CHT
EOT
EGT
Yes
Are the rudder

pedals displaced?
LEFT
Yes
RIGHT
1
Which pedal is BACK?

No
Is rudder pressure
needed to keep
the ball centred?
LEFT
Yes
RIGHT
2
Which pedal?
No
Is there any
tendency to roll
or turn?
No
Yes
Does the aircraft

roll just before
the stall?
LEFT
Yes
RIGHT
3
Which way?
No
LEFT
Rigging is
correct
RIGHT
4
Which way?
Issue:
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Page: 374 of
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2015

Testing>Forms
Sequence #3 Performance & handling

page 1 of 3
Date
WIND
Engine hours start
OAT
QNH
RWY
Loading
Loading rules - either:
Pilot
Pilot < 100Kg only: 100 litres fuel; or

Pilot and 1 PAX to 172Kg total: 50 litres fuel
PAX
Stalls
All stalls are started from 3000 feet AGL or above, starting from 60 KIAS.
Airspeed is decreased at a constant rate of 1 knot per second until the aircraft is
fully stalled and the IAS at the point of stall is recorded below.
Straight Ahead: [40 50]
NO Flap
IDLE
power
30 Bank to LEFT
30 Bank to RIGHT
Straight Ahead
HALF Flap
30 Bank to LEFT
30 Bank to RIGHT
Straight Ahead
FULL Flap
30 Bank to LEFT
30 Bank to RIGHT
Straight Ahead: [38 45]
NO Flap
FULL
power
30 Bank to LEFT
30 Bank to RIGHT
Straight Ahead
HALF Flap
30 Bank to LEFT
30 Bank to RIGHT
Straight Ahead
FULL Flap
30 Bank to LEFT
30 Bank to RIGHT
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Page: 375 of
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2015

Testing>Forms
Sequence #3 Performance & handling

page 2 of 3
Trim test
Cruise power, clean
Idle, full flap
AFT [50-65 KIAS]
AFT [60-70 KIAS]
FWD [90-140 KIAS]
FWD [end of white arc]
Glide at 62 KIAS
Controllability
Control rigging
[1000-1200rpm]
Glide engine RPM
VNE 2700-2900 RPM

Vibration
Buffeting
Controllability
Control rigging
Full power, Straight & Level

P. ALT
IAS at full power
OAT
1013.2 hPa
RPM at full power
CHT
EOP
EGT
EOT
Timed climb at 80 KIAS

Start P. ALT
1013.2 hPa
Finish P. ALT
OAT
Time to climb 1000 ft
sec
CHT
EOP
Rate of climb (indicated)
fpm
EGT
EOT
General
Lateral & Directional
Control Rigging
Rigging
and while
Trim
This document
is controlled
it remains on the Jabiru server.
Issue:

Stability and Control
Longitudinal Static
Once this no longer applies itStability
becomes uncontrolled.
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Testing>Forms
Issue:
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Page: 377 of
37712 January
2015

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What are the major sections of the manual?

Jabiru

Jabiru J170 Constructors Manual

Monday, January 12, 2015

Jabiru J170 Constructors Manual

Rodney Stiff Managing Director

Monday, January 12, 2015

Jabiru J170 Constructors Manual

Which have been further Grouped by:

List of Effective Pages / Issue Status

Monday, January 12, 2015

Jabiru J170 Constructors Manual

Typographic errors fixed.

Monday, January 12, 2015

Jabiru J170 Constructors Manual

Monday, January 12, 2015

Jabiru J170 Constructors Manual

Monday, January 12, 2015

Jabiru J170 Constructors Manual

Monday, January 12, 2015

Jabiru J170 Constructors Manual

General>Tools and equipment

Disposable gloves: for handling of epoxy and resin.

Monday, January 12, 2015

Jabiru J170 Constructors Manual

Optional tools and equipment

Lock the jaws onto both

Monday, January 12, 2015

Jabiru J170 Constructors Manual

and pull back on the twist handle

Jabiru J170 Constructors Manual

Sealant, form-in-place gasket

Thread sealer medium strength

Thread retainer high strength

Cleaner (can use Acetone in place)

Clear solvent, aerosol applicator

Cold climate considerations

Monday, January 12, 2015

Jabiru J170 Constructors Manual

Monday, January 12, 2015

Jabiru J170 Constructors Manual

Quick setting brand name epoxy glue.

AT133 (not supplied)

Fibreglass cloth with wide unidirectional strands, which provides

This is a standard bi-directional cloth that is used extensively for

A 2 wide glass tape.

This 3 wide glass tape is used to joint other glass structures.

Body Filler (bog)

Lightweight automotive filler used in paint preparation.

Patented reusable fasteners used to align parts prior to flocking and

Lightweight core material used to make sandwich panels.

Low-grade short fibre reinforcement for resin. Also used as a verb: to

White polyester resin film used on exterior of supplied fibreglass parts

Fibreglass cloth. Also describes the process of wetting fibreglass cloth

Recessed step where 2 surfaces are to be flush joined.

Resin wetted fibreglass cloth laid into a mould or onto parts.