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Jabiru J450 Constructors Manual

Other manuals for J450: Technical Manual, Technical Manual
Manual is about: Jabiru J450 Model aircraft Constructors Manual

Summary of J450

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    Jabiru j450 constructors manual from kit/serial number 659.

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    Jabiru j450 constructors manual general>introduction tuesday, april 6, 2010 2 of 343 general>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 unt...

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    Jabiru j450 constructors manual general>constructors manual tuesday, april 6, 2010 3 of 343 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 thi...

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    Jabiru j450 constructors manual general>constructors manual tuesday, april 6, 2010 4 of 343 table of contents general general>introduction ................................................................................................................2 general>constructors manual ......................

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    Jabiru j450 constructors manual general>constructors manual tuesday, april 6, 2010 5 of 343 pre-paint>fuselage>interior>console>fit control stick......................................................... 125 pre-paint>fuselage>interior>fit rudder pedal mount blocks ......................................

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    Jabiru j450 constructors manual general>constructors manual tuesday, april 6, 2010 6 of 343 post-paint>fuselage>fit rudder, elevator and elevator trim ................................................... 262 post-paint>fuselage>fit doors ..................................................................

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    Jabiru j450 constructors manual general>constructors manual tuesday, april 6, 2010 7 of 343 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 pilot‟s point of view, where the pilot is a...

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    Jabiru j450 constructors manual general>tools and equipment tuesday, april 6, 2010 8 of 343 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 foll...

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    Jabiru j450 constructors manual general>tools and equipment tuesday, april 6, 2010 9 of 343 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 y...

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    Jabiru j450 constructors manual general>tools and equipment tuesday, april 6, 2010 10 of 343 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). O...

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    Jabiru j450 constructors manual general>glossary tuesday, april 6, 2010 11 of 343 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 wid...

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    Jabiru j450 constructors manual general>registration and certification tuesday, april 6, 2010 12 of 343 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 est...

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    Jabiru j450 constructors manual general>unpacking and support tuesday, april 6, 2010 13 of 343 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 s...

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    Jabiru j450 constructors manual general>composite standard procedures tuesday, april 6, 2010 14 of 343 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 straight...

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    Jabiru j450 constructors manual general>composite standard procedures tuesday, april 6, 2010 15 of 343 epoxy measuring and mixing quality assurance and record keeping in australia the saaa require that a wet and dry bulb thermometer is kept in the room where the lay-ups are done. A further requireme...

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    Jabiru j450 constructors manual general>composite standard procedures tuesday, april 6, 2010 16 of 343 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...

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    Jabiru j450 constructors manual general>aircraft grade bolts and lock nuts tuesday, april 6, 2010 17 of 343 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 ...

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    Jabiru j450 constructors manual general>aircraft grade bolts and lock nuts tuesday, april 6, 2010 18 of 343 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 t...

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    Jabiru j450 constructors manual general>rod ends tuesday, april 6, 2010 19 of 343 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 a...

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    Jabiru j450 constructors manual general>health and safety tuesday, april 6, 2010 20 of 343 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...

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    Jabiru j450 constructors manual pre-paint>fuselage>underbody penetrations tuesday, april 6, 2010 21 of 343 pre-paint>fuselage>underbody penetrations objectives of this task: to turn the fuselage upside down, make all the required penetrations and fit the fairings. Materials required: epoxy resin and...

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    Jabiru j450 constructors manual pre-paint>fuselage>underbody penetrations tuesday, april 6, 2010 22 of 343 firewall datum existing transponder (optional) 22mm fuel vent ½” fuel vents 2 at ½” header tank quick drain 1 1/8” 415m m 750m m 2240mm 2470mm 150mm m 1380mm pitot tube ½” centreline.

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    Jabiru j450 constructors manual pre-paint>fuselage>fit ventral fin and trim horn tuesday, april 6, 2010 23 of 343 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...

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    Jabiru j450 constructors manual pre-paint>fuselage>fit ventral fin and trim horn tuesday, april 6, 2010 24 of 343 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 ...

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    Jabiru j450 constructors manual pre-paint>fuselage>fit ventral fin and trim horn tuesday, april 6, 2010 25 of 343 finish the ventral fin 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 hard...

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    Jabiru j450 constructors manual pre-paint>fuselage>prepare the fuselage tuesday, april 6, 2010 26 of 343 pre-paint>fuselage>prepare the fuselage objectives of this task: once the underbody penetrations and fit ventral fin and trim horn tasks have been completed the fuselage can be turned upright and...

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    Jabiru j450 constructors manual pre-paint>fuselage>prepare the fuselage tuesday, april 6, 2010 27 of 343 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 edge...

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    Jabiru j450 constructors manual pre-paint>fuselage>prepare the fuselage tuesday, april 6, 2010 28 of 343 upper fuselage penetrations 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 ...

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    Jabiru j450 constructors manual pre-paint>fuselage>prepare the fuselage tuesday, april 6, 2010 29 of 343 fuel line conduit, rear bulkhead: the fuel lines will be routed from the upper cabin conduits, though a sheath that will connect to the rear bulkhead conduits and down to the fuel header tank. Th...

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    Jabiru j450 constructors manual pre-paint>fuselage>prepare the fuselage tuesday, april 6, 2010 30 of 343 rudder cable slot in console at the left-hand front of the console there is an access slot for the rudder cable. The actual rudder cable slot needs to be marked directly below that slot but close...

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    Jabiru j450 constructors manual pre-paint>fuselage>prepare the fuselage tuesday, april 6, 2010 31 of 343 cut the fuel header tank opening mark and cut an opening in the rear cabin step to access the area beneath, which is where the fuel header tank, fuel pump and fuel filter will be fitted. To make ...

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    Jabiru j450 constructors manual pre-paint>fuselage>undercarriage>assemble main wheels tuesday, april 6, 2010 32 of 343 pre-paint>fuselage>undercarriage>assemble main wheels objectives of this task: in this task you will assemble the main wheels and tyres and fit the brake discs. Materials required: ...

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    Jabiru j450 constructors manual pre-paint>fuselage>undercarriage>assemble main wheels tuesday, april 6, 2010 33 of 343 this completes the pre-paint>fuselage>undercarriage>assemble main wheels task..

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    Jabiru j450 constructors manual pre-paint>fuselage>undercarriage>assemble main gear tuesday, april 6, 2010 34 of 343 pre-paint>fuselage>undercarriage>assemble main gear objectives of this task: in this task you will assemble the main undercarriage legs, which includes fitting the axles, disc brakes ...

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    Jabiru j450 constructors manual pre-paint>fuselage>undercarriage>assemble main gear tuesday, april 6, 2010 35 of 343 assemble the brake pads fit the brake pads to the backing plates: there are 2 types of backing plates – flat and u channel. Both types use same pads, but the shorter rivets are used o...

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    Jabiru j450 constructors manual pre-paint>fuselage>undercarriage>assemble main gear tuesday, april 6, 2010 36 of 343 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 a...

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    Jabiru j450 constructors manual pre-paint>fuselage>undercarriage>assemble main gear tuesday, april 6, 2010 37 of 343.

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    Jabiru j450 constructors manual pre-paint>fuselage>undercarriage>assemble main gear tuesday, april 6, 2010 38 of 343 assemble the brake and wheel firstly and very importantly place the alloy washer (#6a028b0d on the „main wheels‟ card) on the stub axle with the tapered inner side towards the gear le...

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    Jabiru j450 constructors manual pre-paint>fuselage>undercarriage>assemble main gear tuesday, april 6, 2010 39 of 343 adjust the brakes the objective is to have a wheel that will turn freely while at the same time not having the brake pads too far away from the disc. In order to achieve this it may b...

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    Jabiru j450 constructors manual pre-paint>fuselage>undercarriage>fit main gear tuesday, april 6, 2010 40 of 343 pre-paint>fuselage>undercarriage>fit main gear objectives of this task: in this task you will permanently fit the main undercarriage to the fuselage. Both main gear legs will be fitted to ...

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    Jabiru j450 constructors manual pre-paint>fuselage>undercarriage>fit main gear tuesday, april 6, 2010 41 of 343 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...

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    Jabiru j450 constructors manual pre-paint>fuselage>undercarriage>fit main gear tuesday, april 6, 2010 42 of 343.

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    Jabiru j450 constructors manual pre-paint>fuselage>undercarriage>fit main gear tuesday, april 6, 2010 43 of 343 fit the reinforcing plates cut 2 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...

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    Jabiru j450 constructors manual pre-paint>fuselage>firewall forward>fit firewall tuesday, april 6, 2010 44 of 343 pre-paint>fuselage>firewall forward>fit firewall objectives of this task: to fit the stainless steel firewall plate to the fuselage. This task will require accurate measuring and bending...

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    Jabiru j450 constructors manual pre-paint>fuselage>firewall forward>fit firewall tuesday, april 6, 2010 45 of 343 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 slig...

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    Jabiru j450 constructors manual pre-paint>fuselage>firewall forward>fit firewall tuesday, april 6, 2010 46 of 343 fit the firewall plate run a ¼” 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 easie...

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    Jabiru j450 constructors manual pre-paint>fuselage>firewall forward>fit firewall tuesday, april 6, 2010 47 of 343 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 plat...

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    Jabiru j450 constructors manual pre-paint>fuselage>firewall forward>firewall fittings tuesday, april 6, 2010 48 of 343 pre-paint>fuselage>firewall forward>firewall fittings general: this task requires the drilling of several holes through the stainless steel firewall. Stainless steel is hard, and th...

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    Jabiru j450 constructors manual pre-paint>fuselage>firewall forward>firewall fittings tuesday, april 6, 2010 49 of 343 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 ca...

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    Jabiru j450 constructors manual pre-paint>fuselage>firewall forward>firewall fittings tuesday, april 6, 2010 50 of 343 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 hea...

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    Jabiru j450 constructors manual pre-paint>fuselage>firewall forward>firewall fittings tuesday, april 6, 2010 51 of 343 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 plast...

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    Jabiru j450 constructors manual pre-paint>fuselage>firewall forward>firewall fittings tuesday, april 6, 2010 52 of 343 electrical components 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 th...

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    Jabiru j450 constructors manual pre-paint>fuselage>firewall forward>firewall fittings tuesday, april 6, 2010 53 of 343 air box outlet tube 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 ...

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    Jabiru j450 constructors manual pre-paint>fuselage>firewall forward>assemble and fit nose gear tuesday, april 6, 2010 54 of 343 pre-paint>fuselage>firewall forward>assemble and fit nose gear objectives of this task: to assemble and fit the nose gear including the front wheel to the stage where the a...

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    Jabiru j450 constructors manual pre-paint>fuselage>firewall forward>assemble and fit nose gear tuesday, april 6, 2010 55 of 343 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 so that the rebound rubber and the machined washer can ...

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    Jabiru j450 constructors manual pre-paint>fuselage>firewall forward>assemble and fit nose gear tuesday, april 6, 2010 56 of 343.

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    Jabiru j450 constructors manual pre-paint>fuselage>firewall forward>assemble and fit nose gear tuesday, april 6, 2010 57 of 343.

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    Jabiru j450 constructors manual pre-paint>fuselage>firewall forward>assemble and fit nose gear tuesday, april 6, 2010 58 of 343 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...

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    Jabiru j450 constructors manual pre-paint>fuselage>firewall forward>assemble and fit nose gear tuesday, april 6, 2010 59 of 343 assemble the nose wheel press a bearing into each side of the hub until the bearing reaches the bottom of the machined hole – use a large socket or piece of heavy tube that...

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    Jabiru j450 constructors manual pre-paint>fuselage>firewall forward>assemble and fit nose gear tuesday, april 6, 2010 60 of 343 this completes the pre-paint>fuselage>firewall forward>assemble and fit nose gear task..

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    Jabiru j450 constructors manual pre-paint>fuselage>firewall forward>fit engine mount and engine tuesday, april 6, 2010 61 of 343 pre-paint>fuselage>firewall forward>fit engine mount and engine objectives of this task: in this task the engine mount will be fitted to the firewall at the top attach poi...

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    Jabiru j450 constructors manual pre-paint>fuselage>firewall forward>fit engine mount and engine tuesday, april 6, 2010 62 of 343 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 ne...

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    Jabiru j450 constructors manual pre-paint>fuselage>firewall forward>fit engine mount and engine tuesday, april 6, 2010 63 of 343.

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    Jabiru j450 constructors manual pre-paint>fuselage>firewall forward>fit engine mount and engine tuesday, april 6, 2010 64 of 343 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 co...

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    Jabiru j450 constructors manual pre-paint>fuselage>firewall forward>fit propeller flange extension tuesday, april 6, 2010 65 of 343 pre-paint>fuselage>firewall forward>fit propeller flange extension objectives of this task: to remove the universal propeller flange that is shipped with the engine and...

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    Jabiru j450 constructors manual pre-paint>fuselage>firewall forward>fit propeller flange extension tuesday, april 6, 2010 66 of 343 clean and prepare the screws and hub clean the cap screw threads with a wire brush – make sure that there is no residual loctite in the threads. Clean all threads with ...

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    Jabiru j450 constructors manual pre-paint>fuselage>firewall forward>fit oil cooler tuesday, april 6, 2010 67 of 343 pre-paint>fuselage>firewall forward>fit oil cooler objectives of this task: in this task the oil cooler will be fitted to the base of the sump, the oil filter adapter will be fitted un...

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    Jabiru j450 constructors manual pre-paint>fuselage>firewall forward>fit oil cooler tuesday, april 6, 2010 68 of 343.

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    Jabiru j450 constructors manual pre-paint>fuselage>firewall forward>fit oil cooler tuesday, april 6, 2010 69 of 343 fit the oil lines fit the 2 brass male fittings to the inlet and outlet of the cooler as shown above– apply a smear of pipe sealing compound to the threads and tighten firmly into the ...

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    Jabiru j450 constructors manual pre-paint>fuselage>firewall forward>fit oil cooler tuesday, april 6, 2010 70 of 343 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. ...

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    Jabiru j450 constructors manual pre-paint>fuselage>firewall forward>fit oil cooler tuesday, april 6, 2010 71 of 343 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 rig...

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    Jabiru j450 constructors manual pre-paint>fuselage>firewall forward>fit oil cooler tuesday, april 6, 2010 72 of 343 plastic moulded oil bottle mounting. The oil overflow bottle, plastic moulded type, as shown in the photo on the right, is mounted to the firewall with a saddle clamp on the lower outl...

  • Page 73

    Jabiru j450 constructors manual pre-paint>fuselage>firewall forward>fuel pump fittings tuesday, april 6, 2010 73 of 343 pre-paint>fuselage>firewall forward>fuel pump fittings objectives of this task: in this task the drip tray will be prepared and fitted to the fuel pump and then the fuel lines will...

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    Jabiru j450 constructors manual pre-paint>fuselage>firewall forward>fuel pump fittings tuesday, april 6, 2010 74 of 343 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 car...

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    Jabiru j450 constructors manual pre-paint>fuselage>firewall forward>fit ram air cooling ducts tuesday, april 6, 2010 75 of 343 pre-paint>fuselage>firewall forward>fit ram air cooling ducts objectives of this task: in this task the ram air cooling ducts will be assembled and fitted to the engine. The...

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    Jabiru j450 constructors manual pre-paint>fuselage>firewall forward>fit ram air cooling ducts tuesday, april 6, 2010 76 of 343 test fit the ducts fitting the ducts will require adjustments to be made in several areas: firstly the oil lines to the rockers will need to be accommodated, then the rear b...

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    Jabiru j450 constructors manual pre-paint>fuselage>firewall forward>fit ram air cooling ducts tuesday, april 6, 2010 77 of 343 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...

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    Jabiru j450 constructors manual pre-paint>fuselage>firewall forward>fit ram air cooling ducts tuesday, april 6, 2010 78 of 343 fit the magneto coil cooling tubes starting with the left-hand duct, drill a ½” hole at the top centre rear of the duct and slip the 90° curved aluminium tube into place. Ai...

  • Page 79

    Jabiru j450 constructors manual pre-paint>fuselage>fit windscreen tuesday, april 6, 2010 79 of 343 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 i...

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    Jabiru j450 constructors manual pre-paint>fuselage>fit windscreen tuesday, april 6, 2010 80 of 343 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” ...

  • Page 81

    Jabiru j450 constructors manual pre-paint>fuselage>fit windscreen tuesday, april 6, 2010 81 of 343 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 winds...

  • Page 82

    Jabiru j450 constructors manual pre-paint>fuselage>fit control cables and lines tuesday, april 6, 2010 82 of 343 pre-paint>fuselage>fit control cables and lines objectives of this task: the rudder, elevator, elevator trim cables, static line and vhf antenna cable, along with any electrical wiring, w...

  • Page 83

    Jabiru j450 constructors manual pre-paint>fuselage>fit control cables and lines tuesday, april 6, 2010 83 of 343 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 elevator cable from the rear while ho...

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    Jabiru j450 constructors manual pre-paint>fuselage>fit control cables and lines tuesday, april 6, 2010 84 of 343 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...

  • Page 85

    Jabiru j450 constructors manual pre-paint>fuselage>empennage>fit vertical tail fin tuesday, april 6, 2010 85 of 343 pre-paint>fuselage>empennage>fit vertical tail fin objectives of this task: to fit the vertical tail fin to the fuselage, including fitting the static probe, static tube, optional stro...

  • Page 86

    Jabiru j450 constructors manual pre-paint>fuselage>empennage>fit vertical tail fin tuesday, april 6, 2010 86 of 343 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 ...

  • Page 87

    Jabiru j450 constructors manual pre-paint>fuselage>empennage>fit vertical tail fin tuesday, april 6, 2010 87 of 343 test fit the vertical fin fit a 6g self-tapping screw to each side rear of the fuselage stub at the bottom of the joggle – the intention here is to prevent the back of the fin from bei...

  • Page 88

    Jabiru j450 constructors manual pre-paint>fuselage>empennage>fit vertical tail fin tuesday, april 6, 2010 88 of 343 final fit the vertical fin you will need 2 other people to help you position and final fit the vertical fin. This step takes around 2½ hours in our factory with experienced personnel, ...

  • Page 89

    Jabiru j450 constructors manual pre-paint>fuselage>empennage>fit vertical tail fin tuesday, april 6, 2010 89 of 343 reinforce the fuselage to vertical fin join this step involves laying up 3 layers of glass fibre cloth to each side of the join. If you are doing the laying up alone then do each side ...

  • Page 90

    Jabiru j450 constructors manual pre-paint>fuselage>empennage>fit vertical tail fin tuesday, april 6, 2010 90 of 343 reinforce the fin spar coat the foam wedge that you cut previously with resin and fit it into place at the base of the fin spar channel, with the bottom resting on the horizontal stabi...

  • Page 91

    Jabiru j450 constructors manual pre-paint>fuselage>empennage>fit vertical tail fin tuesday, april 6, 2010 91 of 343 clamp the join wax one side of each of 2 lengths of aluminium angle so that the flock will not stick and place along the full length each side of the join line and secure with a clamp ...

  • Page 92

    Jabiru j450 constructors manual pre-paint>fuselage>empennage>fit vertical tail fin tuesday, april 6, 2010 92 of 343 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 shrin...

  • Page 93

    Jabiru j450 constructors manual pre-paint>fuselage>empennage>fit vertical tail fin tuesday, april 6, 2010 93 of 343 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. Ta...

  • Page 94

    Jabiru j450 constructors manual pre-paint>fuselage>empennage>fit elevator tuesday, april 6, 2010 94 of 343 pre-paint>fuselage>empennage>fit elevator objectives of this task: to fit the elevator to the horizontal stabiliser, to fit the trim tabs to the elevator and the end caps to the elevator and th...

  • Page 95

    Jabiru j450 constructors manual pre-paint>fuselage>empennage>fit elevator tuesday, april 6, 2010 95 of 343.

  • Page 96

    Jabiru j450 constructors manual pre-paint>fuselage>empennage>fit elevator tuesday, april 6, 2010 96 of 343 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...

  • Page 97

    Jabiru j450 constructors manual pre-paint>fuselage>empennage>fit elevator tuesday, april 6, 2010 97 of 343 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 knife to trim out some of the fo...

  • Page 98

    Jabiru j450 constructors manual pre-paint>fuselage>empennage>fit horizontal stabiliser tuesday, april 6, 2010 98 of 343 pre-paint>fuselage>empennage>fit horizontal stabiliser objectives of this task: to fit the horizontal stabiliser to the fuselage and glass it in place. Note that the elevator hinge...

  • Page 99

    Jabiru j450 constructors manual pre-paint>fuselage>empennage>fit horizontal stabiliser tuesday, april 6, 2010 99 of 343 fit the stabiliser there are 2 types of horizontal stabilisers, as the installation differs, first determine which one you have by locating the part identification sticker in the r...

  • Page 100

    Jabiru j450 constructors manual pre-paint>fuselage>empennage>fit horizontal stabiliser tuesday, april 6, 2010 100 of 343 mix a batch of resin and divide into 2 parts. 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 s...

  • Page 101

    Jabiru j450 constructors manual pre-paint>fuselage>empennage>fit horizontal stabiliser tuesday, april 6, 2010 101 of 343 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 an...

  • Page 102

    Jabiru j450 constructors manual pre-paint>fuselage>empennage>fit horizontal stabiliser tuesday, april 6, 2010 102 of 343 glass the stabiliser start by lightly sanding all surfaces, then mix a batch of resin and coat the surfaces where the glass fibre cloth will be placed. Then lay a 100 x 700mm stri...

  • Page 103

    Jabiru j450 constructors manual pre-paint>fuselage>empennage>fit rudder tuesday, april 6, 2010 103 of 343 pre-paint>fuselage>empennage>fit rudder objectives of this task: to fit the rudder to the vertical fin, align the rudder and fit the rudder stops and rudder cable. Materials required: card # j3 ...

  • Page 104

    Jabiru j450 constructors manual pre-paint>fuselage>empennage>fit rudder tuesday, april 6, 2010 104 of 343 remove the rudder and set it aside while the hinges are fitted to the tail fin. Hold a hinge in position and drill the top hole only and temporarily fit the hinge in place with a rivet as shown ...

  • Page 105

    Jabiru j450 constructors manual pre-paint>fuselage>empennage>fit rudder tuesday, april 6, 2010 105 of 343.

  • Page 106

    Jabiru j450 constructors manual pre-paint>fuselage>empennage>fit rudder tuesday, april 6, 2010 106 of 343 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. Li...

  • Page 107

    Jabiru j450 constructors manual pre-paint>fuselage>empennage>fit rudder tuesday, april 6, 2010 107 of 343 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 ...

  • Page 108

    Jabiru j450 constructors manual pre-paint>fuselage>fit cowling tuesday, april 6, 2010 108 of 343 pre-paint>fuselage>fit cowling objectives of this task: 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 an...

  • Page 109

    Jabiru j450 constructors manual pre-paint>fuselage>fit cowling tuesday, april 6, 2010 109 of 343 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. In the factory we have a handy technique that we use to mark the cut: ...

  • Page 110

    Jabiru j450 constructors manual pre-paint>fuselage>fit cowling tuesday, april 6, 2010 110 of 343 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 positio...

  • Page 111

    Jabiru j450 constructors manual pre-paint>fuselage>fit cowling tuesday, april 6, 2010 111 of 343 pre-fit the cowl hinges 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 bot...

  • Page 112

    Jabiru j450 constructors manual pre-paint>fuselage>fit cowling tuesday, april 6, 2010 112 of 343 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 aceton...

  • Page 113

    Jabiru j450 constructors manual pre-paint>fuselage>fit cowling tuesday, april 6, 2010 113 of 343 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 ins...

  • Page 114

    Jabiru j450 constructors manual pre-paint>fuselage>fit cowling tuesday, april 6, 2010 114 of 343 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 fittin...

  • Page 115

    Jabiru j450 constructors manual pre-paint>fuselage>fit cowling tuesday, april 6, 2010 115 of 343 fit the cabin air inlet flange drill 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. Sand the back of the f...

  • Page 116

    Jabiru j450 constructors manual pre-paint>fuselage>fit flap drive shaft bearing blocks tuesday, april 6, 2010 116 of 343 pre-paint>fuselage>fit flap drive shaft bearing blocks objectives of this task: in this task you will position and flock the flap drive shaft bearing blocks to the inside of the f...

  • Page 117

    Jabiru j450 constructors manual pre-paint>fuselage>fit flap drive shaft bearing blocks tuesday, april 6, 2010 117 of 343 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 r...

  • Page 118

    Jabiru j450 constructors manual pre-paint>fuselage>interior>console>pre-fit handbrake tuesday, april 6, 2010 118 of 343 pre-paint>fuselage>interior>console>pre-fit handbrake objectives of this task: to pre-fit the handbrake master cylinder and lever to the centre console. At the completion of this t...

  • Page 119

    Jabiru j450 constructors manual pre-paint>fuselage>interior>console>pre-fit handbrake tuesday, april 6, 2010 119 of 343.

  • Page 120

    Jabiru j450 constructors manual pre-paint>fuselage>interior>console>pre-fit handbrake tuesday, april 6, 2010 120 of 343 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 ...

  • Page 121

    Jabiru j450 constructors manual pre-paint>fuselage>interior>console>pre-fit trim control tuesday, april 6, 2010 121 of 343 pre-paint>fuselage>interior>console>pre-fit trim control objectives of this task: to pre-fit the trim pivot assembly, trim stops and the dual trim levers to the centre console a...

  • Page 122

    Jabiru j450 constructors manual pre-paint>fuselage>interior>console>pre-fit trim control tuesday, april 6, 2010 122 of 343 trim pivot and trim levers: 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 bushe...

  • Page 123

    Jabiru j450 constructors manual pre-paint>fuselage>interior>console>pre-fit trim control tuesday, april 6, 2010 123 of 343 align and fit the trim stops 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 le...

  • Page 124

    Jabiru j450 constructors manual pre-paint>fuselage>interior>console>pre-fit trim control tuesday, april 6, 2010 124 of 343 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 bendi...

  • Page 125

    Jabiru j450 constructors manual pre-paint>fuselage>interior>console>fit control stick tuesday, april 6, 2010 125 of 343 pre-paint>fuselage>interior>console>fit control stick objectives of this task: in this task you will fit the elevator cable to the console and then align and fit the two control co...

  • Page 126

    Jabiru j450 constructors manual pre-paint>fuselage>interior>console>fit control stick tuesday, april 6, 2010 126 of 343.

  • Page 127

    Jabiru j450 constructors manual pre-paint>fuselage>interior>console>fit control stick tuesday, april 6, 2010 127 of 343 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 t...

  • Page 128

    Jabiru j450 constructors manual pre-paint>fuselage>interior>console>fit control stick tuesday, april 6, 2010 128 of 343 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...

  • Page 129

    Jabiru j450 constructors manual pre-paint>fuselage>interior>fit rudder pedal mount blocks tuesday, april 6, 2010 129 of 343 pre-paint>fuselage>interior>fit rudder pedal mount blocks objectives of this task: in this optional task the lower rudder pedal mounting blocks will be checked for vertical ali...

  • Page 130

    Jabiru j450 constructors manual pre-paint>fuselage>interior>fit rudder pedal mount blocks tuesday, april 6, 2010 130 of 343 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 ...

  • Page 131

    Jabiru j450 constructors manual pre-paint>fuselage>interior>fit aileron cable brackets tuesday, april 6, 2010 131 of 343 pre-paint>fuselage>interior>fit aileron cable brackets objectives of this task: in this task the aileron cable brackets will be positioned and mounted to the seat backs. Positioni...

  • Page 132

    Jabiru j450 constructors manual pre-paint>fuselage>interior>fit aileron cable brackets tuesday, april 6, 2010 132 of 343 aileron cable bracket positioning template.

  • Page 133

    Jabiru j450 constructors manual pre-paint>fuselage>interior>fit aileron cable brackets tuesday, april 6, 2010 133 of 343 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 a...

  • Page 134

    Jabiru j450 constructors manual pre-paint>fuselage>interior>fit aileron cable brackets tuesday, april 6, 2010 134 of 343 trim the seat backs for aileron cable clearance 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 ...

  • Page 135

    Jabiru j450 constructors manual pre-paint>fuselage>interior>fit aileron cable brackets tuesday, april 6, 2010 135 of 343 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...

  • Page 136

    Jabiru j450 constructors manual pre-paint>fuselage>interior>fuel system tuesday, april 6, 2010 136 of 343 pre-paint>fuselage>interior>fuel system objectives of this task: to fit the parts of the fuel system from the header tank to the firewall fitting. Note that the fuel lines from the wing tanks to...

  • Page 137

    Jabiru j450 constructors manual pre-paint>fuselage>interior>fuel system tuesday, april 6, 2010 137 of 343.

  • Page 138

    Jabiru j450 constructors manual pre-paint>fuselage>interior>fuel system tuesday, april 6, 2010 138 of 343 fit the fuel pump mount the electric fuel pump to the fuselage on the right of the longitudinal rib as shown on the drawing on the previous page, using countersunk screws and tinnerman washers a...

  • Page 139

    Jabiru j450 constructors manual pre-paint>fuselage>interior>fuel system tuesday, april 6, 2010 139 of 343 fit the fuel tap and main fuel line remove the lever from the fuel tap and set it aside. Mark a position on the left-hand side of the centre console 50mm in front of the base of the armrest and ...

  • Page 140

    Jabiru j450 constructors manual pre-paint>fuselage>interior>fuel system tuesday, april 6, 2010 140 of 343 final check at this stage you should have connected the fuel filter, the electric fuel pump, the fuel tap in the console and the black fuel hose (which is now trimmed to length for the firewall ...

  • Page 141

    Jabiru j450 constructors manual pre-paint>fuselage>interior>fit seatbelt anchors tuesday, april 6, 2010 141 of 343 pre-paint>fuselage>interior>fit seatbelt anchors objectives of this task: this task shows how to fit the seatbelt anchors. While this is quite a simple task it is also an extremely impo...

  • Page 142

    Jabiru j450 constructors manual pre-paint>fuselage>interior>fit seatbelt anchors tuesday, april 6, 2010 142 of 343 top anchor brackets: front seat the top anchor brackets mount behind the whalebone with the centre of the bracket precisely level with the bottom of the upper door compression gusset. M...

  • Page 143

    Jabiru j450 constructors manual pre-paint>fuselage>interior>fit seatbelt anchors tuesday, april 6, 2010 143 of 343 rear seat anchor brackets fit the rear seat anchor brackets (all circled in yellow above) in the locations shown above. The outer bottom brackets are mounted 100mm above the seat bottom...

  • Page 144

    Jabiru j450 constructors manual pre-paint>fuselage>interior>fit rear seat tuesday, april 6, 2010 144 of 343 pre-paint>fuselage>interior>fit rear seat objectives of this task: in this task you will fit the bottom and back of the rear seat into place and fill the cavity under the seat bottom with expa...

  • Page 145

    Jabiru j450 constructors manual pre-paint>fuselage>interior>fit rear seat tuesday, april 6, 2010 145 of 343 next day drill 4 x ½” holes just behind the front lip of the seat bottom, 2 on each side, and fill the entire cavity with expandable foam, using about half of the can per side and aiming the s...

  • Page 146

    Jabiru j450 constructors manual pre-paint>fuselage>pre-fit doors tuesday, april 6, 2010 146 of 343 pre-paint>fuselage>pre-fit doors objectives of this task: in this task you will size and pre-fit the doors to the fuselage then pre-fit the door jamb, all of which will be finally fitted after the fuse...

  • Page 147

    Jabiru j450 constructors manual pre-paint>fuselage>pre-fit doors tuesday, april 6, 2010 147 of 343 fit the striker plate place the striker plate onto the latch pin on the door with the rounded corners facing into the cabin as shown at right, then close the door until the rear of the door is flush wi...

  • Page 148

    Jabiru j450 constructors manual pre-paint>fuselage>pre-fit doors tuesday, april 6, 2010 148 of 343 fit the top latch there is a curved section at the top front of each door for the top latch. Measure in 25mm from inside the door skin and drill a pilot hole and then a ¾” hole down through the door fr...

  • Page 149

    Jabiru j450 constructors manual pre-paint>fuselage>pre-fit doors tuesday, april 6, 2010 149 of 343 fit the key lock remove the bottom section of the door jamb and set aside for the moment. Mark a position 30mm out from the rear of the opening and 130mm up from the bottom of the opening and drill a p...

  • Page 150

    Jabiru j450 constructors manual pre-paint>fuselage>fit windows tuesday, april 6, 2010 150 of 343 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...

  • Page 151

    Jabiru j450 constructors manual pre-paint>fuselage>fit windows tuesday, april 6, 2010 151 of 343 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 anythi...

  • Page 152

    Jabiru j450 constructors manual pre-paint>fuselage>wheel alignment tuesday, april 6, 2010 152 of 343 pre-paint>fuselage>wheel alignment objectives of this task: to ensure that the main wheels are correctly aligned. Overview: some aircraft have reported shuddering through the undercarriage and airfra...

  • Page 153

    Jabiru j450 constructors manual pre-paint>fuselage>wheel alignment tuesday, april 6, 2010 153 of 343 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...

  • Page 154

    Jabiru j450 constructors manual pre-paint>fuselage>pre-fit wheel spats tuesday, april 6, 2010 154 of 343 pre-paint>fuselage>pre-fit wheel spats objectives of this task: 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 d...

  • Page 155

    Jabiru j450 constructors manual pre-paint>fuselage>pre-fit wheel spats tuesday, april 6, 2010 155 of 343 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 no...

  • Page 156

    Jabiru j450 constructors manual pre-paint>fuselage>pre-fit wheel spats tuesday, april 6, 2010 156 of 343 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. Suppor...

  • Page 157

    Jabiru j450 constructors manual pre-paint>wings>general tuesday, april 6, 2010 157 of 343 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, t...

  • Page 158

    Jabiru j450 constructors manual pre-paint>wings>fit fuel tank filler body tuesday, april 6, 2010 158 of 343 pre-paint>wings>fit fuel tank filler body objectives of this task: in this task the fuel tank filler body location will be determined for each wing, a hole will be drilled into the upper wing ...

  • Page 159

    Jabiru j450 constructors manual pre-paint>wings>fit fuel tank filler body tuesday, april 6, 2010 159 of 343 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 ...

  • Page 160

    Jabiru j450 constructors manual pre-paint>wings>fit fuel tank filler body tuesday, april 6, 2010 160 of 343 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 th...

  • Page 161

    Jabiru j450 constructors manual pre-paint>wings>fit fuel tank filler body tuesday, april 6, 2010 161 of 343 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 remo...

  • Page 162

    Jabiru j450 constructors manual pre-paint>wings>prepare wing root tuesday, april 6, 2010 162 of 343 pre-paint>wings>prepare wing root objectives of this task: to fit all of the fuel and breather fittings in the wing root and trim the flap arm cutouts. Materials required: card # j11 “fuel components”...

  • Page 163

    Jabiru j450 constructors manual pre-paint>wings>prepare wing root tuesday, april 6, 2010 163 of 343 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 tak...

  • Page 164

    Jabiru j450 constructors manual pre-paint>wings>prepare wing root tuesday, april 6, 2010 164 of 343 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 fil...

  • Page 165

    Jabiru j450 constructors manual pre-paint>wings>prepare wing root tuesday, april 6, 2010 165 of 343 cut out the flap arm recess you will need to cut out the marked flap arm recess in the top of the wing root: check that the line is 27mm from the wing root and re-mark if required. Care is needed arou...

  • Page 166

    Jabiru j450 constructors manual pre-paint>wings>cut aileron cable openings tuesday, april 6, 2010 166 of 343 pre-paint>wings>cut aileron cable openings objectives of this task: check the position of the wing rib near the aileron cable inspection openings and then check, mark and cut the aileron cabl...

  • Page 167

    Jabiru j450 constructors manual pre-paint>wings>cut aileron cable openings tuesday, april 6, 2010 167 of 343.

  • Page 168

    Jabiru j450 constructors manual pre-paint>wings>cut aileron cable openings tuesday, april 6, 2010 168 of 343 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 ...

  • Page 169

    Jabiru j450 constructors manual pre-paint>wings>fit quick drain sumps tuesday, april 6, 2010 169 of 343 pre-paint>wings>fit quick drain sumps objectives of this task: 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 re...

  • Page 170

    Jabiru j450 constructors manual pre-paint>wings>fit quick drain sumps tuesday, april 6, 2010 170 of 343 fit the quick drain sump body clean away any dust then sand and test fit the quick drain body. Note that the fuel tank may be deeper in the wing and the drain body could be recessed more than the ...

  • Page 171

    Jabiru j450 constructors manual pre-paint>wings>mount flaps tuesday, april 6, 2010 171 of 343 pre-paint>wings>mount flaps objectives of this task: in this task each 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 r...

  • Page 172

    Jabiru j450 constructors manual pre-paint>wings>mount flaps tuesday, april 6, 2010 172 of 343 position the flap the flap is positioned in 3 stages: initial flap position: lay 2 lengths of aluminium angle on the wing surface between the outer peel cloth squares and fix to the forward part of the wing...

  • Page 173

    Jabiru j450 constructors manual pre-paint>wings>mount flaps tuesday, april 6, 2010 173 of 343 flap to wing spacing: tape 6 pairs of mixing sticks together. Place 1 pair into each end of the gap between the flap and the wing (green arrow above right) and 1 pair under the aluminium angle on each side ...

  • Page 174

    Jabiru j450 constructors manual pre-paint>wings>mount flaps tuesday, april 6, 2010 174 of 343 take your time and get each flap exactly right: effort applied at this stage will be repaid in flying pleasure later. When the angle shaping is finished use a straightedge to do a final check of the rear of...

  • Page 175

    Jabiru j450 constructors manual pre-paint>wings>mount flaps tuesday, april 6, 2010 175 of 343 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 fa...

  • Page 176

    Jabiru j450 constructors manual pre-paint>wings>mount flaps tuesday, april 6, 2010 176 of 343 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 p...

  • Page 177

    Jabiru j450 constructors manual pre-paint>wings>mount flaps tuesday, april 6, 2010 177 of 343 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 tr...

  • Page 178

    Jabiru j450 constructors manual pre-paint>wings>fit wing tips tuesday, april 6, 2010 178 of 343 pre-paint>wings>fit wing tips materials required: epoxy resin and flock 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 ...

  • Page 179

    Jabiru j450 constructors manual pre-paint>wings>fit wing tips tuesday, april 6, 2010 179 of 343 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...

  • Page 180

    Jabiru j450 constructors manual pre-paint>wings>fit ailerons tuesday, april 6, 2010 180 of 343 pre-paint>wings>fit ailerons objectives of this task: 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 ai...

  • Page 181

    Jabiru j450 constructors manual pre-paint>wings>fit ailerons tuesday, april 6, 2010 181 of 343 prepare and fit the pre-mould strip turn the wing upside down and wedge the wing so that the top surface is level and solid. Remove the peel cloth from the pre-mould strip (front of the flat part and both ...

  • Page 182

    Jabiru j450 constructors manual pre-paint>wings>fit ailerons tuesday, april 6, 2010 182 of 343 fit the pre-mould strip into place – position carefully slightly above the final location and then press gently forwards and then down into place. Wipe away any excess flock. Place the tape-covered board o...

  • Page 183

    Jabiru j450 constructors manual pre-paint>wings>fit ailerons tuesday, april 6, 2010 183 of 343 check and cut the aileron recess next day turn the wing right side up. Lay the aileron on top of the wing and align the rear edge of the aileron with the rear edge of the flap and the rear edge of the wing...

  • Page 184

    Jabiru j450 constructors manual pre-paint>wings>fit ailerons tuesday, april 6, 2010 184 of 343 place the aileron hinges in those locations with the flat side of each hinge facing upwards and the hinge pin aligned in the centre of the ~1mm gap between the aileron and the wing. Do not place the hinge ...

  • Page 185

    Jabiru j450 constructors manual pre-paint>wings>fit ailerons tuesday, april 6, 2010 185 of 343 fit the hinge gussets turn the wing right side up for this final step. The hinge gussets provide strength and prevent flexing of the pre-mould strip around the aileron hinges. Each hinge will have a gusset...

  • Page 186

    Jabiru j450 constructors manual pre-paint>wings>fit pitot tube to strut tuesday, april 6, 2010 186 of 343 pre-paint>wings>fit pitot tube to strut objectives of this task: 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 t...

  • Page 187

    Jabiru j450 constructors manual pre-paint>wings>fit pitot tube to strut tuesday, april 6, 2010 187 of 343 this completes the pre-paint>wings>fit pitot tube to strut task..

  • Page 188

    Jabiru j450 constructors manual pre-paint>wings>fit vibration damper to strut tuesday, april 6, 2010 188 of 343 pre-paint>wings>fit vibration damper to strut objectives of this task: to fit the vibration damper strips to the rear underside of both struts prior to painting. Materials required: vibrat...

  • Page 189

    Jabiru j450 constructors manual pre-paint>wings>fit vibration damper to strut tuesday, april 6, 2010 189 of 343 this completes the pre-paint>wings>fit vibration damper to strut task..

  • Page 190

    Jabiru j450 constructors manual pre-paint>wings>test fit wings tuesday, april 6, 2010 190 of 343 pre-paint>wings>test fit wings objectives of this task: 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...

  • Page 191

    Jabiru j450 constructors manual pre-paint>wings>test fit wings tuesday, april 6, 2010 191 of 343 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 fi...

  • Page 192

    Jabiru j450 constructors manual pre-paint>wings>test fit wings tuesday, april 6, 2010 192 of 343 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 ...

  • Page 193

    Jabiru j450 constructors manual pre-paint>wings>test fit wings tuesday, april 6, 2010 193 of 343 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 ...

  • Page 194

    Jabiru j450 constructors manual pre-paint>wings>test fit wings tuesday, april 6, 2010 194 of 343 pre-fit the strut/main gear to fuselage fairing 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 th...

  • Page 195

    Jabiru j450 constructors manual paint>general tuesday, april 6, 2010 195 of 343 paint>general objectives of this task: 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 ...

  • Page 196

    Jabiru j450 constructors manual paint>general tuesday, april 6, 2010 196 of 343 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...

  • Page 197

    Jabiru j450 constructors manual paint>masking tuesday, april 6, 2010 197 of 343 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 lin...

  • Page 198

    Jabiru j450 constructors manual paint>surface preparation tuesday, april 6, 2010 198 of 343 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 preparati...

  • Page 199

    Jabiru j450 constructors manual paint>topcoat tuesday, april 6, 2010 199 of 343 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 the...

  • Page 200

    Jabiru j450 constructors manual post-paint>general tuesday, april 6, 2010 200 of 343 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 a...

  • Page 201

    Jabiru j450 constructors manual post-paint>fuselage>fit panel mounted throttle tuesday, april 6, 2010 201 of 343 post-paint>fuselage>fit panel mounted throttle objectives of this task: to fit the panel mounted throttle linkage to the instrument panel housing. Materials required: resin and flock card...

  • Page 202

    Jabiru j450 constructors manual post-paint>fuselage>fit panel mounted throttle tuesday, april 6, 2010 202 of 343 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...

  • Page 203

    Jabiru j450 constructors manual post-paint>fuselage>fit panel mounted throttle tuesday, april 6, 2010 203 of 343 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...

  • Page 204

    Jabiru j450 constructors manual post-paint>fuselage>assemble instrument panel tuesday, april 6, 2010 204 of 343 post-paint>fuselage>assemble instrument panel objectives of this task: to fit all instruments into the instrument panel, fit all of the electrical wiring and terminate to multi-pin connect...

  • Page 205

    Jabiru j450 constructors manual post-paint>fuselage>assemble instrument panel tuesday, april 6, 2010 205 of 343 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 transpo...

  • Page 206

    Jabiru j450 constructors manual post-paint>fuselage>assemble instrument panel tuesday, april 6, 2010 206 of 343 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 r...

  • Page 207

    Jabiru j450 constructors manual post-paint>fuselage>assemble instrument panel tuesday, april 6, 2010 207 of 343 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...

  • Page 208

    Jabiru j450 constructors manual post-paint>fuselage>assemble instrument panel tuesday, april 6, 2010 208 of 343 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 countersin...

  • Page 209

    Jabiru j450 constructors manual post-paint>fuselage>assemble instrument panel tuesday, april 6, 2010 209 of 343 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...

  • Page 210

    Jabiru j450 constructors manual post-paint>fuselage>assemble instrument panel tuesday, april 6, 2010 210 of 343 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...

  • Page 211

    Jabiru j450 constructors manual post-paint>fuselage>assemble instrument panel tuesday, april 6, 2010 211 of 343 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...

  • Page 212

    Jabiru j450 constructors manual post-paint>fuselage>assemble instrument panel tuesday, april 6, 2010 212 of 343 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...

  • Page 213

    Jabiru j450 constructors manual post-paint>fuselage>assemble instrument panel tuesday, april 6, 2010 213 of 343 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 unwire...

  • Page 214

    Jabiru j450 constructors manual post-paint>fuselage>assemble instrument panel tuesday, april 6, 2010 214 of 343 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 spad...

  • Page 215

    Jabiru j450 constructors manual post-paint>fuselage>assemble instrument panel tuesday, april 6, 2010 215 of 343 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 plu...

  • Page 216

    Jabiru j450 constructors manual post-paint>fuselage>electrical wiring diagrams tuesday, april 6, 2010 216 of 343 post-paint>fuselage>electrical wiring diagrams.

  • Page 217

    Jabiru j450 constructors manual post-paint>fuselage>electrical wiring diagrams tuesday, april 6, 2010 217 of 343.

  • Page 218

    Jabiru j450 constructors manual post-paint>fuselage>electrical wiring diagrams tuesday, april 6, 2010 218 of 343.

  • Page 219

    Jabiru j450 constructors manual post-paint>fuselage>electrical wiring diagrams tuesday, april 6, 2010 219 of 343.

  • Page 220

    Jabiru j450 constructors manual post-paint>fuselage>electrical wiring diagrams tuesday, april 6, 2010 220 of 343.

  • Page 221

    Jabiru j450 constructors manual post-paint>fuselage>electrical wiring diagrams tuesday, april 6, 2010 221 of 343 this completes the post-paint>fuselage>electrical wiring diagrams task..

  • Page 222

    Jabiru j450 constructors manual post-paint>fuselage>interior>fit upholstery 1 tuesday, april 6, 2010 222 of 343 post-paint>fuselage>interior>fit upholstery 1 objectives of this task: to fit all of the stage 1 upholstery into the aircraft. This task assumes that you will be using the jabiru upholster...

  • Page 223

    Jabiru j450 constructors manual post-paint>fuselage>interior>fit upholstery 1 tuesday, april 6, 2010 223 of 343 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 ...

  • Page 224

    Jabiru j450 constructors manual post-paint>fuselage>interior>fit upholstery 1 tuesday, april 6, 2010 224 of 343 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/...

  • Page 225

    Jabiru j450 constructors manual post-paint>fuselage>install electrical wiring tuesday, april 6, 2010 225 of 343 post-paint>fuselage>install electrical wiring objectives of this task: to install all of the electrical wiring in the aircraft and connect to the multi-pin plugs. Each wire will need to be...

  • Page 226

    Jabiru j450 constructors manual post-paint>fuselage>install electrical wiring tuesday, april 6, 2010 226 of 343 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 ca...

  • Page 227

    Jabiru j450 constructors manual post-paint>fuselage>install electrical wiring tuesday, april 6, 2010 227 of 343 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...

  • Page 228

    Jabiru j450 constructors manual post-paint>fuselage>install electrical wiring tuesday, april 6, 2010 228 of 343 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 fo...

  • Page 229

    Jabiru j450 constructors manual post-paint>fuselage>install electrical wiring tuesday, april 6, 2010 229 of 343 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 ...

  • Page 230

    Jabiru j450 constructors manual post-paint>fuselage>install electrical wiring tuesday, april 6, 2010 230 of 343 wire the starter solenoid route the short heavy orange cable from the positive side of the battery to the front post of the starter solenoid. Fit an 8mm yellow ring terminal and a red heat...

  • Page 231

    Jabiru j450 constructors manual post-paint>fuselage>install electrical wiring tuesday, april 6, 2010 231 of 343 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 wir...

  • Page 232

    Jabiru j450 constructors manual post-paint>fuselage>install electrical wiring tuesday, april 6, 2010 232 of 343 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 ...

  • Page 233

    Jabiru j450 constructors manual post-paint>fuselage>install electrical wiring tuesday, april 6, 2010 233 of 343 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 pillar...

  • Page 234

    Jabiru j450 constructors manual post-paint>fuselage>install electrical wiring tuesday, april 6, 2010 234 of 343 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 ...

  • Page 235

    Jabiru j450 constructors manual post-paint>fuselage>install electrical wiring tuesday, april 6, 2010 235 of 343 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 heads...

  • Page 236

    Jabiru j450 constructors manual post-paint>fuselage>install electrical wiring tuesday, april 6, 2010 236 of 343 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>fuse...

  • Page 237

    Jabiru j450 constructors manual post-paint>fuselage>interior>fit console controls tuesday, april 6, 2010 237 of 343 post-paint>fuselage>interior>fit console controls objectives of this task: to fit all of the console controls: the control stick, elevator trim and brake system. Materials required: ca...

  • Page 238

    Jabiru j450 constructors manual post-paint>fuselage>interior>fit console controls tuesday, april 6, 2010 238 of 343.

  • Page 239

    Jabiru j450 constructors manual post-paint>fuselage>interior>fit console controls tuesday, april 6, 2010 239 of 343 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 be...

  • Page 240

    Jabiru j450 constructors manual post-paint>fuselage>interior>fit console controls tuesday, april 6, 2010 240 of 343.

  • Page 241

    Jabiru j450 constructors manual post-paint>fuselage>interior>fit console controls tuesday, april 6, 2010 241 of 343 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 t...

  • Page 242

    Jabiru j450 constructors manual post-paint>fuselage>interior>controls>fit rudder pedals tuesday, april 6, 2010 242 of 343 post-paint>fuselage>interior>controls>fit rudder pedals objectives of this task: to fit the rudder pedals and steering links to the aircraft, and fit the rudder cable to the rudd...

  • Page 243

    Jabiru j450 constructors manual post-paint>fuselage>interior>controls>fit rudder pedals tuesday, april 6, 2010 243 of 343 assemble and fit the steering yoke trim off the small moulding lip from around the hole in the rubber bush with a sharp knife if required before fitting. Press the rubber bush in...

  • Page 244

    Jabiru j450 constructors manual post-paint>fuselage>interior>controls>fit rudder pedals tuesday, april 6, 2010 244 of 343 fit the steering pushrods assemble the pushrods: thread a rod end with a plain nut to each end of each pushrod. Do not tighten the nuts until the pushrod lengths have been adjust...

  • Page 245

    Jabiru j450 constructors manual post-paint>fuselage>interior>controls>fit rudder pedals tuesday, april 6, 2010 245 of 343 adjust the push rod lengths and connect the rudder pedals now the pushrods can be adjusted to length and connected to the rudder pedals. Set the nose wheel so that it is facing s...

  • Page 246

    Jabiru j450 constructors manual post-paint>fuselage>interior>controls>fit rudder pedals tuesday, april 6, 2010 246 of 343 connect the rudder cable 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 a...

  • Page 247

    Jabiru j450 constructors manual post-paint>fuselage>interior>controls>fit rudder pedals tuesday, april 6, 2010 247 of 343 fit the centring springs the centring springs are attached to the top of the 2 centre rudder pedals with an3-11a bolts and bundy tube spacers and then anchored by chain links and...

  • Page 248

    Jabiru j450 constructors manual post-paint>fuselage>interior>controls>fit rudder pedals tuesday, april 6, 2010 248 of 343 this completes the post-paint>fuselage>interior>controls>fit rudder pedals task..

  • Page 249

    Jabiru j450 constructors manual post-paint>fuselage>interior>fit flap drive motor tuesday, april 6, 2010 249 of 343 post-paint>fuselage>interior>fit flap drive motor objectives of this task: to fit the flap drive motor and actuating assembly. Materials required: card j16 “electric flaps” fit the fla...

  • Page 250

    Jabiru j450 constructors manual post-paint>fuselage>interior>fit flap drive motor tuesday, april 6, 2010 250 of 343 fit the flap drive motor assembly with the flap shaft in place and all interior trim fitted, move the flap shaft to the fully retracted position (flap drive arm back). Apply power (12v...

  • Page 251

    Jabiru j450 constructors manual post-paint>fuselage>interior>fit flap drive motor tuesday, april 6, 2010 251 of 343 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 indic...

  • Page 252

    Jabiru j450 constructors manual post-paint>fuselage>interior>fit instrument panel housing tuesday, april 6, 2010 252 of 343 post-paint>fuselage>interior>fit instrument panel housing objectives of this task: to fit the instrument panel housing to the aircraft. This task will require 2 people. Materia...

  • Page 253

    Jabiru j450 constructors manual post-paint>fuselage>interior>fit instrument panel housing tuesday, april 6, 2010 253 of 343 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...

  • Page 254

    Jabiru j450 constructors manual post-paint>fuselage>interior>fit instrument panel housing tuesday, april 6, 2010 254 of 343 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 ...

  • Page 255

    Jabiru j450 constructors manual post-paint>fuselage>interior>engine control cabling tuesday, april 6, 2010 255 of 343 post-paint>fuselage>interior>engine control cabling objectives of this task: to fit all engine control cabling from the instrument panel to the engine. Materials required: cables: th...

  • Page 256

    Jabiru j450 constructors manual post-paint>fuselage>interior>engine control cabling tuesday, april 6, 2010 256 of 343 throttle and choke note the cable routing shown above – this photo was taken looking straight down. Fit the throttle cable first: undo the front nut completely until it is resting on...

  • Page 257

    Jabiru j450 constructors manual post-paint>fuselage>interior>engine control cabling tuesday, april 6, 2010 257 of 343 carb heat 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 ...

  • Page 258

    Jabiru j450 constructors manual post-paint>fuselage>interior>fit the instrument panel tuesday, april 6, 2010 258 of 343 post-paint>fuselage>interior>fit the instrument panel objectives of this task: to pre- and final fit the instrument panel to the panel housing. This task will require 2 people so h...

  • Page 259

    Jabiru j450 constructors manual post-paint>fuselage>interior>fit upholstery 2 tuesday, april 6, 2010 259 of 343 post-paint>fuselage>interior>fit upholstery 2 objectives of this task: fit the remaining interior trim to the aircraft, completing the interior fit out. Materials required: jabiru upholste...

  • Page 260

    Jabiru j450 constructors manual post-paint>fuselage>interior>fit upholstery 2 tuesday, april 6, 2010 260 of 343 rear fuel line covering wrap the fuel line sheathing with the supplied lengths of velcro-edged fabric – wrap around the fuel lines and position the velcro join line so that it can be press...

  • Page 261

    Jabiru j450 constructors manual post-paint>fuselage>interior>fit upholstery 2 tuesday, april 6, 2010 261 of 343 front seat covers identify the left and right side front 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...

  • Page 262

    Jabiru j450 constructors manual post-paint>fuselage>fit rudder, elevator and elevator trim tuesday, april 6, 2010 262 of 343 post-paint>fuselage>fit rudder, elevator and elevator trim objectives of this task: to fit the rudder, and elevator and elevator trim assembly to the empennage. Fit the rudder...

  • Page 263

    Jabiru j450 constructors manual post-paint>fuselage>fit rudder, elevator and elevator trim tuesday, april 6, 2010 263 of 343 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 ri...

  • Page 264

    Jabiru j450 constructors manual post-paint>fuselage>fit rudder, elevator and elevator trim tuesday, april 6, 2010 264 of 343 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 tr...

  • Page 265

    Jabiru j450 constructors manual post-paint>fuselage>fit rudder, elevator and elevator trim tuesday, april 6, 2010 265 of 343 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 ass...

  • Page 266

    Jabiru j450 constructors manual post-paint>fuselage>fit rudder, elevator and elevator trim tuesday, april 6, 2010 266 of 343 this completes the post-paint>fuselage>fit rudder, elevator and elevator trim task..

  • Page 267

    Jabiru j450 constructors manual post-paint>fuselage>fit doors tuesday, april 6, 2010 267 of 343 post-paint>fuselage>fit doors objectives of this task: at this stage the doors have been painted and now they can be refitted to the aircraft. Materials required: door hardware from card # j1 „doors‟ fit ...

  • Page 268

    Jabiru j450 constructors manual post-paint>fuselage>fit doors tuesday, april 6, 2010 268 of 343 remove the masking 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 ve...

  • Page 269

    Jabiru j450 constructors manual post-paint>fuselage>fit doors tuesday, april 6, 2010 269 of 343 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 ...

  • Page 270

    Jabiru j450 constructors manual post-paint>fuselage>firewall forward>final assembly tuesday, april 6, 2010 270 of 343 post-paint>fuselage>firewall forward>final assembly objectives of this task: to complete all fitting work in the engine bay. Materials required: card #15 “spares‟ card #22 „hot air m...

  • Page 271

    Jabiru j450 constructors manual post-paint>fuselage>firewall forward>final assembly tuesday, april 6, 2010 271 of 343 connect the inlet air scat hoses air is fed into the carburettor from 2 sources, cold and heated, through the air mixer box on the firewall and then into the carburettor air inlet. I...

  • Page 272

    Jabiru j450 constructors manual post-paint>fuselage>firewall forward>final assembly tuesday, april 6, 2010 272 of 343 fit the equalising tube 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 i...

  • Page 273

    Jabiru j450 constructors manual post-paint>fuselage>firewall forward>final assembly tuesday, april 6, 2010 273 of 343 connect the cabin heater route a length of the smaller size scat hose (card #25) from the top fitting on the heat exchanger to the cabin heat valve on the firewall. Route a length of...

  • Page 274

    Jabiru j450 constructors manual post-paint>fuselage>firewall forward>fit propeller and spinner tuesday, april 6, 2010 274 of 343 post-paint>fuselage>firewall forward>fit propeller and spinner objectives of this task: in this task the propeller will be fitted to the engine and the spinner will be mou...

  • Page 275

    Jabiru j450 constructors manual post-paint>fuselage>firewall forward>fit propeller and spinner tuesday, april 6, 2010 275 of 343 there must be more than 1½ threads and less than 3 threads showing through the nyloc nuts. Pack behind the nuts with flat washers as required. Recheck the torque settings,...

  • Page 276

    Jabiru j450 constructors manual post-paint>fuselage>firewall forward>fit propeller and spinner tuesday, april 6, 2010 276 of 343 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 ev...

  • Page 277

    Jabiru j450 constructors manual post-paint>fuselage>firewall forward>fit propeller and spinner tuesday, april 6, 2010 277 of 343 fit the spinner fit the spinner using 5/32” countersunk screws and tinnerman washers. Use a long sanding block to sand the rear mounting plate flush with the rear of the s...

  • Page 278

    Jabiru j450 constructors manual post-paint>fuselage>fit wheel spats tuesday, april 6, 2010 278 of 343 post-paint>fuselage>fit wheel spats objectives of this task: 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...

  • Page 279

    Jabiru j450 constructors manual post-paint>wings>install aileron cables tuesday, april 6, 2010 279 of 343 post-paint>wings>install aileron cables objectives of this task: to install the aileron cables in the wings. The cable is tied to a pre-installed drawstring and carefully drawn through the wing ...

  • Page 280

    Jabiru j450 constructors manual post-paint>wings>install aileron cables tuesday, april 6, 2010 280 of 343 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 ...

  • Page 281

    Jabiru j450 constructors manual post-paint>wings>fit stall warning tuesday, april 6, 2010 281 of 343 post-paint>wings>fit stall warning objectives of this task: to fit the stall warning device to the left wing. Materials required: card #6: „stall warning‟ 5-minute araldite and flock mark and drill t...

  • Page 282

    Jabiru j450 constructors manual post-paint>wings>fit stall warning tuesday, april 6, 2010 282 of 343 this completes the post-paint>wings>fit stall warning task..

  • Page 283

    Jabiru j450 constructors manual post-paint>wings>prepare wings for fitting tuesday, april 6, 2010 283 of 343 post-paint>wings>prepare wings for fitting objectives of this task: to prepare the wings prior to fitting them to the fuselage. Materials required: resin and flock card #16 „flaps‟ prepare th...

  • Page 284

    Jabiru j450 constructors manual post-paint>wings>prepare wings for fitting tuesday, april 6, 2010 284 of 343 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 g...

  • Page 285

    Jabiru j450 constructors manual post-paint>wings>prepare wings for fitting tuesday, april 6, 2010 285 of 343 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. T...

  • Page 286

    Jabiru j450 constructors manual post-paint>wings>prepare wings for fitting tuesday, april 6, 2010 286 of 343 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 ro...

  • Page 287

    Jabiru j450 constructors manual post-paint>wings>fit wings tuesday, april 6, 2010 287 of 343 post-paint>wings>fit wings objectives of this task: to final fit the wings to the fuselage. This is a repeat of the pre-paint task but because you have already pre-fitted the wings they can now be fitted int...

  • Page 288

    Jabiru j450 constructors manual post-paint>wings>fit wings tuesday, april 6, 2010 288 of 343 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 – t...

  • Page 289

    Jabiru j450 constructors manual post-paint>wings>connect ailerons tuesday, april 6, 2010 289 of 343 post-paint>wings>connect ailerons objectives of this task: 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 positi...

  • Page 290

    Jabiru j450 constructors manual post-paint>wings>connect ailerons tuesday, april 6, 2010 290 of 343 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 aile...

  • Page 291

    Jabiru j450 constructors manual post-paint>wings>connect ailerons tuesday, april 6, 2010 291 of 343 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 the...

  • Page 292

    Jabiru j450 constructors manual post-paint>wings>connect wing tanks tuesday, april 6, 2010 292 of 343 post-paint>wings>connect wing tanks objectives of this task: to connect the fuel lines and earth the wing tanks to the fuel system. Route and connect the fuel lines at this stage all of the fuel lin...

  • Page 293

    Jabiru j450 constructors manual post-paint>wings>connect wing tanks tuesday, april 6, 2010 293 of 343 route the earth wires at this stage you will have an earth wire running inside the sheathing with the fuel lines from each wing tank and emerging from each conduit behind the rear bulkhead. Crimp a ...

  • Page 294

    Jabiru j450 constructors manual post-paint>wings>fit flaps tuesday, april 6, 2010 294 of 343 post-paint>wings>fit flaps objectives of this task: 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...

  • Page 295

    Jabiru j450 constructors manual post-paint>wings>fit flaps tuesday, april 6, 2010 295 of 343 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 ...

  • Page 296

    Jabiru j450 constructors manual post-paint>wings>fit fairings tuesday, april 6, 2010 296 of 343 post-paint>wings>fit fairings objectives of this task: 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. ...

  • Page 297

    Jabiru j450 constructors manual post-paint>wings>fit fairings tuesday, april 6, 2010 297 of 343 lower strut/main gear fairing start by 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 th...

  • Page 298

    Jabiru j450 constructors manual testing>general tuesday, april 6, 2010 298 of 343 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 ta...

  • Page 299

    Jabiru j450 constructors manual testing>weight and balance tuesday, april 6, 2010 299 of 343 testing>weight and balance objectives of this task: 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 t...

  • Page 300

    Jabiru j450 constructors manual testing>weight and balance tuesday, april 6, 2010 300 of 343 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 ...

  • Page 301

    Jabiru j450 constructors manual testing>weight and balance tuesday, april 6, 2010 301 of 343 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 bu...

  • Page 302

    Jabiru j450 constructors manual testing>weight and balance tuesday, april 6, 2010 302 of 343 examples of calculation below is an example calculation showing typical values: item weight (kg) distance to datum (mm) moment (kg/mm) nose wheel 75 - 780 - 58,500 left main wheel 108 + 475 + 51,300 right ma...

  • Page 303

    Jabiru j450 constructors manual testing>rigging check tuesday, april 6, 2010 303 of 343 testing>rigging check objectives of this task: 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...

  • Page 304

    Jabiru j450 constructors manual testing>rigging check tuesday, april 6, 2010 304 of 343 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 th...

  • Page 305

    Jabiru j450 constructors manual testing>rigging check tuesday, april 6, 2010 305 of 343 elevator check the elevator travel use the supplied deflection templates to check the up and down travel of the elevator. Hold the control stick all the way forward (have someone help you) and check the amount of...

  • Page 306

    Jabiru j450 constructors manual testing>calibrate fuel gauges tuesday, april 6, 2010 306 of 343 testing>calibrate fuel gauges objectives of this task: 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 ...

  • Page 307

    Jabiru j450 constructors manual testing>calibrate fuel gauges tuesday, april 6, 2010 307 of 343 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 poi...

  • Page 308

    Jabiru j450 constructors manual testing>registration markings tuesday, april 6, 2010 308 of 343 testing>registration markings objectives of this task: to fit complying registration markings to the aircraft. You will need to determine the requirements of the aviation authority in your own country. In...

  • Page 309

    Jabiru j450 constructors manual testing>final inspection checklist tuesday, april 6, 2010 309 of 343 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:...

  • Page 310

    Jabiru j450 constructors manual testing>final inspection checklist tuesday, april 6, 2010 310 of 343 spark plugs/coil leads 1 spark plugs are secure in cylinder heads 2 spark plug leads are secure on spark plugs 3 spark plug leads not rubbing (on air ducts, cylinder heads) 4 terminal nuts are secure...

  • Page 311

    Jabiru j450 constructors manual testing>final inspection checklist tuesday, april 6, 2010 311 of 343 choke cable 1 lock nuts secure both ends of cable 2 cable end free in carburettor link 3 split pin secure 4 cable alignment correct with outer 5 operational carburettor heat cable 1 lock nuts secure ...

  • Page 312

    Jabiru j450 constructors manual testing>final inspection checklist tuesday, april 6, 2010 312 of 343 nose leg and housing 1 front tyre pressure checked: 34 psi 2 [tyre pressure] decal in place on spat above grommet 3 nose wheel - ease of rotation 4 nose leg – lubricated and ease of rotation left to ...

  • Page 313

    Jabiru j450 constructors manual testing>final inspection checklist tuesday, april 6, 2010 313 of 343 interior fuel system 1 fuel filter secure and flow direction correct 2 fuel pump (electronic) secure and flow direction correct 3 fuel lines secure: a) fuel pickups and breather lines from wing roots...

  • Page 314

    Jabiru j450 constructors manual testing>final inspection checklist tuesday, april 6, 2010 314 of 343 controls rudder pedals 1 rudder springs installed properly 2 rudder stops lining up properly 3 2 x pedal mount bolts secure (pushrod to pedals) 4 rudder pedal keepers secure and correct 5 2 x ¼” and ...

  • Page 315

    Jabiru j450 constructors manual testing>final inspection checklist tuesday, april 6, 2010 315 of 343 brake 1 handle assembly correct and secure 2 check safety hole within limits 3 operation 4 free play 5 fluid level full 6 stainless striker in place 7 handbrake correct and operational throttle 1 cab...

  • Page 316

    Jabiru j450 constructors manual testing>final inspection checklist tuesday, april 6, 2010 316 of 343 aileron cable left right 1 cable anchor wedges in place 2 “r” clips in place 3 rivets x 3 tlr through each bracket and seat back 4 rod end secure 5 safety hole is within limits on rod ends 6 jam nuts...

  • Page 317

    Jabiru j450 constructors manual testing>final inspection checklist tuesday, april 6, 2010 317 of 343 instrument panel 1 secure and level 2 instruments square (check that the slip/skid ball is centred). 3 slip/skid ball air bubble not visible 4 circuit breakers secure and correctly labelled 5 switche...

  • Page 318

    Jabiru j450 constructors manual testing>final inspection checklist tuesday, april 6, 2010 318 of 343 upholstery: 1 fitted and clean 2 seat covers 3 map pockets 4 flap shaft upholstered 5 centre console upholstered 6 fuel line covers in place placards and decals: 1 [no smoking] on panel 2 [no intenti...

  • Page 319

    Jabiru j450 constructors manual testing>final inspection checklist tuesday, april 6, 2010 319 of 343 exterior wings: left right 1 root bolts inspected (correct tension) x 2 2 strut bolts x 2 inspected, correct tension 3 warning decals in wing roots x 2 [do not tighten] 4 wing root cover strips secur...

  • Page 320

    Jabiru j450 constructors manual testing>final inspection checklist tuesday, april 6, 2010 320 of 343 ailerons left right 1 deflections a) neutral (level with lower wing skin) with stick centred b) up ________degrees, or touches template c) down ________degrees 2 hinge pins and pin retainers secure 3...

  • Page 321

    Jabiru j450 constructors manual testing>final inspection checklist tuesday, april 6, 2010 321 of 343 main undercarriage left right 1 main gear legs secure 2 stub axle secure 3 hubs secure 4 stub axle extension is secure 5 calliper secure 6 discs secure 7 ease of rotation 8 tyre pressure 45 psi 9 [ty...

  • Page 322

    Jabiru j450 constructors manual testing>final inspection checklist tuesday, april 6, 2010 322 of 343 empennage elevator deflections 1 up ________ degrees, or touches the up template 2 down ________ degrees, or touches the down template 3 2mm clearance to the stop on fuselage at full down deflection ...

  • Page 323

    Jabiru j450 constructors manual testing>final inspection checklist tuesday, april 6, 2010 323 of 343 ventral fin: 1 retained nuts in fuselage secure 2 elevator horn not hitting cut-out in ventral fin at full up deflection 3 inspection holes drilled 4 drain holes drilled out 5 ventral fin secure onto...

  • Page 324

    Jabiru j450 constructors manual testing>flight testing tuesday, april 6, 2010 324 of 343 testing>flight testing objectives of this task: 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 chara...

  • Page 325

    Jabiru j450 constructors manual testing>flight testing tuesday, april 6, 2010 325 of 343 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...

  • Page 326

    Jabiru j450 constructors manual testing>flight testing tuesday, april 6, 2010 326 of 343 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 signif...

  • Page 327

    Jabiru j450 constructors manual testing>flight testing tuesday, april 6, 2010 327 of 343 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 ...

  • Page 328

    Jabiru j450 constructors manual testing>flight testing tuesday, april 6, 2010 328 of 343 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: ...

  • Page 329

    Jabiru j450 constructors manual testing>flight testing tuesday, april 6, 2010 329 of 343 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 ...

  • Page 330

    Jabiru j450 constructors manual testing>flight testing tuesday, april 6, 2010 330 of 343 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 for...

  • Page 331

    Jabiru j450 constructors manual testing>flight testing tuesday, april 6, 2010 331 of 343 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 t...

  • Page 332

    Jabiru j450 constructors manual testing>flight testing tuesday, april 6, 2010 332 of 343 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 necessar...

  • Page 333

    Jabiru j450 constructors manual testing>flight testing tuesday, april 6, 2010 333 of 343 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 st...

  • Page 334

    Jabiru j450 constructors manual testing>flight testing tuesday, april 6, 2010 334 of 343 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 lu...

  • Page 335

    Jabiru j450 constructors manual testing>flight testing tuesday, april 6, 2010 335 of 343 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 e...

  • Page 336

    Jabiru j450 constructors manual testing>flight testing tuesday, april 6, 2010 336 of 343 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 flig...

  • Page 337

    Jabiru j450 constructors manual testing>forms tuesday, april 6, 2010 337 of 343 testing>forms objectives of this task: 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 sequence...

  • Page 338: Aircraft Identification

    Jabiru j450 constructors manual testing>forms tuesday, april 6, 2010 338 of 343 aircraft identification j model engine serial number asi registration propeller : jabiru / sensenich serial number size x pitch alt serial number vsi etc flight instrumentation tach eop jabiru # serial number eot cht egt...

  • Page 339

    Jabiru j450 constructors manual testing>forms tuesday, april 6, 2010 339 of 343 sequence #1 – ground run eop eot cht egt run up - 2000 rpm left mag right mag carb heat rpm drop (200rpm max) eop eot cht egt full power check maximum sustained rpm eop eot cht egt idle check idle rpm date taxi tests 297...

  • Page 340: Sequence #2 – Rigging

    Jabiru j450 constructors manual testing>forms tuesday, april 6, 2010 340 of 343 sequence #2 – rigging does the aircraft fly straight and level with the ball centred? Are the rudder pedals displaced? Is there any tendency to roll or turn? Does the aircraft roll just before the stall? Rigging is corre...

  • Page 341

    Jabiru j450 constructors manual testing>forms tuesday, april 6, 2010 341 of 343 date oat wind rwy qnh pilot loading rules - either: engine hours start pilot and 1 pax to 172kg total: 50 litres fuel pilot pax loading stalls all stalls are started from 3000 feet agl or above, starting from 60 kias. Ai...

  • Page 342

    Jabiru j450 constructors manual testing>forms tuesday, april 6, 2010 342 of 343 trim test aft [50-65 kias] fwd [90-140 kias] cruise power, clean aft [60-70 kias] fwd [end of white arc] idle, full flap glide at 62 kias v ne 2700-2900 rpm full power, straight & level timed climb at 80 kias oat p. Alt ...

  • Page 343

    Jabiru j450 constructors manual testing>forms tuesday, april 6, 2010 343 of 343 equipment ground handling post flight review vhf comm #1 operation vhf comm #2 operation transponder operation gps operation instrumentation other equipment: lights, uhf, etc undercarriage brakes - landing control - land...