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Skyranger Nynja Build Manual

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Version 1.4d
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Nynja Build Manual 1.4d

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  • Page 1 Nynja Build manual Version 1.4d Nynja Build Manual 1.4d...
  • Page 2 Figure 1 tube numbering scheme. Nynja Build Manual 1.4d...
  • Page 3 Figure 2 Basic frame (Skyranger). Nynja Build Manual 1.4d...
  • Page 4 Figure 3 uncovered Skyranger frame. Nynja Build Manual 1.4d...
  • Page 5 Figure 4 Uncovered Nynja frame Figure 5 Nynja fuselage with rear fairings removed Nynja Build Manual 1.4d...
  • Page 6 Figure 6 Nynja fuselage with rear fairings removed – rear view Figure 7 simply assemble thus! Nynja Build Manual 1.4d...

  • Page 7: Table Of Contents

    Attaching the Wings to the Fuselage ................. 121 Aileron Control Cables ....................... 122 Flaps ........................... 126 Covering the Wings ......................128 Inserting the Battens ......................135 Windscreen Frame and Throttles ..............138 Windscreen Frame ......................138 Throttles ..........................143 Nynja Build Manual 1.4d...
  • Page 8 22 Wheel Spats – Standard ................238 22.1 Nose Wheel ........................238 22.2 Main Wheels ........................239 23 Fitting the teardrop spat option..............241 Nose Wheel ............................. 241 Main Wheel spats ..........................242 24 Fairings ......................246 Nynja Build Manual 1.4d...
  • Page 9 Weight and Balance ......................265 28.8 Placards ..........................266 28.9 Test Flying .......................... 266 27 Additional Information ..................268 27.1 Example BMAA Homebuilt Registration Form ................ 268 27.2 Wire-locking........................270 28 Index ......................... 274 28 Amendments ....................277 Nynja Build Manual 1.4d...

  • Page 10: Introduction

    Introduction How to Build Your Aircraft Building the Nynja is a fairly straightforward process, but it can be made much more difficult than necessary if one basic rule is not followed: READ THE INSTRUCTIONS! Figure 8 A rare sight, but essential for successful building (the manual that is, not Rob)! The Build Manual Reading the whole manual before starting is suggested.
  • Page 11 If you have a problem that you cannot resolve by a careful read of the instructions with the appropriate parts in front of you please have a look in the Skyranger internet discussion group, send an email, or if all else fails ring:...

  • Page 12: The Bmaa Homebuilt Aircraft System

    Technical Information section, click on Forms, and download form BMAA/AW/022. An example form for a Nynja fitted with a Rotax 912ULS and standard Kiev prop 283 is shown towards the end of this manual. You will have to find a BMAA Inspector to oversee the project. A list of Inspectors is available from the BMAA if required.
  • Page 13 Note that the Nynja succeeds in providing a capable aeroplane at an excellent price by following the principle of simplicity. Some areas may look basic at first glance, but meet the stringent requirements of BCAR Section S without adding cost and weight.

  • Page 14: General Assembly Notes

    Remember to replace any non locking nuts with Nyloc nuts before final assembly, and also: REMEMBER TO USE LOCTITE 243 ON ALL NUTS. Nynja Build Manual 1.4d...
  • Page 15 Generally bolts should not be tightened up until all the parts in a particular sub-assembly are assembled, to avoid the common problem of the final bolt not fitting! Nynja Build Manual 1.4d...
  • Page 16 Turn nuts, not bolts whenever possible, when tightening, as this may damage the plating and encourage corrosion. Washers are only needed under nuts to allow them to be turned, whereas bolt heads should not be turned. Do not over-tighten bolts, avoid deformation of tubes or brackets. Nynja Build Manual 1.4d...
  • Page 17 Handle the coverings with care, pay attention to the risk of bolt heads, corners and reinforcements/stiffeners damaging the covering as it is put on. Dacron coverings need care to avoid getting dirty and becoming stained. Keep your hands and tools clean and oil-free when working with or near these coverings. Nynja Build Manual 1.4d...

  • Page 18: Finish

    It is also not unusual to find small areas of silver paint applied at the final stage over any small remaining marks prior to leaving the factory. Some light scuff marks may be present as a result of storage and transit. Nynja Build Manual 1.4d...
  • Page 19 Application in low temperatures is to be avoided, and some work with a heat gun and application of pressure will be required to work the Vinyl into the weave and stitching to ensure good long term adhesion. Seek specific advice before application. Nynja Build Manual 1.4d...

  • Page 20: Weight

    1.5 Weight The UK prototype Nynja with Xlam coverings, Rotax 912ULS and standard ‘console’ dash, basic analogue instrument fit, installed intercom box, aerial and radio, and including doors (see note below***), has been found to have a basic empty reference weight of approximately 258kg.

  • Page 21: Forward Fuselage

    Refer to these drawings for tube numbers throughout the forward fuselage assembly sequence. Figure 11 cabin lower and upper triangle tube numbering. Figure 12 cabin viewed from port side, and rear cabin frame viewed from rear. Nynja Build Manual 1.4d...
  • Page 22 Figure 13 forward fuselage from front quarter. Figure 14 Cabin upper rear corner Nynja Build Manual 1.4d...

  • Page 23: Fuselage Frame Assembly Overview

    2.2 Fuselage frame assembly overview Lower triangle assembly Attaching TU14 Upper triangle assembly Attaching upper triangle to TU14 Attaching rear cabin uprights TU6 Attaching Upper triangle to uprights Nynja Build Manual 1.4d...
  • Page 24 Cabin diagonals TU27 attached Twin TU19 tubes in position Front seat support TU15 and braces Forward engine mount assembly fitted Assembling tailcone Tailcone fitted to cabin Figures 15 – assembly overview Nynja Build Manual 1.4d...

  • Page 25: Lower Cabin Triangle

    The bolts should pass from bottom to top (contrary to the drawing, but as per the photographs), to clear the undercarriage legs later. Nynja Build Manual 1.4d...
  • Page 26 Figure 19. Bolt spacers are not needed in the steel undercarriage tube. The bolts should pass upwards, to clear the undercarriage legs later. Figure 18 starboard end of tu9, looking from front. Nynja Build Manual 1.4d...
  • Page 27 UKMOD: a spacer tube is used on the U-bracket and nose leg guide securing bolt as it passes through the front vertical tu14. UKMOD: The guide SKR90 has additional webs welded onto it top and bottom, Figure 20 Figure 20 UKMOD nose leg lower guide. Nynja Build Manual 1.4d...
  • Page 28 Note: Stud shown also supplied as a bolt, and should be fitted head up. Figure 21 forward end of lower cabin triangle. Nynja Build Manual 1.4d...
  • Page 29 The studs should be long end downwards to mount the bottom of the firewall and the front of the fuselage covering later.Discard the curved metal washer if fitted – as this is a Skyranger part not used for the Nynja.

  • Page 30: Upper Cabin Triangle

    The bolts will be tilted down and backwards compared to the vertical bolt holes for the cabin upper triangle and tail cone tubes, as the rear cabin frame is raked backwards. Figure 22 Port end of the upper rear cabin cross-piece. Figure 23 upper rear cabin cross-piece. Nynja Build Manual 1.4d...
  • Page 31 Fix the U-bracket SKR75 and the pair of U-brackets SKR78 for the leading- edges on the front vertical tube SKR14. b) Mount the aileron cable pulleys. c) Assemble the two upper cabin triangle tubes SKR10, linking them to the double U-bracket SKR75. Nynja Build Manual 1.4d...
  • Page 32 Figure 25 forward end of upper cabin triangle. 8,,,SKR.94.SB 24,,,WASHER.8 30,,,CASTLENUT.8 31,,,SAFETY PIN 8,,,SKR.94.SB 24,,,WASHER.8 30,,,CASTLENUT.8 31,,,SAFETY PIN Figure 26 forward end of upper cabin triangle. Nynja Build Manual 1.4d...

  • Page 33: Rear Cabin Frame

    TU2 should be angled for the tailcone taper. The nuts may foul the upper rear cabin cross-piece SKR7, in this case file away a little from the TU7 to provide clearance. A spacer should be used on the bolt inside the tube. Nynja Build Manual 1.4d...

  • Page 34: Rear Cabin Frame Bracing

    Assemble the steel end pieces into the rear cabin frame diagonals SKR27. The one with the 8mm hole goes at the upper end and the one with the 6mm hole goes at the lower end. Nynja Build Manual 1.4d...
  • Page 35 These should be oriented with the supporting part towards the middle of the aircraft. Note that the spacer tube is also shown on Figure 30 as well as the small bracket piece. The Nynja should be supplied with round peg support as per picture below.
  • Page 36 SKR144 before the rear cabin uprights SKR6 and finally the attachment plate on the rear cabin frame cross-tube SKR40. Include a thin plastic washer between the brace and the aluminium rear cabin uprights. 2.6.1 Fuel tank upper mounting pieces. Refer to Figure 32 Nynja Build Manual 1.4d...

  • Page 37: Engine Supports

    Ensure that the end of the bolt is below the level of the rear surface of the wooden pieces. Long side faces outwards Figure 32 fuel tank wooden tank spreader pieces. Engine Supports 2.7.1 Rotax 912. Figure 33 Rotax 912 engine mounts Nynja Build Manual 1.4d...
  • Page 38 Remove this washer Figure34 Rotax 912 mounting bracket – note position of TU310 is reversed for Nynja – as shown correctly below Fig 35 Nynja engine mount assembly Nynja Build Manual 1.4d...
  • Page 39 Fig 36 Nynja firewall support brackets, should be fitted on the engine mount bolts at the front of the SKR19’s at this stage as shown (normally found packaged with firewall) Aluminium washers – Note that TU14 different diameter – make sure the...
  • Page 40 SKR9. d) Loosely fix the two stainless-steel upper triangulation tubes SKR24 to the top of the front vertical SKR14, including saddle washers. Nynja Build Manual 1.4d...
  • Page 41 Note that the 298 plates are handed and the starboard one has a recess machined in, as shown below. Note recessed section on starboard 298 plate only Fig 39 handing the 298 plates Nynja Build Manual 1.4d...
  • Page 42 Fig 40 Forward end of SKR19 and Liaison of engine mount plates 298BK, SKR310, upper triangulation tubes SKR24’s and lower triangulation tubes SKR23. Note arrangement of plastic washers – only fit them where shown. Figure 41 upper engine mount triangulation tubes. Nynja Build Manual 1.4d...
  • Page 43 Figure 43 lower triangulation tubes TU23 and lower engine mounts g) Loosely fix the two stainless-steel lower triangulation tubes SKR23 to the front vertical tube SKR14, including saddle washers, Figure 42 and 43. Nynja Build Manual 1.4d...
  • Page 44 It may be necessary to adjust the spacer size under the rear bolts that hold the plates in position adding or subtracting 1or3mm plastic washers, to get this measurement. 175-180mm Figure 45 Rotax 912 engine mounts, front view. Nynja Build Manual 1.4d...
  • Page 45 Check that the distance between the plates has not changed during this process. 0-5mm Figure 46 fixing position for TU310 k) The lower engine mounts, Figure 43 and 47, should be attached to the front vertical SKR14. Figure 47 Rotax 912 lower engine mounts. Nynja Build Manual 1.4d...

  • Page 46: Floor

    Cut a hole in the floor for the battery box: The hole is located on the centreline, approximately 1cm back from the rudder pedal mounting bar SKR18. The hole is 15cm long by 9cm wide. Figure 48 battery location. Figure 49 view of installed floor. Nynja Build Manual 1.4d...
  • Page 47 SKR15 to the lower cabin triangle tubes SKR12 with a thin plastic washer or saddle washer between the steel tube and the aluminium tube. Figure 51 SKR15 seat front support tube. Nynja Build Manual 1.4d...

  • Page 48: Rudder Pedals

    Make sure that there are saddle washers between the pedal bar and the floor but NOT between the floor and the lower cabin tubes – this may mean removing a set from the assembly Figure 52 rudder pedals. Nynja Build Manual 1.4d...

  • Page 49: Control Stick Assembly

    Cut off any protruding ends of the rudder pedal mounting bar bolts beneath the aircraft, to prevent them rubbing on the coverings. Nut caps may also be fitted. 2.10 Control Stick Assembly Figure 53 control stick and torque-tube parts Nynja Build Manual 1.4d...
  • Page 50 Fit the plastic torque-tube bearing into the rear pivot support. The bearing is inserted from the front. Then if the forward pivot bolt were to fail, the stick would still be held in place by this bearing. Figure 54 torque-tube bearing. Nynja Build Manual 1.4d...
  • Page 51 SKR19 to allow it to take up the exact alignment of the torque-tube, but note the rudder stop cables will have some effect on this alignment. i) Insert and secure the bolts holding the fittings into the ends of the torque-tube. Nynja Build Manual 1.4d...

  • Page 52: Finishing The Forward Fuselage

    An additional thin plastic washer may be fitted between the central brace and the starboard central cabin tube to increase clearance for the rudder cable. The bolts should pass from the middle towards the outside, to clear the elevator cables. Nynja Build Manual 1.4d...
  • Page 53 Figure 55 central bracing pieces. Note the bolts should be the other way around (as shown in photo fig 56). Figure 56 central bracing pieces. Nynja Build Manual 1.4d...

  • Page 54: Rear Fuselage

    If you do not have suitable supports or a helper to hold the front ends of the tubes at this stage it can be helpful to mount the bracing frame (as detailed below) to the lower pair of longitudinal tubes, followed by Nynja Build Manual 1.4d...
  • Page 55 Figure 58 rear end of upper rear fuselage tubes. Figure 59 rear end of lower rear fuselage tubes. Nynja Build Manual 1.4d...

  • Page 56: Bracing Frame

    Figure 60 rear fuselage bracing frame. Note orientation arrow. b) Attach the Upper and lower bracing cables A and B to the central frame at this point. – see section 3.4 for details Nynja Build Manual 1.4d...

  • Page 57: Front End

    Figure 61 forward end of lower rear fuselage tubes Note upper tubes have brackets orientated at 90 degrees from that shown and cables are arranged differently on Nynja. See Figure(s) 62 c) Mount the front ends of the upper tubes onto the SKR6 tubes as shown below.

  • Page 58: Fuselage Bracing Cables

    Both bent Lengths taken from tang hole centers. Cable C is made up with a turnbuckle at the forward end and a tang. Length taken is total length from tang end hole centers with turnbuckle fully closed Nynja Build Manual 1.4d...
  • Page 59 C cable tang under A cable tang E cable tang over D cable tang Note both pairs rear cables cross at rearmost attachment point C cable tang under F cable tang Figure 64 fuselage cable ends detail Nynja Build Manual 1.4d...
  • Page 60 Figures 65 cable arrangement further overview Nynja Build Manual 1.4d...
  • Page 61 Figure 66 cable arrangement Upper starboard side of central frame C cable F cable plastic washer between tangs and tube B cable 1mm plastic washer between tang and tube only Forwards Figure 67 cable arrangement lower port side of central frame Nynja Build Manual 1.4d...
  • Page 62 – use another bolt or thin screwdriver inserted at the top to hold spacer in position and bolt is withdrawn and reinserted. g) Apply light tension to the cables but do not tighten at this time. Nynja Build Manual 1.4d...

  • Page 63: Tailplane Front Mounting

    The SKR22 nay be supplied with slotted mounting holes. This is so it can be adjusted slightly fore and aft for the tailplane fit. Figure 68 vertical and horizontal stabiliser front mounting. Nynja Build Manual 1.4d...

  • Page 64: Fuel Tank Support And Flap Handle

    Fit the fuel tank support SKR20 to the lower rear fuselage tubes SKR4, with the U-bracket located towards the port side of the fuselage and facing upwards, Figure 69 and 70. Figure 70 flap handle and fuel tank support bar. Nynja Build Manual 1.4d...
  • Page 65 Figure 72 flap lever detail Fit the S70 spring from the flap handle to the detent lever, in position shown in figure 72. The eye end may need opening up slightly to fit in the rear hole Nynja Build Manual 1.4d...

  • Page 66: Not Tightening The Bolts And Cables

    Figure 73 Flap handle Not Tightening the Bolts and cables! Do not finally tighten the bolts or cables around the rear fuselage at this stage – this will be detailed later after the landing gear is attached. Nynja Build Manual 1.4d...

  • Page 67: Undercarriage

    Figure 76. Note that the hub has a machined face with square inside corners one side and a radiused face the other. The machined face should sit against the wheel halves. Do not assemble with hub between wheel halves! Nynja Build Manual 1.4d...
  • Page 68 Figure 76 placing a hub against the wheel halves. Figure 77 a wheel minus the tyre. Nynja Build Manual 1.4d...

  • Page 69: Main Undercarriage

    Take care to make a handed pair. The callipers and holes for them are to the rear of the undercarriage legs, and at the narrow end of the legs. Figure 78 hole for brake calliper mounting. Nynja Build Manual 1.4d...
  • Page 70 Fit the brake mounting piece to the forward upper stub axle bolt, and tighten the stub axle bolts. Note if spats are fitted the stub axles should be attached with the outer fixing bolt vertical – not horizontal as shown below. Figure 79 Nynja undercarrige leg Nynja Build Manual 1.4d...
  • Page 71 Fit the undercarriage legs to the main undercarriage cross-beam SKR9 Make sure that the legs are on the correct sides to place the brake callipers towards the rear! Steel drag braces Figure 81 main gear leg mounting. Nynja Build Manual 1.4d...
  • Page 72 It may be necessary to adjust with washers under the nut to achieve this balance. 8-40 saddle washer Metal washer under bolt head and nut 3mm plastic washer Figure 83 rear and forward ends of starboard drag brace Nynja Build Manual 1.4d...

  • Page 73: Nose Gear

    If a small tweak does not suffice, the holes securing the lower guide may be elongated slightly, parallel with the nose leg. Do not Nynja Build Manual 1.4d...
  • Page 74 Ensure that the lower engine mount triangulation tubes passing either side of the nose leg do not touch it. Use additional washers to space out the lower ends of the triangulation tubes if necessary. Nynja Build Manual 1.4d...
  • Page 75 4.3.2 Nose wheel steering a) The nose leg fits to the steering bar between the two 90 degree brackets. UKMOD Fit rubber grommets here UKMOD, remove these washers and change for rubber grommets Figure 86 Nose wheel steering. Nynja Build Manual 1.4d...
  • Page 76 Figure 87 nose wheel steering bar, with rubber grommets between pushrods and box section and pushrods and rudder pedals, note the white plastic washers shown near the arrows should not be fitted. Nynja Build Manual 1.4d...

  • Page 77: Brakes

    Figure 88 brake calliper mounting. Note bolts are usually the other way round, heads towards the wheel which keeps the threads away from the axle flange. Make sure spacer / bolt sits against gear leg like this. Figure 89 spacers on brake mounts. Nynja Build Manual 1.4d...
  • Page 78 Leave a little slack to allow for movement of the control stick. Check that there are no high points between the brakes and the lever, as this could trap air bubbles and give a spongy feel to the brakes. Nynja Build Manual 1.4d...
  • Page 79 The hydraulic fittings on the brake callipers may need to be tightened up quite a lot to prevent weeping of fluid. Run-in the brakes on the ground before flight testing commences. Nynja Build Manual 1.4d...

  • Page 80: Tail Surfaces

    Finally secure all cables where they cross with a small length of split thin wall tubing (the pitot tubing can be used) over one cable, and a cable tie. Figure 91 securing crossing cables, and check for incorrect fixing of lower central frame. Nynja Build Manual 1.4d...

  • Page 81: Elevator Trim Tab

    If desired, leave the actual riveting on of the tab until the elevator halves are mounted on the aircraft, to keep the tab out of the way. However, it is worth drilling all the holes at this stage. Figure 92 trim tab and horns position. Nynja Build Manual 1.4d...
  • Page 82 Use two short 4mm diameter bolts, cut down to length if necessary. Figure 94 Trim tab horns aligned with cable bracket and hinge pin Nynja Build Manual 1.4d...

  • Page 83: Tailplane

    The forward mounting should be left fairly loose to allow the halves to pivot, and will have to be undone later when the fuselage fairings are fitted, so do not threadlock it at this stage. Figure 96 horizontal stabiliser rear mountings. Nynja Build Manual 1.4d...
  • Page 84 Slide the joiner into place onto the port elevator and then fit the starboard elevator. c) Make sure that the joiner is fully pressed back onto the elevator tubes and fits snugly. Nynja Build Manual 1.4d...
  • Page 85 Align the elevators with the tailplane, using two wing under-surface battens or similar straight edge and some bungee cord to hold them level, Figure 98. Figure 98 elevator joiner and alignment (note: Skyranger joiner shown – Nynja version has integral elevator horn).
  • Page 86 Ensure joiner sits so holes are drilled perpendicular to elevator centerline ! 90deg Figure 100 Nynja elevator joiner with integral control horn Nynja Build Manual 1.4d...

  • Page 87: Rudder

    Rudder 5.4.1 Rudder horn assembly Figure 101 rudder horn assembly (note: Skyranger rudder frame shown. Nynja Rudder is slightly different shape). a) Remove the fabric over the 6mm holes in the rudder leading edge spar with a soldering iron. These holes can be felt through the covering, Put in place the bracing angles and secure them lightly with a 6mm diameter, 35mm plain shank length bolt through the hole.
  • Page 88 – get a narrower gun if this is the case. j) Finally tighten the bolts, remembering to use a small dab of threadlock. Don’t get it on the covering! Figure 103 Nynja rudder (note: trim tab not required) Nynja Build Manual 1.4d...
  • Page 89 For vertical alignment washer may have to be added under the heads of one or two of the eyebolts. When the rudder is finally fitted later assemble with grease which will further provide free movement and protect these steel parts against wear and corrosion. Nynja Build Manual 1.4d...

  • Page 90: Control Cables

    WARNING! – when fitting the cables do not have the battery installed. Otherwise there is a risk that the cables may make a connection across the terminals and melt the cable or set fire to the aircraft! Figure 105 Elevator cable schematic Nynja Build Manual 1.4d...
  • Page 91 Figure 106 Rudder cable schematic 5.5.2 Pulleys Elevator cable to upper right side of stick Elevator cable lower left side of stick Rudder cables Trimmer cable bracket Figure 107 Nynja central pulley block arrangement loking rearwards Nynja Build Manual 1.4d...
  • Page 92 The control stick may have more than one set of cable attachment holes. If so the pair closest to the stick pivot should be used. Figure 108 Nynja elevator cable connection on control stick. (Note: hole closest to pivot used, and that a thin plastic washer is fittedbetween tang and stick) b) Tighten up the bolt passing through the pulley bearings c) Looking rearwards.
  • Page 93 If necessary, adjust this by filing the top and bottom edges of the stick pivot piece where the stop- rings bear. These are somewhat flexible, so set the deflection with some pressure on the stick. Nynja Build Manual 1.4d...
  • Page 94 Figure 110 Port rudder cable fairlead k) Connect the rudder centring cables - a pair of steel cables connected together at one end, to the shackles on the rudder horn using the other ends Nynja Build Manual 1.4d...
  • Page 95 This will be adjusted on flight test. Three loops of bungee cord return rudder central position. Rudder trim can be made by sliding loops left or right on frame Figure 111 rudder centering bungee arrangemnt Nynja Build Manual 1.4d...
  • Page 96 SKR19. Note that they fit between the stick pivot support and theSKR19 tubes. They will have to be sprung apart to get them in. Figure 113 rudder stop cables attached to rear stick pivot. Nynja Build Manual 1.4d...
  • Page 97 The bolt on the pedal end should be loose enough to allow rotation as the pedal is deflected. j) Secure the middle of the stop cables with a short length of light Bungee looped over the control stick torque-tube just out of sight under the Nynja Build Manual 1.4d...
  • Page 98 Adjustment of the cables and the pulleys will require some fiddling to achieve nice clean cable runs which do not rub, so don’t tighten the bolts up until this is achieved. Figure 115 starboard rudder cable routing past central braces. Nynja Build Manual 1.4d...
  • Page 99 Nynja Build Manual 1.4d...

  • Page 100: Fitting The Rear Fuselage Fairings

    A Dremel multi tool is recommended for these tasks and can be used with a cutting disc to open up the holes, and a sanding attachment to trim exactly to the cut lines. Some final hand or block sanding may be required for that perfect edge. Figure 116 fairing cutouts Nynja Build Manual 1.4d...

  • Page 101: Fitting The Rear Fuselage Fairings

    Then rotate so the upper edge ‘clips’ over the upper fuselage longeron. Fit the portside in the same manner taking care to overlap the starboard fairing on the joins. Figure 117 fitting the rear fairings in position. Nynja Build Manual 1.4d...
  • Page 102 Figure 119 showing alignment of rear fairing with TU6 upright tube. This should also coincide with the rear of the fairing halves being butted up against the rear of the fin post – Fig 120 below. Nynja Build Manual 1.4d...
  • Page 103 Start first by drilling an upper and lower hole to fix the fairings on to the finpost. Make sure the halves are tightly together when you do this. Stretching some packing tape across between the two may help to pull them together for final fit. Nynja Build Manual 1.4d...
  • Page 104 Fix them to the nearest bolts in the fairing (Change these to 4mm metal bolts). Drill to fit to the central brace (4mm bolts) so that no pressure is put on the glassfibre pushing or pulling. Nynja Build Manual 1.4d...

  • Page 105: Engine Installation Rotax 912Ul/912Uls

    90 degrees to the starboard side of the engine, see the engine instructions for the procedure. Take care not to lose the O-ring seal and note the torque value of 10Nm (1kgm, 7ftlb) for the fixing screws. Figure 124 water pump outlet in correct position Nynja Build Manual 1.4d...
  • Page 106 – this makes changing them in situ much easier later in the life of the aircraft. Mounting a) Position the engine on the Nynja making sure you do not bump the CDI pickups located on top of the flywheel. Figure 126 engine mounts.
  • Page 107 It is not necessary to fit this to the 912UL engine The strap replaces the snubbing washer on the outside of the top engine mount rubber and runs down to the replace the subbing washer on the inside Nynja Build Manual 1.4d...
  • Page 108 This then provides support against bending loads due to torque being applied to the top engine mount bolt. Fig 128 Overview and views of the upper and lower attachment points of the bracing strap Nynja Build Manual 1.4d...
  • Page 109 2. Clean all the threads thoroughly. Refit the assembly and screw in the elbows to the right position. Mark the correct position with a pen line. 3. Reassemble using Loctite243, positioning the outlets with reference to the marks. 4. Refit to engine and connect hoses Nynja Build Manual 1.4d...

  • Page 110: Wings

    It is worth filing 2-3mm off the side closest to the wing root before the saddle washer is fitted to the spar. Nynja Build Manual 1.4d...
  • Page 111 Join the leading and trailing edge tubes with the oval tube SKR37.3 (maybe marked SKR54) at the tip, Figs 142,143,144. Figure 131 Front of tip Figure 132 rear of tip. Nynja Build Manual 1.4d...
  • Page 112 Figure 134 forward and rearjury strut attachments. Note: The Aerofoil section jury strut option (Swift and Nynja) uses a different upper mounting, replacing the bolts and small L brackets in the following drawings with eyebolts as above. Note they may be either male ended (as shown above) or female ‘forked’...
  • Page 113 Figure 135 front jury strut attachment. Figure 136 rear jury strut attachment. Nynja Build Manual 1.4d...
  • Page 114 U-bracket, with a thin plastic washer between it and the bracket. Leave the bolt securing the pulleys loose at this stage, to allow the aileron cables to be passed through later. Figure 137 lift strut attachments. Figure 138 UKMOD aileron pulleys. Nynja Build Manual 1.4d...
  • Page 115 ( The bolts holding the pulleys and the tu37 should point upwards to avoid pressing against the coverings. Alternatively they may point downwards, but then nutcaps must be used to protect the coverings from the protruding bolt ends. ) Nynja Build Manual 1.4d...
  • Page 116 Note: the lift strut plates (front and rear) have changed slightly and are now in common with the LS version spec and have an extra hole and link plate – they should be assembled as below: Figure 140 rear lift strut attachment. Nynja Build Manual 1.4d...
  • Page 117 The split pins can be secured now, but do not wirelock the turnbuckle until the covering has been fitted. To protect the coverings the bolt securing the turnbuckle should be cut off leaving only a couple of threads showing above the Nyloc. File to remove any sharp edges. Nynja Build Manual 1.4d...
  • Page 118 File edge of this saddle washer clear bracket on fuselage Figure 141 front and rear of tensioning tube. Figure 142 tensioning tube fittings, front in left photo (note bolt through compression tube), rear in right photo. Nynja Build Manual 1.4d...

  • Page 119: Aileron Horn Assembly

    Temporarily mount the aileron onto the wing, and line up the long brace to point at the aileron pulleys.  This will put the brace at around 90 to the trailing edge of the aileron. Nynja Build Manual 1.4d...
  • Page 120 Check the alignment of the rivet holes. These may have to be gently eased with a 4mm drill or reamer. o) Insert all rivets, from the horn side, to ensure they all fit, then pull up the rivets. Nynja Build Manual 1.4d...

  • Page 121: Attaching The Wings To The Fuselage

    Do not overtighten the upper bolts holding the lift struts to the wings, there is no need to distort the connecting brackets. Check that the lower strut attachments lie nice and flat against the TU9 tube. If not carefully bend them until they do. Nynja Build Manual 1.4d...

  • Page 122: Aileron Control Cables

    Select the pair of upper aileron cables, those with the turnbuckles on one end. d) Thread the ends without the turnbuckles around the upper pulleys inside the wings and through the U-brackets at the jury strut attachment locations. Work from the ailerons inwards towards the fuselage. Nynja Build Manual 1.4d...
  • Page 123 Prepare the fittings for attaching the aileron cables to the driving horn connected to the control stick. The Nynja may be supplied with Aileron cables with derig connections on the sections from the pulleys on top of the TU14 tube where they run along behind the front wing spar tube before entering the wing.
  • Page 124 Check the angle of the lower pulley bracket inside the wing. This is the bracket for the cable ca6 that connects to the lower control horn on the aileron. You will need to bend the bracket with a twisting Nynja Build Manual 1.4d...
  • Page 125 If the cables are found to “slap” against the leading edge tubes within the cabin area, either apply tape, or position a couple of cable ties or similar around the leading edge tubes to act as buffers for the cables. Nynja Build Manual 1.4d...

  • Page 126: Flaps

    Flaps a) Remove the horns on the flap roots. b) Fit the longer Nynja items. These fit on the other side of the tube. Cut a slot in the fabric to facilitate them. Fig 152 Nynja Flap horns c) Temporarily mount the flaps on the wings.
  • Page 127 Figure 153 flap handle, looking rearwards and flap rods (note Nynja flap rods have slight bend in upper ends, not shown in this drawing) Nynja Build Manual 1.4d...

  • Page 128: Covering The Wings

    Do not use thick, heavy tape, such as prop tape or gaffer tape, as this adds too much weight, is too grippy, and can look horrible! g) Thicker tape should be applied only to the U-brackets at the wing tips to prevent chafing of the coverings. Nynja Build Manual 1.4d...
  • Page 129 It can be done later but is easier to get in now. These just smooth the leading edge fabric in this inner bay which can otherwise wrinkle where the sail is pushed upwards over the head of the vertical bolt in the Leading edge. Nynja Build Manual 1.4d...
  • Page 130 Check that the fabric is properly seated at the tips of the leading and trailing edges. It should be nice and snug, with no wrinkles near the tip. If prop tape or similar has been incorrectly used it is possible that it will Nynja Build Manual 1.4d...
  • Page 131 Use a piece of cloth between timber and spar to prevent scratching. Pop the cam in and then remove the wood. Figure 157 fitting the compression tube. Nynja Build Manual 1.4d...
  • Page 132 They will fit into the holes cut in the fabric for this purpose. The longer end of the tensioning tubes goes uppermost. The holes cut into these tubes must clip over the battens, and the threaded rod must enter the holes in the compression tube, figure 159 Nynja Build Manual 1.4d...
  • Page 133 Turn the rod with a spanner on the outermost nut, whilst holding the nut behind the tensioning tube with another spanner. The threaded rod will push against the compression tube and tension the fabric. Figure 160 compression tube bowing. Nynja Build Manual 1.4d...
  • Page 134 Measure the distance from the fabric to the end of the leading edge and make both wings the same, otherwise it will look odd when aligned with the cabin doors. A typical measurement is around 44cm. Nynja Build Manual 1.4d...

  • Page 135: Inserting The Battens

    Figure 161 inserting a batten. Use your other hand to prevent the batten twisting. The tip batten in Swift and Nynja wings has considerably less camber that the other battens due to the taper in depth of the wing as it approaches the tip.
  • Page 136 ‘collar’ to release the plastic end. Clean up the end of the batten with a file and re insert the plastic end. Align it to match the tip insert (90 degrees to camber) and fix in place by centre punching the side of the tube. Nynja Build Manual 1.4d...
  • Page 137 After the fabric has settled for a few weeks, any remaining minor wrinkles can be taken out using a heat gun to shrink the fabric. Great care must be taken not to burn the fabric! Nynja Build Manual 1.4d...

  • Page 138: Windscreen Frame And Throttles

    The vertical bolts also pass through the floor (omitted from this picture above for clarity), and the outer one each side should have a penny washer under the nut to spread the load into the floor without crushing. Nynja Build Manual 1.4d...
  • Page 139 900mm apart, so that the upper curved tubes are run parallel back to the rear attachments. The cabin uprights will then lean slightly outwards from their bases. 900mm Figure 170 Position TU34 uprights 900mm apart Nynja Build Manual 1.4d...
  • Page 140 / aft movement of the TU34 upright tube which may close the gap to the leading edge tube once the weight of the cowling is on them. Rivet each side and one in front, and rear rivets here each side Figure 172 – stabilising with rivets Nynja Build Manual 1.4d...
  • Page 141 Figure 173 straight edge across cabin upper tubes. Measurement of 85mm from under tube to straight edge at point of max camber Figure 174 match up with wing so clear roof section will later fit flush like this Nynja Build Manual 1.4d...
  • Page 142 These can be held in place simply by a tube, such as a piece of plastic drainpipe or similar and cable ties / tape. Or a more ‘engineered’ system using aluminium tube and brackets. The aim is to securely locate the tubes. Figure 175 measuring and holding the frame in position. Nynja Build Manual 1.4d...

  • Page 143: Throttles

    Right side throttle pivot has a single nyloc nut, and is not tightened fully Figure 176 dual throttle parts (Note Nynja has slightly different plates than those shown as SKR 736 in drawing- see photos above). Nynja Build Manual 1.4d...
  • Page 144 Do not drill within 12mm of the end of the tube. There should be two rings of four rivets each, Verify the alignment of the levers before riveting the starboard lever in place. Figure 177 throttle torque-tube rivets. 420mm Figure 178 throttle plate fixing dimensions Nynja Build Manual 1.4d...
  • Page 145 – preferably using a pillar drill. Be careful to drill the centre of the tube. Vertical alignment should match the vertical part of the throttle handles where it passes up out of the machined end fitting – figure 179. Nynja Build Manual 1.4d...
  • Page 146 Once the friction has been set, lock the two friction nuts together at both ends. o) Check that the spacing and centralisation of the parts holding the tops of the cabin uprights has not been disturbed by the fitment of the throttles. Nynja Build Manual 1.4d...

  • Page 147: Floor Pan, Firewall And Cowlings

    80 grit paper to achieve a nice even fit. d) Check the rear sides and ensure overlap or alignment with joggled edge of rear fuselage shells. See Fig 178 below Nynja Build Manual 1.4d...
  • Page 148 Offer up the sides and mark and cut so the edge aligns neatly with the joggle in the rear fuselage shells. Use a Dremel cutting wheel, or a fine hacksaw blade worked at a fine angle. Finish with a sanding block to get a nice smooth line with good alignment. Nynja Build Manual 1.4d...
  • Page 149 Fix the rear edge with 4x10 white plastic screws and self locking plastic nuts. l) Cut slot in floor to allow flap detent lever to pass through – see Figure 181 Nynja Build Manual 1.4d...

  • Page 150: Firewall And Scuttle Moulding

    4mm steel rivets with 4mm washers on the back side. If the heater option is to be fitted it may be easier to cut the hole for it and trial fit before fixing the firewall. 95mm Figure 188 position and fixing of firewall to engine mount Nynja Build Manual 1.4d...
  • Page 151 The aluminium will also need triming to match the edge of the moulding. When happy with the fit fix using 3mm countersunk rivets. Use just two for now 50mm either side of the dead centre. The rest will be fitted when Nynja Build Manual 1.4d...
  • Page 152 It is applied to the cockpit side of firewall. It can be done at this early stage or applied near to finish of build. Further sealing grommets can be fitted if desired as in fig above – use non flammable material such as leather etc. Nynja Build Manual 1.4d...

  • Page 153: Engine Cowlings

    Clecos/Skinpins or 4mm nuts and bolts. Starting from the front and working backwards will give the best results with less chance of bulging between fixings. 10mm 30mm Figure 193 front cowling fixing 50mm Figure 194 position and spacing of fixings on side of cowling Nynja Build Manual 1.4d...
  • Page 154 60mm from the final edge. 30mm 170mm 25mm 60mm Figure 195 fixing the cowlings to the scuttle (note cowling may now be supplied with moulded vent holes in lower sides, adjust position of fixing holes accordingly). Nynja Build Manual 1.4d...
  • Page 155 The support should be a similar diameter to the spinner. = to spinner radius Figure 196 cowling support - horseshoe shaped to fit behind engine drive flange. 10-15mm gap Figure 197 spinner / cowling alignment Nynja Build Manual 1.4d...
  • Page 156 Figure 198 fixing the rear of the scuttle g) Fix the firewall to the floor. Use 6 x 4mm rivets each side of centre with a spacing of around 50mm – don’t fit the outer rivets just yet. Nynja Build Manual 1.4d...
  • Page 157 Use the 3mm countersunk rivets, with a spacing of around 50mm evenly arranged around the holes for the cowling fixings. Figure 201 finishing fixing firewall j) All exposed glassfibre within the engine compartment must be painted with the supplied intumescant paint to give them fire resistance. Nynja Build Manual 1.4d...

  • Page 158: Engine Ancillaries

    Centre the muffler side-to-side by reference to the engine mounts and the ridges on the muffler. Note the oil line fitting is off-centre. e) Tighten up the exhaust mounting bolts. Tighten until there is very slight distortion visible in the flanges. Nynja Build Manual 1.4d...
  • Page 159 Fit the twin outlet pipes. Adjust their position so they are clear of the firewall by approximately 20mm, then tighten. Lockwire between the safety loops (this is to prevent loss of a pipe if the clamping comes loose for some reason). Figure 204 overview from port side. Nynja Build Manual 1.4d...

  • Page 160: Oil Cooling

    6-8mm at its lower edge and 2-3mm at its upper edge. using cardboard or similar. Align so both lower edges are level, and with right hand edge 65mm from side tank on water radiator. Nynja Build Manual 1.4d...
  • Page 161 The lip in the opening as supplied is quite large and must be cut right back using a Dremel or similar for the radiator to sit nicely on its brackets without interference. One correct position has been determined mark and drill 5mm. Attach to the cowling with 5mm pan-head bolts. Nynja Build Manual 1.4d...
  • Page 162 Figure 209 routing of oil hose from oil cooler connection to outlet on oil tank. Note use of cableties through short lengths of fuel tubing to act as standoffs on fuel pump and inlet manifold to secure hose. Nynja Build Manual 1.4d...
  • Page 163 Figure 212 Routing of oil hose from Sump connection to inlet of oil tank. It should be cabletied up to the small water pipes under the engine in the position marked to keep it clear of exhaust. Nynja Build Manual 1.4d...

  • Page 164: Water Cooling

    Figure 214 water pipe attachment elbows to left of, and under, inlet manifold. e) The water temperature gauge sender T piece should be installed in the front port water pipe on top of the engine, Fig 215 Nynja Build Manual 1.4d...
  • Page 165 The intake manifold balancing tube, crossing the engine in front of the carburettors, must be curved forward more than its standard position to allow more room for the expansion tank in its new position. Figure 217 expansion tank and rubber elbow. Nynja Build Manual 1.4d...
  • Page 166 Note that either type should have an overflow pipe through the cap. This should be routed down the side of the tank with its end expelling downwards. Figure 219 overflow tank. l) Finally, check the tightness of all the jubilee clips. Nynja Build Manual 1.4d...

  • Page 167: Fuel System

    - examples – both sides of fuel filter, Connections to fuel pump, final connections to carburettors. The crimp type connectors are crimped using a simple pair of pincher pliers: Figure 221 crimp connectors Nynja Build Manual 1.4d...

  • Page 168: Engine Compartment

    Make sure the holes in the firewall are edged or grommeted to prevent the fuel lines from Chafing. Nynja Build Manual 1.4d...

  • Page 169: Fuel Tanks

    Figure 224 aluminium fuel line, cable tie and standoff. 12.3 Fuel Tanks Figure 225 tanks overview Nynja Build Manual 1.4d...

  • Page 170: Fitting Instructions For Hads Optional Mod 33 - Large Diameter Balance Pipe Between Fuel Tanks

    Your (UK) Nynja fuel tanks are supplied pre drilled for the fittings, and the outlet strainer fitting should be ready fitted.. Check the holes in the tanks have smooth sides without flashings. If necessary lightly sand with fine wet and dry sandpaper.

  • Page 171: Fitting

    Hold the fitting firmly whilst tightening to stop it turning with the nut. Tanks can then be refitted. Leave the fixing straps a little loose so tanks can be moved around to fit the fuel hose Fig 232 Nynja Build Manual 1.4d...

  • Page 172: Fuel Tank Load Spreader Bars

    Fit the tank securing straps, There are one long and one shorter one for each tank. The long one goes over the top of the tank, down the other side and Nynja Build Manual 1.4d...

  • Page 173: Fuel Tank Connections

    The fuel tap should be mounted between the fuel tanks towards the starboard side, Figure 230. The mount for the fuel tap is a small piece of aluminium angle, attached with a 4mm steel rivet onto the cross-tube below it. Figure 230 fuel tap, filter and connections Nynja Build Manual 1.4d...
  • Page 174 Just above where the breathers pass through the floor, fit a T piece in each and a joiner pipe between them Breather Breather Fuel return Breathers link together near fuselage skin End of T piece through floor secured with small piece of Tygon and cable Figure 231 fuel tank breathers Nynja Build Manual 1.4d...

  • Page 175: Fuel Filler

    The flexible hose can now be cut to size and fitted – secured with two ‘jubilee’ clips. e) Finally fit a cap on the breather tube on the filler fitting. Use a 6mm plastic nutcap and epoxy or hot glue. Cap on breather tube here Figure 234 Tank filler hose Nynja Build Manual 1.4d...

  • Page 176: Instrument Panel

    Figure 236 dashboard supports and instrument panel framing angles b) Start with fixing the angle (part A) to the firewall flush with its top and centrally positioned, as shown in Fig 218 below. Use 2x 4mm aluminium rivets. Figure 237 mounting angle A Nynja Build Manual 1.4d...
  • Page 177 Standard Part C results in the instrument panel leaning forwards at the top. We lengthened the part C on ours to make the panel fit a little more upright. This also gives additional clearance for long instruments from the Nynja Build Manual 1.4d...
  • Page 178 Overlap by around 25mm. It will also need cutting to allow for the dual throttle torque tube. h) When happy with the fit mark up and drill the securing holes. Use the 4mm clipnuts (or rivuts) over the securing angles and the edges of the triangular Nynja Build Manual 1.4d...
  • Page 179 There are some markings for the aileron cable exit – we didnt use then eaxctly and cut as per photo below. Not that part C has been filed to allow for cable clearence at full aileron deflection Figure 242 Cable exit hole Nynja Build Manual 1.4d...

  • Page 180: Throttle And Choke Cables

    Figure 243 Cable guide viewed from engine bay, and from inside cabin b) Throttle cable outers run in a big loops to pass behind the carburettors and attach via a 90 degree guide peice. Figures 244 Route of throttle cable to starboard carburettor (in white) Nynja Build Manual 1.4d...
  • Page 181 It fits as shown in Fig 225 below: Hook secured with 4mm bolt S70 spring Long 4mm bolt with nut securing it to angle piece, and another nut and washer on far end to contain spring Figures 246 throttle balance spring Nynja Build Manual 1.4d...
  • Page 182 Figure 248 route of choke cable to port carburettor (in white) f) The choke inner cable is a simple loop of cable covered with plastic tube where it passes through the instrument panel on the port side, Fig 250 Nynja Build Manual 1.4d...
  • Page 183 Possible interference with bonnet – the engine rocks quite a bit when starting. On some Nynja’s it has been found that the choke cable guide on the starboard carburettor in the position supplied from Rotax, can come in contact with the bonnet and cracks can develop.

  • Page 184: Instruments

    The Pitot probe should be mounted at the port forward lift strut to wing attachment using a P-clip, fig 229 Replace the standard bolt with a longer bolt (supplied with pitot tube). Nynja Build Manual 1.4d...
  • Page 185 The connecting tube should be routed down the inside of the lift strut, to a push fit joiner tube at the fuselage to lift strut bolt. c) The fuselage piece of tube should enter the cockpit and pass under the floor and up behind the instrument panel to the ASI. Nynja Build Manual 1.4d...

  • Page 186: Electrical System

    16 Electrical System Figure 253 overall wiring schematic, Rotax 912 and standard analogue instruments. (ensure all colours are visible when printed out) Nynja Build Manual 1.4d...
  • Page 187 Figure 254 heavy duty power wiring schematic, Rotax 912. Nynja Build Manual 1.4d...
  • Page 188 Figure 255 low current wiring schematic, Rotax 912. Nynja Build Manual 1.4d...
  • Page 189 Figure 256 instrument wiring schematic, Rotax 912. Nynja Build Manual 1.4d...

  • Page 190: Soft Start Wiring

    To enable this system the engine is wored to the start solenoid. Nynja wiring looms now contain the wiring for this and just need the connects making to the engine plugs. See below the explanatory wiring diagram from the Rotax manual.

  • Page 191: Wiring General Points

    This will serve you well throughout your flying career, not just whilst wiring your Nynja! When making connections, crimping is generally the quickest and best method.
  • Page 192 The capacitor also provides a fail-safe against accidental disconnection of the battery whilst the engine is running, which would otherwise cause the regulator voltage to rise with possible damage to instruments, radio etc. Nynja Build Manual 1.4d...

  • Page 193: Battery

    Ensure that the engine block is well earthed to the airframe, d) Figure 236. Here an extra hole has been drilled in the engine mount. Alternatively, attach the earth to one of the existing bolts if enough thread length is available. Nynja Build Manual 1.4d...
  • Page 194 Ensure the battery terminal boots are firmly in place, and that the rudder stop cables are held away from the battery by their bungee restraint. Failure to do this may result in a short circuit and fire! Nynja Build Manual 1.4d...

  • Page 195: Windscreen And Rear Windows

    The lexans should come marked with the screen pattern. But produced be,low is a full drawing should you need it: The corner patterns should print out full size but use measurements below and scale if necessary 50mm 100mm Nynja Build manual 1.4d...
  • Page 196 Use pattern in preceding page to cut this shape 830mm Trim these lines 260mm in situ to match door pillar Full sheet width Around 800mm and leave plenty then trim to fit in situ Fig 263 – screen pattern Nynja Build manual 1.4d...
  • Page 197 Check that you have not left the leading-edge securing pins in place, as if you do, and they are incorrectly inserted from the front instead of their proper insertion from the rear, you will not be able to get them out again when you have fitted the windscreen! Nynja Build manual 1.4d...
  • Page 198 Before rivetting the lexan in position, apply 3mm self adhesive foam strip to lexan edge so it protects the covering from chafing with the lexan (a good seal also enhances flight and stall characteristics). This can be done later, but will require the wings removing to do it. Nynja Build manual 1.4d...
  • Page 199 – it won’t be easy to get out afterwards.. Use the black 4mm aluminium rivets. j) Get two helpers, one on each side of the fuselage pushing the Lexan tightly into the inside of the curved part of the cowling. Nynja Build manual 1.4d...
  • Page 200 Drill the roof batten (not the screen centre batten) matching the spacing on the adjacent windscreen supports Apply the thin self adhesive foam strip to the batten ensemble where it will touch the lexan. Nynja Build manual 1.4d...
  • Page 201 Dress the rear side edges of the windscreen smooth with a sanding block. Apply two lines of 1x10mm self adhesive foam strip to the edge, where the door will overlap later. Fig 269 windscreen side fillet, and vista vent Nynja Build manual 1.4d...

  • Page 202: Rear Windows

    There are two ways they can be fixed relative to the rear edge of the windscreen: 1. On the UK Nynja demonstrator: We overlapped with the rear windows sliding underneath the rear edge of the windscreen by around 25mm and passing over the cabin cross tube centre.
  • Page 203 TU2 upper fuselage tubes. A dremel cutting wheel and sanding drum makes light work of this. Figure 278 lexan cut around end of TU2 and template to get exact hole shape Nynja Build manual 1.4d...
  • Page 204 Trim the edge of the lexan to be flush with forward edge of tube. Use the trim beading over the exposed edge. The rivet line should be covered with a strip of 3mm self adhesive foam Figure 279 finished installed rear window Nynja Build manual 1.4d...

  • Page 205: Doors

    This is included in UK kits. So you decide which way to do it on your aircraft! Figure 280 fabric enclosure, and extended angle to close gap to wing undersurface rivetted to top of angle. Nynja Build manual 1.4d...
  • Page 206 This edge can then be trimmed to an even overlap. The aluminium door angle should be butted up underneath, drilled to fit in that position. Nynja Build manual 1.4d...

  • Page 207: One Piece Door

    18.2 One Piece Door Figure 282 one piece door frame. Nynja Build manual 1.4d...
  • Page 208 If not fitted already fit this now. It runs the whole way up to align with the joggle in the door sill. Trim and dress the edges of the windscreen and cowling moulding to align just beyond the centre of TU34 – leaving enough edge distance for the rivets. Nynja Build manual 1.4d...
  • Page 209 Fit in position using the gusset plates shown in drawing Fig 285 and 286, with 4mm aluminium rivets. Fig 286 front and rear gusset plates i) Do a final check of fit and operation of the doorframe. Nynja Build manual 1.4d...
  • Page 210 Fit the door and mark carefully the overlap for cutting to final position. The front and lower edge should be cut to match the recess. The rear can overlap the rear window, or another glassfibre strip can be used. Nynja Build manual 1.4d...
  • Page 211 It should be fitted with the bolt tightened to ensure enough friction to prevent inadvertent rotation. A convenient hole in tu34 can be used as a detent, or one drilled for the purpose. Figure 288 front catch. Nynja Build manual 1.4d...
  • Page 212 Alternatively a stay can be fabricated or small gas filled struts fitted to hold the door open Figure 289 door open keeper, and example of an alternative fabricated stay. Nynja Build manual 1.4d...

  • Page 213: Two Piece Door

    This should then match the windscreen lower edge and but against or near it. Lower edge should fit level with the top edge of the floor pan moulding sill. 25mm – to match screen lexan overlap Figure 291 upper and lower hinge positions Nynja Build manual 1.4d...
  • Page 214 Make sure that the rear part of the door frame is close enough to the rear cabin upright to allow the door catch to reach 5-10mm overlap with catch plate. Figure 293 door catch overlap Nynja Build manual 1.4d...
  • Page 215 It is imporatnt that the outwards bend matches the position of the bend in the upper door frame. Get this now and tap it in position so that this can be ascertained and the tube trimmed to fit accordingly. Nynja Build manual 1.4d...
  • Page 216 – 4mm diameter in TU34 and 5mm in TU6. c) Offer it up again, mark and drill the TU34 and TU6 to match, and temporarily fix into position and verify fit, then remove. d) Attach the hinges. Nynja Build manual 1.4d...
  • Page 217 It should fit in the opening with even spacing – again of 10-15mm. Use some spacers to sand it off from the lower door frame and TU34 at this spacing. Adjust the bends as required to get a nice fit. Nynja Build manual 1.4d...
  • Page 218 Figure 298 top rail tube fixed to hinge i) Check opening and closing of door frame and good alignment. Tweak as necessary, then rivet on the upper corners gusset plates, with 4mm aluminium rivets. Figure 299 upper corner gusset plates. Nynja Build manual 1.4d...
  • Page 219 When drilling angle the drill slightly away from the last rivet. When squeezing the rivets bring the rivet upright. This then applies some light tension to the Lexan and prevents the Lexan bulging between rivets. Take care when drilling to ensure the tube is drilled centrally. Nynja Build manual 1.4d...
  • Page 220 Apply 3mm self adhesive foam strip on the upper edge of the lexan aligned with the top edge, where the upper door will overlap. Figure 301 lower door lexan fit g) Refit the upper doors, mark and trim the lexan. Figure 302 upper door lexan fit Nynja Build manual 1.4d...
  • Page 221 Fit the forward catch by drilling a 5mm hole in the forward vertical of the upper door frame just above the bend radius (see Figure 308) Assemble the parts with two 3mm plastic washers, and a saddle washer between catch and doorframe. f) Adjust the tension to achieve some friction. Nynja Build manual 1.4d...
  • Page 222 The door catch is activated by pulling the wire. Fix the front end with a 4mm rivet to the underside of the door tube leaving a slight bow. Figure 305 door catch Nynja Build manual 1.4d...
  • Page 223 Still holding it in position and slightly overbent, apply the rivets. This will then make the door far more torsionally rigid. Figure 307 upper and lower gusset plates (port side lower door) Nynja Build manual 1.4d...

  • Page 224: Tail Surfaces Again

    Figure 308 trim tab cable. b) Fit the trim tab cable bracket on the bolt at the front of the flap lever guide in the position as shown below: Figure 309 trim tab forward cable bracket Nynja Build manual 1.4d...
  • Page 225 Figure 311 position of hole in top elevator surface. f) Also melt a hole in the lower surface of the elevator fabric for the inner cable, 140mm rearwards of the centre of the leading edge and 170mm away from Nynja Build manual 1.4d...
  • Page 226 Attach two springs in parallel from this to the thimble eye emanating from the cable bracket on the lower side of the elevator leading edge (shown in fig 312) Nynja Build manual 1.4d...
  • Page 227 ‘top hat’ bush – as shown in Figure 314 below. e) Fit the stop bolt This is an M5-30 bolt, the threaded end of which sticks out and is covered by a length of tygon tube. It touches the TU19 at limits of Nynja Build manual 1.4d...
  • Page 228 The cable wraps around the top hat bush and is secured using two solderless nipples. The holes in these need to be drilled out to 3mm to accommodate two lengths of the inner cable passing through. Figure 315 cable connection and stop movement illustration Nynja Build manual 1.4d...
  • Page 229 Ensure that the trimmer works in the correct sense! Trim lever forwards, trim tab deflects upwards, pushes elevator downwards, tail goes up, nose goes down. Nynja Build manual 1.4d...

  • Page 230: Centre Console

    Put it loosely in position and mark and cut a preliminary slot for the trim lever (30mm from centreline of console) – or alternatively undo the lever and lay it out of the way and make the slot later. Nynja Build manual 1.4d...
  • Page 231 Use thin Aluminium angle fixed to the floor with self taping screws, to mount the lower edge of the centre console. The angles should be 150mm apart The console should fix to the angle with srews each side – use the 4mm captive lugnut clips and self tapping screws. Nynja Build manual 1.4d...
  • Page 232 These fit with 4x16mm stainless screws, nuts and washers. 115mm 150mm Figure 321 Control stick gaiter fixings. g) Carefully trim the slot for the trim lever to allow full movement. Nynja Build manual 1.4d...
  • Page 233 Figure 322 trim lever finished and edged slot. h) The front edge of the console where it buts against the instrument panel can also be edged with teh rubber beading. Nynja Build manual 1.4d...

  • Page 234: Seats And Seatbelts

    Rest the glassfibre part of the seats on the base and drill and fix them. Front is fixed passing the SKR 0.27eyebolt through the seat base. At the rear the seat is fixed with a P clip, and 5mm panhead bolt Figure 324 Front and rear fixings Nynja Build manual 1.4d...
  • Page 235 The covers have a cord running around a pocket in their perimeter. Make sure this is slack and then tighten after fitting. Push the east cover down into the seat pan to fully engage with the Velcro strips. Figure 327 seat cover fitting Nynja Build manual 1.4d...
  • Page 236 The Nynja seats have two height positions. Seats attach onto the female eyebolts on TU15. The Nynja has long eyebolts with small spacer sleeves. Thse spacers can be fitted above the TU15 – in which case they lift the front of the seat, or can be fitted under the TU15 if a lower position is desired.

  • Page 237: Seatbelts

    The seatbelt should be brought around the sides of the seat. Belts have a single adjusters for lap and shoulder harnesses. Make sure belts are free running and can centre. Don’t be tempted to secure to the beams. Nynja Build manual 1.4d...

  • Page 238: Wheel Spats - Standard

    – or very slightly raised at the rear for best aerodynamic effect. 490mm approx, from end of spat to hole centre – depends on angle so this is a guide only, check fit by offering up before drilling! Figure 333 nose wheel spat. Nynja Build manual 1.4d...

  • Page 239: Main Wheels

    22.2 Main Wheels a) The spats may be positioned as per Fig 334 Note the bulge goes to the inside to encompass the brakes, with the flat spat side outwards. Figure 334 main wheel spats Nynja Build manual 1.4d...
  • Page 240 Fit the spats and secure them with M5 bolts with Nylon washers under the heads to protect the fibreglass. Three bolts secure each spat, two on the inside and one on the outside. Figure 336 spat, showing outer mount bolt. Nynja Build manual 1.4d...

  • Page 241: Fitting The Teardrop Spat Option

    As a guide the holes should follow the following measurements – all using a flexible measuring tape laid to follow curve – a dressmaking tape is ideal: 377m 284mm from seam 469 mm Figure 338 Nynja Build manual 1.4d...

  • Page 242: Main Wheel Spats

    Main Wheel spats Refer to template – fig 345. The template references on the inner attachment screw holes. Position of these holes is shown below (all dimensions around curve as previously: Nynja Build manual 1.4d...
  • Page 243 M6 bolts supplied. The outer attachment bracket fits on top of the axle and is held by the wheel retaining bolt – the bolt should pass through the second hole in the bracket – fig 342 Nynja Build manual 1.4d...
  • Page 244 Figure 344 The spats as supplied have generic openings for the wheels. It will be necessary to trim in places to give adequate clearance from the tyre. Aim for a minimum 10mm gap between tyre and spats. Nynja Build manual 1.4d...
  • Page 245 Some final sanding and fettling may be necessary on the gear leg cut out section and inner attachment holes to get angles aligned between left and right spats, and to avoid abrasion on the gear legs and the brake lines. Figure 345 cut out pattern Nynja Build manual 1.4d...

  • Page 246: Fairings

    Secure the fairing to the fuselage using aluminium white 4mm rivets. c) The edges can be taped over with white self adhesive vinyl tape if desired. 24.2 Upper Fin Fairing Figure 347 Upper fin fairing Nynja Build manual 1.4d...
  • Page 247 Use 3 rivets on each side through the rear spar – taking care to position the top rivet hole below the existing rivet under the covering at the top of the tube. 140mm 20mm Figure 348 rivet position Nynja Build manual 1.4d...

  • Page 248: Wing Root Fairings

    24.4 Cable Exit Fairings Figure 350 Cable exit fairings Make sure cable exit holes are generous, then fix fairings with the white 4x10mm plastic panhead screws. Nynja Build manual 1.4d...

  • Page 249: Tailplane Leading Edge Fairings

    These are simple reinforced fabric fairings that velcro into position on the outer strut ends as shown below. Strips of velco are then stuck on the wing covering to secure the outer ends. Figure 352 strut end fairings Nynja Build manual 1.4d...

  • Page 250: Wingtip Fairings

    Use the white 4mm aluminium rivets. These should fix the wingtip fairing to the TU37a tip tube. Take care not to drill through the U brackets at the ends of the tubes. Don’t drill here ! Figure 354 Wing tip Nynja Build manual 1.4d...
  • Page 251 After verifying where to drill, and checking clearance from aileron, drill the wingtip fairing first. Then offer it up and drill through the holes into the tip tube. Figure 355 marking, drilling and fixing the wingtip fairings. Nynja Build manual 1.4d...

  • Page 252: Aerofoil Profile Support Blocks

    Cut the 10mm wide foam strip supplied into 155mm lengths. Cut 2 for the very end battens 110mm. b) Using some 80 grit sandpaper wrapped around a batten sized tube, sand in some grooves on the edges Figure 357 below Figure 357 Support block dimesnions and grooves Nynja Build manual 1.4d...
  • Page 253 The best technique appears to be to slot against the lower batten first and push , then push the block downwards and under the upper batten into place. Slide the block so as its centre is around 350mm behind the rear face of the leading edge. Nynja Build manual 1.4d...

  • Page 254: Fitting The Heater Option

    This hole should be positioned at or close to the centre of the firewall and so box sits just above the stiffening angle b) Fix the valve to the firewall using 5mm panhead bolts and nyloc nuts orinetae the heater box to be horizontal. Figure359 cockpit side Nynja Build manual 1.4d...
  • Page 255 Cable inner and outer as supplied should be overlong, and can be trimmed to length. Adjust so that valve closes full – just fractionally before the knob hits its stop. Figure 360 heater control knob example Nynja Build manual 1.4d...

  • Page 256: Fitting The Storage Side Pockets

    Or use a sperate strip of thin plastic to apply the velcro to, and then fix that to the cockpit side using the screen fixing screws and nuts – like we did in the middle picture below. Figure 361 side pocket fixing Nynja Build manual 1.4d...

  • Page 257: Preparing For Flight

    Jury strut fits over this. Grommet not required if female eyebolt. It is then fixed with a 4-35mm bolt and Nynja Build manual 1.4d...
  • Page 258 Washers should be used both under the head of the bolt and under the nut. Figure 362 Aerofoil jury strut overview Upright edge Fig 363 Rear and front lower fittings. Note orientation (looking from rear) Nynja Build manual 1.4d...

  • Page 259: General Checks

    Loop the rear securing straps around the base of the rear fuselage bracing frame at its lower corners, with the buckle towards the fuel tanks. The strap should loop around the back of all the tubes. Nynja Build manual 1.4d...

  • Page 260: Controls

    Check the full and free movement, in the correct sense, of all combinations of the controls. c) Check the neutral positions of the flaps and their operation. The flaps should be set with the centre of their trailing edges 125mm above the corner of the fuselage fairing Nynja Build manual 1.4d...
  • Page 261 If any friction is felt then remove the aileron eyebolt hinges and file the holes in the aileron leading edges until the ailerons move freely. This will greatly improve the feel of the aileron controls. Nynja Build manual 1.4d...
  • Page 262 With the rudder straight, the nose-wheel should be straight. Rudder  movement should be 25 each way. Nose-wheel movement should be symmetrical each way. l) Wire-lock all turnbuckles. m) Check the correct operation of the brakes. Nynja Build manual 1.4d...

  • Page 263: Powerplant

    Set enough friction by tightening the inboard nut to prevent the throttles from vibrating open or closed, then lock this setting with the second nut. Do not set any friction at all on the starboard end of the torque tube. Nynja Build manual 1.4d...
  • Page 264 1. Carburettor levers touching the stops on carbs before the throttle lever touches its stop – wind them well clear! 2. Insufficient throttle lever friction. 3. Too much throttle lever friction (causes a ‘stepped’ opening and closing) Nynja Build manual 1.4d...

  • Page 265: Weight And Balance

    The aircraft will have to be weighed with the assistance of your Inspector, using the information given in the HADS, and using current BMAA format for the report. Note that the weighing attitude is critical on a tall aircraft like the Skyranger, and that bathroom scales are notoriously inaccurate.

  • Page 266: Placards

    Please do not put them in the awkward position of having to refuse. The inconvenience of moving the aeroplane to a suitable test flying location is far less than the inconvenience of a rebuild! Nynja Build manual 1.4d...
  • Page 267 Some spare hardware – split pins, nyloc nuts etc. All 450kg of associated paperwork! Refer back to section 1.2 for more information on the paperwork and test flying procedure. And finally, don’t forget your camera to record the moment! Happy Flying! Nynja Build manual 1.4d...

  • Page 268: Additional Information

    27 Additional Information 27.1 Example BMAA Homebuilt Registration Form Nynja Build manual 1.4d...
  • Page 269 Nynja Build manual 1.4d...

  • Page 270: Wire-Locking

    27.2 Wire-locking Nynja Build manual 1.4d...
  • Page 271 Nynja Build manual 1.4d...
  • Page 272 Nynja Build manual 1.4d...
  • Page 273 Nynja Build manual 1.4d...

  • Page 274: Index

    112 central cabin tubes tu19, 39 leading edge tube tu49, 110 compression tubes tu38, 131 Lexan, 197, 219 control stick, 49 LOCTITE, 14 Copaslip, 158 longitudinal tubes tu2, 54 covering, 128 longitudinal tubes tu4, 54 Nynja Build manual 1.4d...
  • Page 275 T-piece, 168 rudder post, 54 trailing edge tube tu50, 110 rudder stops, 51, 96 trim lever, 227 seat front support tube tu15, 47 trim tab horns, 82 seatbelts, 237 trim tabs, 81 seats, 234 trimmer cables, 224 Nynja Build manual 1.4d...
  • Page 276 130 upper cabin triangle tubes tu10, 31 wing root, 132 upper rear cabin cross-piece tu7, 30, wing tensioning tubes, 132 wings, 110 vertical fin, 80 wings, attaching, 121 water overflow tank, 166 wiring loom, 191 Nynja Build manual 1.4d...

  • Page 277: Amendments

    2.9 saddle washer sequence adjustment.10.3 – corrected ommision of application of intumescent paint.5.4 – additional information for fitment of rudder brace. 07.02.15 Change of contact details, numbering of instrument panel angles, fuel Nynja Build manual 1.4d...
  • Page 278 5.4.2 change of text to reflect 3 hinge rudder, and new figs. Fuel tanks – change to incorporate new type strainer, new fig 225. 14.12.16 Update of teardrop spat fixing instructions to reflect change in mounting bracket design. Now 1.4D Nynja Build manual 1.4d...

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