Page 1 Jabiru J450 Constructors Manual from kit/serial number 659...
Page 2: General>Introduction
The gear stays down, the prop pitch is fixed and a simple switch operates the flaps. The brakes are hydraulic and the simplicity will delight you. Your Jabiru kit is designed to be simple to complete and finish, and will provide you with many years of enjoyable flying.
Page 3: General>Constructors Manual
In this Manual you will find all the instructions that you will need to build your very own Jabiru, one step or task at a time. Each task in this Manual stands alone, with the intention that each task will be completed before you move on to the next task. There are many good reasons for this approach: you can easily keep track of where you are in the build;...
Page 4: Table Of Contents
Jabiru J450 Constructors Manual General>Constructors manual Table of Contents General General>Introduction ........................2 General>Constructors manual ....................3 General>Tools and equipment ....................8 General>Glossary ........................11 General>Registration and certification ..................12 General>Reference documentation ..................12 General>Unpacking and support ..................... 13 General>Composite standard procedures ................. 14 General>Aircraft grade bolts and lock nuts ................
Page 5 Jabiru J450 Constructors Manual General>Constructors manual Pre-Paint>Fuselage>Interior>Console>Fit control stick............125 Pre-Paint>Fuselage>Interior>Fit rudder pedal mount blocks ..........129 Pre-Paint>Fuselage>Interior>Fit aileron cable brackets ............131 Pre-Paint>Fuselage>Interior>Fuel system ................136 Pre-Paint>Fuselage>Interior>Fit seatbelt anchors ..............141 Pre-Paint>Fuselage>Interior>Fit rear seat ................144 Pre-Paint>Fuselage>Pre-fit doors ..................146 Pre-Paint>Fuselage>Fit windows ..................
Page 6 Jabiru J450 Constructors Manual General>Constructors manual Post-Paint>Fuselage>Fit rudder, elevator and elevator trim ........... 262 Post-Paint>Fuselage>Fit doors ....................267 Post-Paint>Fuselage>Firewall forward>Final assembly ............270 Post-Paint>Fuselage>Firewall forward>Fit propeller and spinner .......... 274 Post-Paint>Fuselage>Fit wheel spats ..................278 Post-Paint>Wings>Install aileron cables................279 Post-Paint>Wings>Fit stall warning ..................281 Post-Paint>Wings>Prepare wings for fitting ................
Page 7 Jabiru J450 Constructors Manual General>Constructors manual 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 assumed to be sitting in the pilot‟s seat facing towards the front of the aircraft.
Page 8: General>Tools And Equipment
Jabiru J450 Constructors Manual General>Tools and equipment General>Tools and equipment Before getting started we recommend that you acquire the following tools and equipment: these tools are not included in the kit and must be supplied by you. Required tools The following tools and equipment will be required as a bare minimum to complete this kit: Allen keys: imperial set.
Page 9 Jabiru J450 Constructors Manual General>Tools and equipment Optional tools and equipment The following tools are not essential, but they will certainly make the job more pleasant: Air Compressor & Air Gun. You can probably do without this if you plan to contract out your filling and painting job, but if you intend to prime/fill/paint then you'll definitely need to use the air gun to clean out crevices and pinholes in the gel coat.
Page 10 Try aircraft parts or engineering suppliers for this product. Comes in several colours. Loctite compounds This brand name compound is considered essential in the construction of your Jabiru. Purchase the following grades: Type...
Page 11: General>Glossary
Resin system that uses a catalyst to cure. Does not provide good structural properties like epoxies, and for this reason is not used on any structural parts in your Jabiru. Q-Cells (not supplied) Inorganic micro-spheres mixed with resin and used as a lightweight filler, usually used in paint preparation.
Page 12: General>Registration And Certification
Internationally you will need to establish the requirements for building your aircraft under the appropriate regulations governing amateur aircraft building in your particular country. Your local Jabiru distributor can give you guidance on who to consult and how your project should be administered.
Page 13: General>Unpacking And Support
You could also make a note of where you plan to store each part or group of parts. Please notify Jabiru of any missing parts within 3 months of the receipt of your kit. At this stage it would be a good idea to store your instruments in a low humidity environment.
Page 14: General>Composite Standard Procedures
Jabiru J450 Constructors Manual General>Composite standard procedures General>Composite standard procedures Composite introduction Composite construction techniques may seem mystifying to those who have never been involved with composites before but they are straightforward and require only a few basic procedures. Composite surface preparation...
Page 15 10mm in depth otherwise the heat generated during curing may affect the result. Measuring epoxy The Epoxy system used for the production of Jabiru Aircraft is LC3600, which is mixed in a 3:1 ratio, which means that 3 parts of resin are mixed with 1 part of hardener.
Page 16 Jabiru J450 Constructors Manual General>Composite standard procedures Composite general Glassing procedure Any lay-up of glass fibre cloth should follow this general procedure: make a mix of resin and brush a coat of resin onto the entire area to be glassed, then lay the first piece of cloth on and...
Page 17: General>Aircraft Grade Bolts And Lock Nuts
General>Aircraft grade bolts and lock nuts General All bolts 3/16” or larger in diameter that have been supplied with your Jabiru kit are Aircraft grade bolts. Under no circumstances must any bolts other than Aircraft grade bolts be used on your Jabiru.
Page 18 Lock nuts All bolted components on your Jabiru aircraft are held in place with lock nuts, either a Nyloc type fibre lock nut for most uses or a steel lock nut for hot areas such as in the engine bay.
Page 19: General>Rod Ends
This is of the utmost importance and cannot be overstated! Drive connection Most of the rod ends on your Jabiru are driven by a 3/16” bolt through the spherical bush, and they must be connected in the following manner: between the rod end and the drive lever, fit one 3/16”...
Page 20: General>Health And Safety
Jabiru J450 Constructors Manual General>Health and safety General>Health and safety Working with composites is no different than working with other chemicals and flammable materials, and caution and common sense should prevail at all times. NO SMOKING Do not smoke or have any exposed flames near your kit or resin storage area.
Page 21: Pre-Paint>Fuselage>Underbody Penetrations
Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Underbody penetrations 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 flock Procedure Roll the fuselage over carefully onto a padded surface– some old bedding material is ideal –...
Page 22 Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Underbody penetrations Firewall datum 415m 750m Transponder (optional) 22mm 1380mm Fuel vent ½” 2240mm Centreline 2470mm Pitot tube ½” Existing 150mm Fuel vents 2 at ½” Header tank quick drain 1 1/8” Tuesday, April 6, 2010...
Page 23: Pre-Paint>Fuselage>Fit Ventral Fin And Trim Horn
Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Fit ventral fin and trim horn Pre-Paint>Fuselage>Fit ventral fin and trim horn Objectives of this task: To fit the ventral fin, trim horn and cut the related rear fuselage penetrations. This task is carried out while the fuselage is inverted and supported on trestles.
Page 24 Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Fit ventral fin and trim horn Fit the ventral fin Use a chalk line to mark the fore and aft centreline of the fuselage. Lay the ventral fin on the rear of the fuselage and seat it so that it matches the curve of the fuselage, then check that the fin is centred at the front and the rear and tape it in place.
Page 25 Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Fit ventral fin and trim horn Finish the ventral fin Resin Drain holes Cut out Sand the inside bottom rear quarter of the ventral fin. Mix around 200 grams of polyester resin and add a few drops of hardener (take care not to use too much hardener or there may be heat issues as it cures) and pour into the bottom of the ventral fin then prop the fin up at a 45°...
Page 26: Pre-Paint>Fuselage>Prepare The Fuselage
Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Prepare the fuselage Pre-Paint>Fuselage>Prepare the fuselage Objectives of this task: Once the Underbody penetrations Fit ventral fin and trim horn tasks have been completed the fuselage can be turned upright and the remaining penetrations made. This allows the bulk (but not all) of the mess to be made early in the build.
Page 27 Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Prepare the fuselage Remove peel cloth Remove the peel cloth from the vertical fin stub and around the rear of the empennage generally, including around the horizontal stabiliser opening. Lightly sand around the edges of the areas under the peel cloth to remove any peel cloth threads that remain.
Page 28 Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Prepare the fuselage Upper fuselage penetrations 15mm high 20mm from 65mm 35mm bottom of lug 45mm 290mm 2¼” dia from rear of lug 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.
Page 29 Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Prepare the fuselage 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. This step just involves fitting the conduits to the rear bulkhead.
Page 30 Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Prepare the fuselage 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...
Page 31 Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Prepare the fuselage 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.
Page 32: Pre-Paint>Fuselage>Undercarriage>Assemble Main Wheels
Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Undercarriage>Assemble main wheels 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: Cards # J21 „Main wheels‟ Talcum powder for fitting the inner tube Assemble the main wheels Use a press or a vise to press the bearings into the main hub –...
Page 33 Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Undercarriage>Assemble main wheels This completes the Pre-Paint>Fuselage>Undercarriage>Assemble main wheels task. Tuesday, April 6, 2010 33 of 343...
Page 34: Pre-Paint>Fuselage>Undercarriage>Assemble Main Gear
Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Undercarriage>Assemble main gear 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 and wheels and adjusting the brakes. Materials required: Cards # J8 „Dual Brakes‟ and J21 „Main wheels‟...
Page 35 Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Undercarriage>Assemble main gear 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 on the flat backing plate.
Page 36 Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Undercarriage>Assemble main gear Assemble the brake calipers In this step you will assemble the hydraulic disc brake calipers. Cleanliness is essential when working with hydraulic brake parts, so clean your working area and your hands thoroughly before starting this step.
Page 37 Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Undercarriage>Assemble main gear Tuesday, April 6, 2010 37 of 343...
Page 38 Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Undercarriage>Assemble main gear 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 leg and away from the wheel –...
Page 39 Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Undercarriage>Assemble main gear 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 be necessary to slightly bend the brake mounting plate away from the disc –...
Page 40: Pre-Paint>Fuselage>Undercarriage>Fit Main Gear
Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Undercarriage>Fit main gear 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 the fuselage at the same time and the mounting bolt reinforcing plates will be flocked to the cabin floor as part of the fitting process.
Page 41 Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Undercarriage>Fit main gear Use a pencil to mark the position of the clamp plate on the top and bottom of the gear leg – the clamp plate will be flocked onto the gear leg and the marks indicate where you will need to roughen the gear leg in order to provide a key for the flock.
Page 42 Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Undercarriage>Fit main gear Tuesday, April 6, 2010 42 of 343...
Page 43 Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Undercarriage>Fit main gear 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 the curved side facing outwards, followed by a flat washer and a Nyloc nut.
Page 44: Pre-Paint>Fuselage>Firewall Forward>Fit Firewall
Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Firewall forward>Fit firewall 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 of the firewall plate: it is possible to make an accurate bend by...
Page 45 Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Firewall forward>Fit firewall Measure from the centre of the lower bend back to the centre of the upper bend on the fuselage and transfer that measurement to the firewall plate – note that the measurement may be slightly different from side to side so measure each side independently.
Page 46 Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Firewall forward>Fit firewall 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 easier.
Page 47 Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Firewall forward>Fit firewall Once the plate is held in place in this manner you can start to fix it permanently with pop rivets, working carefully around the plate, drilling through the pre-drilled holes in the plate and through the plywood and taking care to always put a washer on the back of each rivet (circled above centre) –...
Page 48: Pre-Paint>Fuselage>Firewall Forward>Firewall Fittings
Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Firewall forward>Firewall fittings 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 the best way to drill it is to use very sharp drill bits and drill very slowly: drill too fast and your drill bit will very quickly become blunt and the stainless will work- harden as well.
Page 49 Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Firewall forward>Firewall fittings 290mm 65mm Fit the right hand cable collar: measure in 290mm from the right hand side of the firewall and up 65mm from the upper bend and drill a 22mm hole through the firewall then fit the cable collar with 6G stainless steel screws (drill 1/8”...
Page 50 Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Firewall forward>Firewall fittings Cabin heater Measure up 180mm from the lower bend and in 340mm from the left hand side of the firewall step and drill a pilot hole, then drill a 1 5/8” (41mm) hole for the cabin heater firewall fitting.
Page 51 Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Firewall forward>Firewall fittings Fuel fitting Assemble the firewall fuel line fitting: Press the flat plate of the brass bulkhead fuel fitting into the top of the aluminium sleeve (this sleeve connects to the plastic fuel sheath on the inside of the firewall), and bond it into place with 5-minute Araldite.
Page 52 Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Firewall forward>Firewall fittings Electrical components 30mm 50mm Use some 3mm aluminium to make backing plates for the solenoid and the earth terminal as shown below – these are to spread the load and minimise crushing of the plywood firewall.
Page 53 Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Firewall forward>Firewall fittings Air box outlet tube Remove the cover from the air box: it is held in place by 4 screws, one at each corner. 15° Cut a hole in the bottom of the angled lower front part of the cover and fit the supplied short length of fibreglass tube and fit in place so that when the cover is laying on the workbench as shown at above left the tube angles upwards at an angle of 15°.
Page 54: Pre-Paint>Fuselage>Firewall Forward>Assemble And Fit Nose Gear
Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Firewall forward>Assemble and fit nose gear 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 aircraft is standing on its own 3 wheels, the main gear having been fitted previously.
Page 55 Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Firewall forward>Assemble and fit nose gear Lever Nose leg Main rubbers Rebound rubber 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...
Page 56 Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Firewall forward>Assemble and fit nose gear Tuesday, April 6, 2010 56 of 343...
Page 57 Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Firewall forward>Assemble and fit nose gear Tuesday, April 6, 2010 57 of 343...
Page 58 Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Firewall forward>Assemble and fit nose gear Fit the nose leg housing Level the aircraft laterally: a straightedge across the bottom of the front doorframes or across the front wing attachment lugs will provide a good reference, then pack under the main wheels as required in order to level the aircraft in the lateral or rolling plane.
Page 59 Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Firewall forward>Assemble and fit nose gear 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...
Page 60 Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Firewall forward>Assemble and fit nose gear This completes the Pre-Paint>Fuselage>Firewall forward>Assemble and fit nose gear task. Tuesday, April 6, 2010 60 of 343...
Page 61: Pre-Paint>Fuselage>Firewall Forward>Fit Engine Mount And Engine
Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Firewall forward>Fit engine mount and engine 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 points only, the engine will be attached to the engine mount, then the engine angle of incidence will be set and finally the engine mount will be fitted to the bottom attach points on the firewall.
Page 62 Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Firewall forward>Fit engine mount and engine Fit the engine to the engine mount Fit the female rubbers to the top mounts and the machined spacers and male rubbers to the bottom mounts – refer to the drawing on the next page for details.
Page 63 Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Firewall forward>Fit engine mount and engine Tuesday, April 6, 2010 63 of 343...
Page 64 Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Firewall forward>Fit engine mount and engine Set the engine angle of incidence In this step the engine will be adjusted until a level or digital protractor (pictured below) placed on the top of the crankcase reads completely level fore and aft, which indicates an angle of incidence of 0°...
Page 65: Pre-Paint>Fuselage>Firewall Forward>Fit Propeller Flange Extension
Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Firewall forward>Fit propeller flange extension 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 fit the model- specific propeller flange extension to the crankshaft. While this is a straightforward mechanical task it is most definitely a critical task and care must be taken.
Page 66 Re-check the torque values again and then lockwire each pair of cap screws together. Lockwiring cap screws in extended propeller flanges is very difficult. Jabiru only lockwire cap screws in standard propeller flanges. This completes the Pre-Paint>Fuselage >Firewall forward>Fit propeller flange extension task.
Page 67: Pre-Paint>Fuselage>Firewall Forward>Fit Oil Cooler
Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Firewall forward>Fit oil cooler 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 under the oil filter and the whole assembly plumbed up and the oil overflow bottle will be fitted to the firewall.
Page 68 Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Firewall forward>Fit oil cooler Tuesday, April 6, 2010 68 of 343...
Page 69 Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Firewall forward>Fit oil cooler 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 cooler. Do not over tighten, as the brass threads can strip if excess pressure is applied.
Page 70 Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Firewall forward>Fit oil cooler 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.
Page 71 Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Firewall forward>Fit oil cooler Oil overflow bottle Fibreglass moulded oil bottle mounting. The oil overflow bottle, as shown in Inlet Outlet the photo on the right, fits into a fibreglass bracket that is mounted on the lower right side of the firewall.
Page 72 Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Firewall forward>Fit oil cooler Plastic moulded oil bottle mounting. The oil overflow bottle, plastic moulded type, as shown in the photo on the right, is mounted to Inlet the firewall with a saddle clamp on the lower outlet, on the lower right side of the firewall.
Page 73: Pre-Paint>Fuselage>Firewall Forward>Fuel Pump Fittings
Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Firewall forward>Fuel pump fittings 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 be fitted from the firewall fitting to the fuel pump and then to the carburettor.
Page 74 Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Firewall forward>Fuel pump fittings Fit the fuel lines and drain hoses The fuel lines are connected in 2 runs: from the firewall fitting to the engine-driven fuel pump; and from the engine-driven fuel pump to the carburettor fuel inlet fitting. If you are fitting a fuel flow or fuel pressure sensor it should be inserted into the fuel line between the fuel pump and the carburettor at a point near the midpoint of the line.
Page 75: Pre-Paint>Fuselage>Firewall Forward>Fit Ram Air Cooling Ducts
Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Firewall forward>Fit ram air cooling ducts 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 final step, where the front of the ducts are trimmed to length to match the bottom...
Page 76 Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Firewall forward>Fit ram air cooling ducts Oil line cutouts Oil lines 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 baffle and the air dams will need to be adjusted and then the sequence repeated perhaps 2 or 3 times until the fit is correct.
Page 77 Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Firewall forward>Fit ram air cooling ducts Left-hand duct, shown here upside down. The pencil marking is on the rear baffle The baffles at the rear of each duct will need to be trimmed to allow the duct to sit down correctly.
Page 78 Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Firewall forward>Fit ram air cooling ducts Fit the magneto coil cooling tubes Left-hand magneto coil – cut the tube parallel to the side of the coil Starting with the left-hand duct, drill a ½” hole at the top centre rear of the duct and slip the 90°...
Page 79: Pre-Paint>Fuselage>Fit Windscreen
Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Fit windscreen Pre-Paint>Fuselage>Fit windscreen The windscreen is an integral structural component of the airframe, providing strength and rigidity, and the correct fitting method is very important. The windscreen is made from strong but brittle Perspex and care must be taken to avoid marking or cracking the windscreen while it is being fitted.
Page 80 Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Fit windscreen Drill the screw holes With the windscreen still held firmly in place by the tape, the next step is to drill a series of 11/64” holes around the perimeter at the positions shown above. Note that 11/64” is slightly bigger than the screws –...
Page 81 Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Fit windscreen Fit the windscreen Mix 160 grams of flock and fill the entire joggle up to the level of the foam strip. Carefully place the windscreen onto the bed of flock – start at one corner and position the windscreen with a rivet or similar to get the alignment of the holes and then lower it into position.
Page 82: Pre-Paint>Fuselage>Fit Control Cables And Lines
Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Fit control cables and lines 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, will be routed from the empennage to the cockpit for later connection.
Page 83 Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Fit control cables and lines 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 holding the electrical cables and the static tube from moving back –...
Page 84 Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Fit control cables and lines 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...
Page 85: Pre-Paint>Fuselage>Empennage>Fit Vertical Tail Fin
Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Empennage>Fit vertical tail fin 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 strobe light wiring and the VHF antenna coax cable.
Page 86 Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Empennage>Fit vertical tail fin Prepare the vertical fin Start by laying the vertical fin on its side and drilling out the marked inspection hole on the left-hand side with a hole saw. Turn the vertical fin over and cut out the marked slot for the...
Page 87 Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Empennage>Fit vertical tail fin 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 being able to slip down further than the joggle at the back.
Page 88 Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Empennage>Fit vertical tail fin 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, so allow yourself at the very least 4 hours, possibly longer depending if your helpers can lay up glass fibre cloth with you or not.
Page 89 Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Empennage>Fit vertical tail fin 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 one at a time – finish one side completely before moving on to the other side.
Page 90 Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Empennage>Fit vertical tail fin 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 stabiliser.
Page 91 Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Empennage>Fit vertical tail fin 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 at the front and the rear and one as close to the middle as possible.
Page 92 Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Empennage>Fit vertical tail fin Next day, shorten the VHF coax cable to length, and fit ferrite toroids, crimp 4.5mm electrical ring terminal connectors to the inner cable and the outer coax sheath and fit heat shrink tubing over the terminal joins, as shown in the sketch below.
Page 93 Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Empennage>Fit vertical tail fin 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.
Page 94: Pre-Paint>Fuselage>Empennage>Fit Elevator
Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Empennage>Fit elevator 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 the horizontal stabiliser. This task is performed on trestles prior to the fitting of the horizontal stabiliser to the fuselage.
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 Fit the elevator hinges Test fit the hinges using 2 Clecoes per side and slide the hinge pin into place as shown above. Fit the 2 outer hinges first – this will hold the elevator in place while the inner hinges are fitted.
Page 97 Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Empennage>Fit elevator 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 foam in the end of the elevator and then test fit each end cap.
Page 98: Pre-Paint>Fuselage>Empennage>Fit Horizontal Stabiliser
Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Empennage>Fit horizontal stabiliser 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 hinges were fitted in the previous task Pre-Paint>Fuselage>Empennage>Fit elevator.
Page 99 Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Empennage>Fit horizontal stabiliser 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 rear channel of the horizontal stabiliser and note the part number.
Page 100 Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Empennage>Fit horizontal stabiliser 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 stabiliser in to place, pushing it fully forward.
Page 101 Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Empennage>Fit horizontal stabiliser Glass the tailcone In this step you will apply 3 layers of 320 x 200mm glass fibre cloth to the tailcone, starting at the top and wrapping the glass cloth behind the stabiliser and under the tailcone.
Page 102 Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Empennage>Fit horizontal stabiliser 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 strip of glass fibre cloth around the stabiliser-to-fuselage join and brush into place.
Page 103: Pre-Paint>Fuselage>Empennage>Fit Rudder
Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Empennage>Fit rudder 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 „Rudder‟ Epoxy resin and flock...
Page 104 Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Empennage>Fit rudder 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...
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Page 106 Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Empennage>Fit rudder 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.
Page 107 Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Empennage>Fit rudder Fit the rudder cable bracket clamp Fit a rod end to the rudder cable: thread it on to half the thread depth. The total cable travel is 80mm: pull the inner cable all the way out and make a mark at 40mm from the outer cable then push the inner cable in to that mark.
Page 108: Pre-Paint>Fuselage>Fit Cowling
Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Fit cowling 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 and small adjustments to get the fit just right: take your time and your reward will be a perfectly fitting, great-looking cowl.
Page 109 Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Fit cowling 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. To mark Line up and cut...
Page 110 Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Fit cowling Fit the bottom cowl to the fuselage Offer the bottom cowl up to the top cowl – a well padded saw stool can be used to hold the cowl up – and fit the locating section at the front of both cowls to position the bottom cowl.
Page 111 Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Fit cowling 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.
Page 112 Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Fit cowling Fix the cowl hinges Sand the bonding surface on each cowl half and the backs of each hinge half to give the flock a good key to bond to. Clean your Clecoes in Acetone and dry them. Keep the tin of Acetone handy for later (in fact storing your Clecoes in Acetone can be a good idea because it keeps them free of oil and other contaminants that could affect an efficient bond).
Page 113 Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Fit cowling Fit the hinge pin guides These guides are the 2 lengths of aluminium tube on the Card that are used to guide the hinge pins through the door jambs and into the cowl hinges. When the cowls are finally installed the ends of the hinge pins will be bent in at right angles and the door will hold them in place.
Page 114 Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Fit cowling Final fit the cowling Fit the top and bottom cowls to the fuselage and insert the hinge pins from the front door openings. Drill one 5/16” hole through each side of the propeller boss for a Camloc fitting (shown circled at right).
Page 115 Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Fit cowling Fit the cabin air inlet flange a 30mm hole on the left front of the lower cowl, 100mm below the bottom lip of the air Drill inlet and 180mm to the left of the propeller centreline.
Page 116: Pre-Paint>Fuselage>Fit Flap Drive Shaft Bearing Blocks
Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Fit flap drive shaft bearing blocks 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 fuselage.
Page 117 Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Fit flap drive shaft bearing blocks Fit the bearing blocks Roughen the inside of the fuselage around the area where the bearing blocks will be mounted and sand the backs of the bearing blocks, mix a small batch of resin and coat the area to be...
Page 118: Pre-Paint>Fuselage>Interior>Console>Pre-Fit Handbrake
Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Interior>Console>Pre-fit handbrake 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 task the handbrake will be removed and stored until final fitting following painting and installation of the interior trim.
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 Fit the handbrake lever Assemble the two red knobs to the handbrake lever, with the longer knob to the left of the lever (the same side as the machined recess) and secure with the supplied bolt and nut.
Page 121: Pre-Paint>Fuselage>Interior>Console>Pre-Fit Trim Control
Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Interior>Console>Pre-fit trim control 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 and fit the trim cable clamp to the seat base. At the completion of this task the trim levers will be removed and put aside until the final fitting following painting and installation of the upholstery.
Page 122 Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Interior>Console>Pre-fit trim control Trim pivot and trim levers: Trim levers Friction washers Pivot bushes Pivot barrel Pivot shaft Align and fit the trim pivot bushes Pilot holes for the pivot bushes are pre-drilled in the console. Start by enlarging the holes for the pivot bushes slightly with a round file until the pivot bushes can be fitted snugly and the file sits level through the holes and square to the console when viewed from above.
Page 123 Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Interior>Console>Pre-fit trim control 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 level with the top of the forward console.
Page 124 Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Interior>Console>Pre-fit trim control Align and fit the trim cable clamp It is important that the trim cable clamp is accurately positioned against the left-hand side of the console in a way that minimises any bending loads on the trim cable. The procedure is as...
Page 125: Pre-Paint>Fuselage>Interior>Console>Fit Control Stick
Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Interior>Console>Fit control stick 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 column bushes into the console, set up the endplay of the control column and fit the control stick to the console.
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 Fit the bushes to the console Fit the stick pivot plate carefully into the Front bush control shaft and secure with 2 x AN3- 13A bolts, spacers, washers and Nyloc nuts. The nuts should face the left-hand...
Page 128 Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Interior>Console>Fit control stick It is very important that the rear bush and mounting plate are fitted to the console at precisely 90° to the control shaft, and that there is no friction between the bushes and the shaft.
Page 129: Pre-Paint>Fuselage>Interior>Fit Rudder Pedal Mount Blocks
Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Interior>Fit rudder pedal mount blocks 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 alignment and if necessary the lower blocks will be flocked into place on the floor brackets.
Page 130 Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Interior>Fit rudder pedal mount blocks Sand a slightly bigger area than the marked area and sand the bottom of each mount block to ensure a good key for the flock. Mix a small batch of flock and apply to the marked areas, taking care to keep flock out of the three captive nuts under the centre mount block, then loosely place each mount block into position again with a single bolt in each centre hole.
Page 131: Pre-Paint>Fuselage>Interior>Fit Aileron Cable Brackets
Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Interior>Fit aileron cable brackets 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. Positioning of the aileron cable brackets is absolutely critical and great care must be taken in this task.
Page 132 Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Interior>Fit aileron cable brackets Aileron cable bracket positioning template Tuesday, April 6, 2010 132 of 343...
Page 133 Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Interior>Fit aileron cable brackets Align the template and mark the bracket positions Temporarily attach the template to the control yoke with 2 bolts placed through the yoke and into the template as shown circled at the bottom of the photo at right.
Page 134 Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Interior>Fit aileron cable brackets 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 area shown in the left-hand photo below: cut just far enough to remove the curved lip from the side of the seat back, about 10mm.
Page 135 Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Interior>Fit aileron cable brackets 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: Pre-Paint>Fuselage>Interior>Fuel System
Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Interior>Fuel system 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 the header tank will be sized slightly over- length and stored for later connection in the Post-Paint>Wings>Fit wings...
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 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 and Nyloc nuts and tighten the nuts to safety.
Page 139 Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Interior>Fuel system 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 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 fitting and sealed) and sized the blue fuel lines from the upper fuselage conduits through to the fuel header tank and stored the lines for later fitting.
Page 141: Pre-Paint>Fuselage>Interior>Fit Seatbelt Anchors
Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Interior>Fit seatbelt anchors 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 important one – the seat belts must be anchored correctly because if you ever really need your seat belt (and here‟s hoping that you never do) it has to be attached to the airframe...
Page 142 Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Interior>Fit seatbelt anchors Top anchor brackets: front seat The top anchor brackets mount behind the Front of aircraft whalebone with the centre of the bracket precisely level with the bottom of the upper door compression gusset. Mark as shown in the photo at right.
Page 143 Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Interior>Fit seatbelt anchors Rear seat anchor brackets 100mm 100mm 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 while the inner brackets are mounted 25mm from the longitudinal rib.
Page 144: Pre-Paint>Fuselage>Interior>Fit Rear Seat
Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Interior>Fit rear seat 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 expandable foam to provide rigidity.
Page 145 Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Interior>Fit rear seat 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 spray generally backwards.
Page 146: Pre-Paint>Fuselage>Pre-Fit Doors
Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Pre-fit doors 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 fuselage has been painted. In the photos that follow the pilots door is shown, however the exact same technique is used for each door.
Page 147 Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Pre-fit doors 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...
Page 148 Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Pre-fit doors 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”...
Page 149 Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Pre-fit doors Fit the key lock Remove the bottom section of the door jamb and set aside for the moment. 30mm 30mm 60mm 130mm 130mm Front Back 20mm door door Mark a position 30mm out from the rear of the opening and 130mm up from the bottom of the opening and drill a pilot hole, then drill out to 18mm and elongate the hole with a round file until the door lock barrel can be mounted snugly into the hole.
Page 150: Pre-Paint>Fuselage>Fit Windows
Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Fit windows Pre-Paint>Fuselage>Fit windows The windows are formed from strong but brittle acrylic and care must be taken to avoid marking or cracking the windows while they are being fitted. The windows are fixed in place with flock and without screws, however screws are used around the windows to hold the windows in place while the flock cures and are then removed.
Page 151 Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Fit windows Prepare the window Remove the window carefully and clean and blow away any dust and debris from the joggle. Place the window face down on the bubble wrap packing material, taking care not to allow anything to scratch the surface, and carefully sand around the entire inside edge with emery tape –...
Page 152: Pre-Paint>Fuselage>Wheel Alignment
Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Wheel alignment 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 airframe on rotation or landing. The amount of shuddering seems to be variable, depending on the all up weight of the aircraft.
Page 153 Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Wheel alignment Mark the position of the straightedge in both forward and aft positions and join the two points, repeating the same procedure for the opposite side. Take measurements from the straight edge positions to the centreline of the fuselage, repeat for the opposite side and compare the numbers to see if the wheels have toe-in or toe-out.
Page 154: Pre-Paint>Fuselage>Pre-Fit Wheel Spats
Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Pre-fit wheel spats 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 done in the stages described below.
Page 155 Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Pre-fit wheel spats Check that the tire has about 5mm clearance all round the bottom of each spat, then remove the spats and set aside for painting. Completed main wheel spats are shown above. Nose wheel spat The nose wheel spat is in 2 sections, front and back.
Page 156 Jabiru J450 Constructors Manual Pre-Paint>Fuselage>Pre-fit wheel spats 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.
Page 157: Pre-Paint>Wings>General
Jabiru J450 Constructors Manual Pre-Paint>Wings>General Pre-Paint>Wings>General In our factory we combine several smaller tasks on the wing into the one three day operation: we work on the top surface first, starting with the fuel filler body and then the winglet, then we move to the wing root and install the fuel fittings, fit the breather tube and cut the recess for the flap arm.
Page 158: Pre-Paint>Wings>Fit Fuel Tank Filler Body
Jabiru J450 Constructors Manual Pre-Paint>Wings>Fit fuel tank filler body 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 surface and a smaller hole will be drilled into the wing tank and then the filler body will be fitted and then flocked into place and covered with peel cloth while the flock cures.
Page 159 Jabiru J450 Constructors Manual Pre-Paint>Wings>Fit fuel tank filler body 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.
Page 160 Jabiru J450 Constructors Manual Pre-Paint>Wings>Fit fuel tank filler body Fit the filler body Now, working slowly, enlarge the hole in the tank (sandpaper taped to a section of tubing is useful for this) just enough so that the filler body is a good firm fit into the tank. Remove the filler body and clean all of the area surrounding the holes.
Page 161 Jabiru J450 Constructors Manual Pre-Paint>Wings>Fit fuel tank filler body When the flock is almost level with the top of the wing surface, cut a piece of peel cloth and carefully brush it into place with no wrinkles or bubbles. Leave overnight to cure. Next day remove the peel cloth and seal the opening with a square of plastic or heavy card secured with masking tape to keep the tank free of dust and dirt.
Page 162: Pre-Paint>Wings>Prepare Wing Root
Jabiru J450 Constructors Manual Pre-Paint>Wings>Prepare wing root 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 Fit the breather tube and the fuel cap The breather tube will now be visible through the fuel filler opening on top of the wing. Move it to the rear of the opening and behind the filler body, then take the plain earth wire...
Page 164 Jabiru J450 Constructors Manual Pre-Paint>Wings>Prepare wing root The drawing above shows the components and the process of assembly so that you can see how the parts all fit together, while the photo below right shows the actual fitting taking place in the fuel filler opening.
Page 165 Jabiru J450 Constructors Manual Pre-Paint>Wings>Prepare wing root Cut out the flap arm recess 27mm 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 around the wing attachment lug (circled): under no circumstances must any material be removed from the lug.
Page 166: Pre-Paint>Wings>Cut Aileron Cable Openings
Jabiru J450 Constructors Manual Pre-Paint>Wings>Cut aileron cable openings 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 cable openings. Check and cut the aileron cable inspection opening Turn the wing upside down and pack under the trailing edge so that the wing is stable.
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 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...
Page 169: Pre-Paint>Wings>Fit Quick Drain Sumps
Jabiru J450 Constructors Manual Pre-Paint>Wings>Fit quick drain sumps 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.
Page 170 Jabiru J450 Constructors Manual Pre-Paint>Wings>Fit quick drain sumps 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 example shown in the photos on this page.
Page 171: Pre-Paint>Wings>Mount Flaps
Jabiru J450 Constructors Manual Pre-Paint>Wings>Mount flaps 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 rear of the wing with the front...
Page 172 Jabiru J450 Constructors Manual Pre-Paint>Wings>Mount flaps 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 with cloth tape as shown above.
Page 173 Jabiru J450 Constructors Manual Pre-Paint>Wings>Mount flaps 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 of the flap to wing gap (blue arrows above right) to create the required curve to the underside of the wing as shown above left.
Page 174 Jabiru J450 Constructors Manual Pre-Paint>Wings>Mount flaps 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 Fit the flap brackets In this step the flap brackets will be flocked into place and then covered with 3 layers of glass fibre cloth. This all needs to be completed in the one continuous operation. In our factory this step takes over an hour with an experienced person, so allow perhaps 2 hours or slightly more.
Page 176 Jabiru J450 Constructors Manual Pre-Paint>Wings>Mount flaps 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...
Page 177 Jabiru J450 Constructors Manual Pre-Paint>Wings>Mount flaps Check the slot size At this point you have mounted the flap to the wing with the flap upper surface correctly aligned in relation to the trailing edge of the wing. Now the slot size – the gap between the trailing edge of the wing and the leading edge of the flap –...
Page 178: Pre-Paint>Wings>Fit Wing Tips
Jabiru J450 Constructors Manual Pre-Paint>Wings>Fit wing tips 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 strobe wiring along behind the leading edge and out of the wing root.
Page 179 Jabiru J450 Constructors Manual Pre-Paint>Wings>Fit wing tips Fit the strobes (optional) Should you elect to fit strobe lights to the wingtips you will find a shaped fibreglass strobe mounting base in with the strobe packing. Decide exactly where you want the strobe to fit and...
Page 180: Pre-Paint>Wings>Fit Ailerons
Jabiru J450 Constructors Manual Pre-Paint>Wings>Fit ailerons 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 ailerons will be fitted to the wings.
Page 181 Jabiru J450 Constructors Manual Pre-Paint>Wings>Fit ailerons 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 sides of the curved rib) and sand lightly.
Page 182 Jabiru J450 Constructors Manual Pre-Paint>Wings>Fit ailerons 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 on top of the pre-mould strip and weight with several paving blocks or half-bricks.
Page 183 Jabiru J450 Constructors Manual Pre-Paint>Wings>Fit ailerons 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 tip/winglet and check that the pre-marked aileron recess on the top of the wing is parallel to the front edge of the aileron.
Page 184 Jabiru J450 Constructors Manual Pre-Paint>Wings>Fit ailerons 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.
Page 185 Jabiru J450 Constructors Manual Pre-Paint>Wings>Fit ailerons 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 flocked in place at each side.
Page 186: Pre-Paint>Wings>Fit Pitot Tube To Strut
Jabiru J450 Constructors Manual Pre-Paint>Wings>Fit pitot tube to strut 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. 340mm Take the right hand strut and measure down 340mm from the upper/wing end of the airfoil- shaped section, mark and drill a 10mm hole in the front of the strut.
Page 187 Jabiru J450 Constructors Manual Pre-Paint>Wings>Fit pitot tube to strut This completes the Pre-Paint>Wings>Fit pitot tube to strut task. Tuesday, April 6, 2010 187 of 343...
Page 188: Pre-Paint>Wings>Fit Vibration Damper To Strut
Jabiru J450 Constructors Manual Pre-Paint>Wings>Fit vibration damper to strut 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: Vibration damping strips (approx 975 x 11 x 3mm, pack of 2) ►...
Page 189 Jabiru J450 Constructors Manual Pre-Paint>Wings>Fit vibration damper to strut This completes the Pre-Paint>Wings>Fit vibration damper to strut task. Tuesday, April 6, 2010 189 of 343...
Page 190: Pre-Paint>Wings>Test Fit Wings
Jabiru J450 Constructors Manual Pre-Paint>Wings>Test fit wings 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 that may be required so that there will be no issues during the final fit after the wings and fuselage have been painted.
Page 191 Jabiru J450 Constructors Manual Pre-Paint>Wings>Test fit wings Test fit the wing Because the precise alignment of the wing bolts is critical the bushes in the wing attach lugs in the wing root that the bolts pass through are mounted in a bed of flock to allow for fine adjustment during fitting.
Page 192 Jabiru J450 Constructors Manual Pre-Paint>Wings>Test fit wings The important thing at this stage is to relieve the weight of the wing while the flock cools and sets in the correctly aligned position, and this is done by lifting the outboard end of the wing up about 35mm from the resting position and supporting it overnight.
Page 193 Jabiru J450 Constructors Manual Pre-Paint>Wings>Test fit wings 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.
Page 194 Jabiru J450 Constructors Manual Pre-Paint>Wings>Test fit wings 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 the main gear mounting recess.
Page 195: Paint>General
Jabiru J450 Constructors Manual Paint>General 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 topcoat. Body filler adds weight to your aircraft and Q-Cell is the lightest filler available so we suggest that you use Q-Cell for the larger fills and finish off with a lightweight body filler.
Page 196 Jabiru J450 Constructors Manual Paint>General Sandpaper: Generally we recommend and use “3M” brand (or 150mm “Stickit” brand pads for a random orbital sander) aluminium oxide sandpaper in the following grades and quantities:  First all over sand 180-grit 1 box ...
Page 197: Paint>Masking
Jabiru J450 Constructors Manual Paint>Masking Paint>Masking General: we recommend and use regular automotive masking tape and brown masking paper. We do not recommend the use of newspaper for masking due to its porous/absorbent nature. We recommend and use “Fine Line” brand edging tape (photo below left) to define the edges of windscreen and windows then follow up with normal 1”...
Page 198: Paint>Surface Preparation
Jabiru J450 Constructors Manual Paint>Surface preparation Paint>Surface preparation It is true that any paint job is only as good as the preparation – shiny paint will most definitely not hide anything, and in fact shiny paint will only magnify any lack of preparation so surface preparation will be the most time-consuming (and ultimately rewarding) part of the painting process.
Page 199: Paint>Topcoat
Jabiru J450 Constructors Manual Paint>Topcoat Paint>Topcoat This is what you have been working towards – the application of the topcoat. This is a critical task where you only get one chance to get it right. If you are unsure of your ability to apply the topcoat then you may want to hire a professional painter –...
Page 200: Post-Paint>General
Jabiru J450 Constructors Manual Post-Paint>General Post-Paint>General Objectives of this section: This is the beginning of the Post-Paint section of the Constructors Manual. At this point you should have a shiny white painted fuselage and a large number of painted aircraft parts along with boxes of upholstery, wiring and instrumentation in your workshop.
Page 201: Post-Paint>Fuselage>Fit Panel Mounted Throttle
Jabiru J450 Constructors Manual Post-Paint>Fuselage>Fit panel mounted throttle 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 # J4 “Panel Mount Throttle” Bearing blocks...
Page 202 Jabiru J450 Constructors Manual Post-Paint>Fuselage>Fit panel mounted throttle Fit the rod ends to the inside of the input levers with AN3-8A bolts fitted through the input levers, then an AN960-416 (3/16”) flat washer, then the rod end followed by an AN960-515 (1/4”) flat washer and a Nyloc nut as shown in the photo on the previous page.
Page 203 Jabiru J450 Constructors Manual Post-Paint>Fuselage>Fit panel mounted throttle Fit the instrument panel retaining nuts At this point tape the instrument panel back in place and drill through the instrument panel mounting holes in the panel with a 5/32” drill. Remove the panel and fit captive nuts behind each hole –...
Page 204: Post-Paint>Fuselage>Assemble Instrument Panel
Jabiru J450 Constructors Manual Post-Paint>Fuselage>Assemble instrument panel 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 connectors ready for installation into the instrument panel housing.
Page 205 Jabiru J450 Constructors Manual Post-Paint>Fuselage>Assemble instrument panel Fit the hardware to the panel The panel assembly sequence is: prepare and fit the circuit breakers, then the switches and panel lights, then the instruments, radio(s), intercom and transponder. The Standard panels have a single long earth busbar while Jumbo panels have 3 earth busbars, 1 for the circuit breakers, 1 for the panel lights and 1 for general use.
Page 206 Jabiru J450 Constructors Manual Post-Paint>Fuselage>Assemble instrument panel Lay the panel face down on a soft surface and fit the earth busbar over the back of the circuit breakers. Fit the switches though the earth busbar and though the panel. Each switch has 2 retaining nuts: one nut will remain behind the panel and be used to tighten the switch in place and the other nut will be fitted to the front of the switch on the panel face.
Page 207 Jabiru J450 Constructors Manual Post-Paint>Fuselage>Assemble instrument panel Fit the LED lights through to the panel and busbar. The green light is the Master light; the rest will be red lights. The connectors are labelled [+] and [-] – align all the [+] connectors to face in the same direction.
Page 208 Write the Jabiru stock number on the tagged end and put it aside – this information along with all other instrument serial numbers will be entered on the Aircraft Identification form in this Manual.
Page 209 Jabiru J450 Constructors Manual Post-Paint>Fuselage>Assemble instrument panel Fit analogue instrumentation Analogue instrumentation (ASI, ALT, VSI, ETC, engine instruments) will require each individual wire to be connected to the back of each instrument. There are 3 methods of fitting analogue instruments: screws though the panel and into the instrument (flight instrumentation), or retaining brackets or retaining screw rings (engine instrumentation).
Page 210 Jabiru J450 Constructors Manual Post-Paint>Fuselage>Assemble instrument panel Fit digital instrumentation Digital instrumentation (EFIS, EMS, radio(s), transponder, intercom, GPS) will usually have a pre-wired harness and a multi-pin connector fitting at the rear of the instrument. The Dynon brand EFIS displays are supplied with mounting hardware and the fitting method...
Page 211 Jabiru J450 Constructors Manual Post-Paint>Fuselage>Assemble instrument panel 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 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...
Page 213 Jabiru J450 Constructors Manual Post-Paint>Fuselage>Assemble instrument panel Fitting the multi-pin connectors What follows is the pin layout that is used in our factories. Some pins may not be used on your particular panel in which case simply leave that pin unwired, and the connector layout here will be referred to again in the Post-Paint>Fuselage>Install electrical wiring...
Page 214 Jabiru J450 Constructors Manual Post-Paint>Fuselage>Assemble instrument panel Group the wires for each plug together and trim each group to an even length, then strip 4mm from the insulation of each wire and fit the appropriate connector type to each wire: male spade connectors for a female connector body and female spade connectors for a male connector body.
Page 215 Jabiru J450 Constructors Manual Post-Paint>Fuselage>Assemble instrument panel Fit digital wiring harnesses The digital wiring harnesses can now be fitted to the plugs at the rear of the digital instruments and the VHF radio, transponder and intercom. Tighten the plug screws by hand.
Page 216: Post-Paint>Fuselage>Electrical Wiring Diagrams
Jabiru J450 Constructors Manual Post-Paint>Fuselage>Electrical wiring diagrams Post-Paint>Fuselage>Electrical wiring diagrams Tuesday, April 6, 2010 216 of 343...
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 This completes the Post-Paint>Fuselage>Electrical wiring diagrams task. Tuesday, April 6, 2010 221 of 343...
Page 222: Post-Paint>Fuselage>Interior>Fit Upholstery 1
To fit all of the stage 1 upholstery into the aircraft. This task assumes that you will be using the Jabiru upholstery kit. If you are using the Jabiru kit it contains extremely detailed instructions, however you may want to use your own materials in which case this task can be used for more general guidance.
Page 223 Jabiru J450 Constructors Manual Post-Paint>Fuselage>Interior>Fit upholstery 1 Firewall – glue the 10mm foam layer to the firewall and then glue the fabric to the foam. Cut around the ribs as required. Lower firewall – fit the fabric down and back along the floor slightly and also over the rudder pedal mounts.
Page 224 Jabiru J450 Constructors Manual Post-Paint>Fuselage>Interior>Fit upholstery 1 Front hood lining/roof: main panels (a) then the longitudinal rib (b) Rear hood lining/roof as for the front (not applicable to J160/J170) Rear sidewalls (not applicable to J160/J170) Door panels Door pockets – attached with snap fasteners and Velcro Instrument panel housing Cable covers and all other small trim items.
Page 225: Post-Paint>Fuselage>Install Electrical Wiring
Jabiru J450 Constructors Manual Post-Paint>Fuselage>Install electrical wiring 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 cut from the supplied coils of aircraft grade wire. The length required will vary depending on how you choose to route the wire and so it is difficult to give any exact lengths, but generally you should allow a little extra length to be on the safe side.
Page 226 Jabiru J450 Constructors Manual Post-Paint>Fuselage>Install electrical wiring Engine wiring All wires will need to be long enough to route from the respective sources, around the engine in the manner shown, and either to a connection point on the firewall in some cases or through the firewall plus about 300mm for connection to a multi-pin plug for the majority of cases.
Page 227 Jabiru J450 Constructors Manual Post-Paint>Fuselage>Install electrical wiring Fit the tacho sender unit For this step you will need to rotate the engine, which may cause 1 or 2 of the sealing Tacho timing plugs to pop off of the exhaust pipes and...
Page 228 Jabiru J450 Constructors Manual Post-Paint>Fuselage>Install electrical wiring Engine wiring routing Cut the zip ties that hold the alternator wires to the engine and bend the wires to the right. At this stage you will have wires at the top left rear of the engine for oil pressure and temperature, left magneto, CHT and tacho.
Page 229 Jabiru J450 Constructors Manual Post-Paint>Fuselage>Install electrical wiring Wire the regulator connector Power from the alternator will go to the regulator through the regulator connector, and power from the regulator will go to the positive and negative sides of the battery as well as the power to the main bus and to the optional low voltage warning light, also through the regulator connector.
Page 230 Jabiru J450 Constructors Manual Post-Paint>Fuselage>Install electrical wiring Wire the starter solenoid From battery To main bus Front positive: heavy bar 15A circuit orange cable breaker 10g From regulator plug 10g To starter To starter pilot button 16g light 16g To starter...
Page 231 Jabiru J450 Constructors Manual Post-Paint>Fuselage>Install electrical wiring Engine bay wiring routing The engine wiring bundle can now be zip tied to the right top engine mount and then the starter cables and the breather tube can be zip tied over top of those wires. Take some time to route all of the wires neatly and zip tie any loose wires together.
Page 232 Jabiru J450 Constructors Manual Post-Paint>Fuselage>Install electrical wiring Wire the fuel pump Two fuel pump wires were fitted through the console to the fuel pump in the Pre-Paint> Fuselage>Fit control cables and lines task: one wire will be the positive and one wire will be the negative or earth to the fuel pump.
Page 233 Jabiru J450 Constructors Manual Post-Paint>Fuselage>Install electrical wiring Fuel gauge wiring from the wing tank fuel gauges Before completing the upholstery around the windscreen the 2 wires from the wing tank fuel gauges must be routed down the windscreen pillars. Drill a 5mm (arrowed above) hole slightly in...
Page 234 Jabiru J450 Constructors Manual Post-Paint>Fuselage>Install electrical wiring Connect the multi pin connectors Each wire inside the cabin has been labeled with masking tape as it was fitted in order to clearly identify where it came from. If any wires have not been labeled then use a circuit tester to trace the wire to its source and then label it clearly.
Page 235 Jabiru J450 Constructors Manual Post-Paint>Fuselage>Install electrical wiring Fit the VHF radio wiring harness The Aircraft Harness pack includes the wiring harness and all of the necessary hardware: the Push To Talk (PTT) buttons for the control stick and the headset jacks for the top of the cross beam outboard of the seat backs.
Page 236 Jabiru J450 Constructors Manual Post-Paint>Fuselage>Install electrical wiring Connect the VHF antenna cable The VHF coaxial antenna cable was installed in the Pre-Paint>Fuselage>Fit control cables and lines task and connected to the VHF antenna in the Pre-Paint>Fuselage>Empennage> Fit vertical tail fin task.
Page 237: Post-Paint>Fuselage>Interior>Fit Console Controls
Jabiru J450 Constructors Manual Post-Paint>Fuselage>Interior>Fit console controls 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: Card # J17 „Elevator System and Control Stick‟ Card # J8 „Dual Brakes‟...
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 Brake system Cut a short length of sheet aluminium the width of the brake lever slot and about 40mm in length. Bend the aluminium strip in half, apply a smear of Araldite inside the bend and crimp it to the front of the brake lever slot –...
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 Elevator trim lever assembly Connect the trim cable rod end to the left- hand trim lever with an AN3-10A bolt, 3/16” and 1/4” flat washers and a Nyloc nut. Clean any debris away from the trim bush and fit...
Page 242: Post-Paint>Fuselage>Interior>Controls>Fit Rudder Pedals
Jabiru J450 Constructors Manual Post-Paint>Fuselage>Interior>Controls>Fit rudder pedals 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 rudder pedals and set the deflection of the rudder.
Page 243 Jabiru J450 Constructors Manual Post-Paint>Fuselage>Interior>Controls>Fit rudder pedals 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 into the smaller hole in the steering yoke as...
Page 244 Jabiru J450 Constructors Manual Post-Paint>Fuselage>Interior>Controls>Fit rudder pedals 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 adjusted later in this task.
Page 245 Jabiru J450 Constructors Manual Post-Paint>Fuselage>Interior>Controls>Fit rudder pedals 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 straight ahead – move the aircraft back a few meters and then move it forward in a straight line so that the nose wheel is aligned correctly.
Page 246 Jabiru J450 Constructors Manual Post-Paint>Fuselage>Interior>Controls>Fit rudder pedals 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 at the bottom of this page that show a rudder position/deflection jig in place under the rudder) and hold it in that position with some cloth tape or have someone hold it in place for you.
Page 247 Jabiru J450 Constructors Manual Post-Paint>Fuselage>Interior>Controls>Fit rudder pedals 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 link tabs to the aluminium bracket that is riveted to the lower console –...
Page 248 Jabiru J450 Constructors Manual Post-Paint>Fuselage>Interior>Controls>Fit rudder pedals This completes the Post-Paint>Fuselage>Interior>Controls>Fit rudder pedals task. Tuesday, April 6, 2010 248 of 343...
Page 249: Post-Paint>Fuselage>Interior>Fit Flap Drive Motor
Jabiru J450 Constructors Manual Post-Paint>Fuselage>Interior>Fit flap drive motor 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 flap shaft Remove the inner flap drive arm from the flap drive shaft by removing the 2 x AN3 bolts and pulling the flap drive arm completely off of the shaft.
Page 250 Jabiru J450 Constructors Manual Post-Paint>Fuselage>Interior>Fit flap drive motor Fit the flap drive motor assembly Whalebone Mounting bracket Flap shaft and flap drive arm Flap motor assembly Actuating shaft Rod end With the flap shaft in place and all interior trim fitted, move the flap shaft to the fully retracted position (flap drive arm back).
Page 251 Jabiru J450 Constructors Manual Post-Paint>Fuselage>Interior>Fit flap drive motor Fit the flap indicator Assemble the flap indicator: paint the outside of the indicator washer red and mark the 3 flap positions in a dark colour. Push the inner cable through the indicator body and through the indicator washer then all the way into the long end of the indicator body.
Page 252: Post-Paint>Fuselage>Interior>Fit Instrument Panel Housing
Jabiru J450 Constructors Manual Post-Paint>Fuselage>Interior>Fit instrument panel housing 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. Materials required: Card #4: “Panel mount throttle” Prepare the panel housing...
Page 253 Jabiru J450 Constructors Manual Post-Paint>Fuselage>Interior>Fit instrument panel housing Fit the rubber grommets and the machined aluminium washers to the rear lip of the panel – use a machined washer to mark the centre of each hole then drill each hole to 22mm and fit a grommet into each hole.
Page 254 Jabiru J450 Constructors Manual Post-Paint>Fuselage>Interior>Fit instrument panel housing Locate and fit the throttle cable The last step is to drill through the firewall for the throttle cable. The positioning of the hole is important to minimise the chance of the throttle cable binding in the full forward/full throttle position: start by positioning the throttle linkage almost fully forward until the input lever is about 10mm away from the front of the panel housing –...
Page 255: Post-Paint>Fuselage>Interior>Engine Control Cabling
Jabiru J450 Constructors Manual Post-Paint>Fuselage>Interior>Engine control cabling 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: Throttle Cables: Throttle, Carb Heat, Choke, Cabin Heat (optional – see Card #25)
Page 256 Jabiru J450 Constructors Manual Post-Paint>Fuselage>Interior>Engine control cabling Throttle and choke Throttle cable Carburettor bracket Choke cable 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 the inner cable and then fit the inner cable through the slotted top hole in the bracket and fit the threaded cable end into the bracket.
Page 257 Jabiru J450 Constructors Manual Post-Paint>Fuselage>Interior>Engine control cabling 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 forward and then fit the ferrule into the hole in the drive arm.
Page 258: Post-Paint>Fuselage>Interior>Fit The Instrument Panel
Jabiru J450 Constructors Manual Post-Paint>Fuselage>Interior>Fit the instrument panel 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 have a friend come over and help you for an hour or so.
Page 259: Post-Paint>Fuselage>Interior>Fit Upholstery 2
Jabiru J450 Constructors Manual Post-Paint>Fuselage>Interior>Fit upholstery 2 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 upholstery kit or equivalent High heat contact adhesive Card J9 “Seatbelts”...
Page 260 Jabiru J450 Constructors Manual Post-Paint>Fuselage>Interior>Fit upholstery 2 Rear Headset bracket Sheathed fuel lines Sound curtain 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 pressed against the top outside of the cabin above the rear windows–...
Page 261 Jabiru J450 Constructors Manual Post-Paint>Fuselage>Interior>Fit upholstery 2 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 the cover over the seat base and pat the Velcro front edge into place.
Page 262: Post-Paint>Fuselage>Fit Rudder, Elevator And Elevator Trim
Jabiru J450 Constructors Manual Post-Paint>Fuselage>Fit rudder, elevator and elevator trim 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 Hold the rudder up to the vertical fin and fit it into...
Page 263 Jabiru J450 Constructors Manual Post-Paint>Fuselage>Fit rudder, elevator and elevator trim Adjust the rudder travel Make a template that will sit over the rear of the empennage and tape it in place. Find the centreline of the fuselage and mark a 5mm offset to the right of the centreline onto the template, then mark 98mm each side of that offset mark as shown in the photos above.
Page 264 Jabiru J450 Constructors Manual Post-Paint>Fuselage>Fit rudder, elevator and elevator trim 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 Elevator through the top hole. Tighten firmly and trim off any drive arm excess bolt length.
Page 265 Jabiru J450 Constructors Manual Post-Paint>Fuselage>Fit rudder, elevator and elevator trim Assemble and fit the elevator trim assembly Refer to the drawing on the next page: Assemble the trim pivot: press the 2 sealed bearings into the hub and then pop rivet the assembly together. Assemble the trim spring unit, adjust the rod end to almost full thread depth and tighten the lock nut.
Page 266 Jabiru J450 Constructors Manual Post-Paint>Fuselage>Fit rudder, elevator and elevator trim This completes the Post-Paint>Fuselage>Fit rudder, elevator and elevator trim task. Tuesday, April 6, 2010 266 of 343...
Page 267: Post-Paint>Fuselage>Fit Doors
Jabiru J450 Constructors Manual Post-Paint>Fuselage>Fit doors 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 the door seals Clean the inside of the door lip and fit the white door seal rubber around the entire outer edge of the door.
Page 268 Jabiru J450 Constructors Manual Post-Paint>Fuselage>Fit doors 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 very carefully peel the “Fine Line”...
Page 269 Jabiru J450 Constructors Manual Post-Paint>Fuselage>Fit doors Fit the door locks Fit the door locks though the lock holes in the fuselage behind each door and fix in place with the retaining nuts. Tighten each retaining nut firmly. Fit the locking arm to the end of the shaft with the supplied screw: apply a drop of Loctite 242 to each screw.
Page 270: Post-Paint>Fuselage>Firewall Forward>Final Assembly
Jabiru J450 Constructors Manual Post-Paint>Fuselage>Firewall forward>Final assembly 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 mixer box‟ Card #23 „Oil bottle‟ Card #25 „Cabin heater‟...
Page 271 Jabiru J450 Constructors Manual Post-Paint>Fuselage>Firewall forward>Final assembly Connect the inlet air scat hoses Carb inlet Heated air Cold air Engine bay viewed from above showing the inlet air hose arrangement Air is fed into the carburettor from 2 sources, Inlet air horn...
Page 272 Jabiru J450 Constructors Manual Post-Paint>Fuselage>Firewall forward>Final assembly Fit the equalising tube Air mixer box Eq tube Eq tube Carburettor Route a length of 4mm clear tube from the fitting on the right of the air mixer box to the compensator fitting on the right rear of the carburettor as shown in the photos above.
Page 273 Jabiru J450 Constructors Manual Post-Paint>Fuselage>Firewall forward>Final assembly 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 scat hose from the cold air...
Page 274: Post-Paint>Fuselage>Firewall Forward>Fit Propeller And Spinner
On each bolt place pairs of Belleville washers in a „cup to cup‟ arrangement: ( ) ( ) (Jabiru prop: 4 pairs, Sensenich prop: 3 pairs) followed by a single flat washer and a Nyloc nut.
Page 275 Jabiru J450 Constructors Manual Post-Paint>Fuselage>Firewall forward>Fit propeller and spinner 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, applying a slow, steady pressure on the torque wrench until the correct torque value is reached.
Page 276 Jabiru J450 Constructors Manual Post-Paint>Fuselage>Firewall forward>Fit propeller and spinner Pre-fit the spinner Test fit the spinner – it can be fitted in 2 positions, so try it each way and use the position where the holes all line up the best while giving an even gap around the base of the propeller.
Page 277 Jabiru J450 Constructors Manual Post-Paint>Fuselage>Firewall forward>Fit propeller and spinner 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 spinner.
Page 278: Post-Paint>Fuselage>Fit Wheel Spats
Jabiru J450 Constructors Manual Post-Paint>Fuselage>Fit wheel spats 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 main wheel spat is held in place by a single bolt on the outside of the spat that fits into Each the axle extension and 4 screws on the inside that fit to the spat mounting plate.
Page 279: Post-Paint>Wings>Install Aileron Cables
Jabiru J450 Constructors Manual Post-Paint>Wings>Install aileron cables 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 ribs. This task requires two people: one person to pull the drawstring and a helper to feed the cable into the wing.
Page 280 Jabiru J450 Constructors Manual Post-Paint>Wings>Install aileron cables Connect the aileron cable The cable is held to a strengthened rib inside the wing by a saddle clamp and 2 x AN3 bolts and Nyloc nuts. Access is from the aileron cable inspection opening and the 38mm hole...
Page 281: Post-Paint>Wings>Fit Stall Warning
Jabiru J450 Constructors Manual Post-Paint>Wings>Fit stall warning 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 the wing root...
Page 282 Jabiru J450 Constructors Manual Post-Paint>Wings>Fit stall warning This completes the Post-Paint>Wings>Fit stall warning task. Tuesday, April 6, 2010 282 of 343...
Page 283: Post-Paint>Wings>Prepare Wings For Fitting
Jabiru J450 Constructors Manual Post-Paint>Wings>Prepare wings for fitting 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 the flaps Run a 3/16” drill though the bolt hole in each flap hanger to clear any paint and debris out of the holes.
Page 284 Jabiru J450 Constructors Manual Post-Paint>Wings>Prepare wings for fitting Fit the fuel gauges Remove the masking tape from over the fuel gauge boss in the wing root and clean the area. Test fit each fuel gauge – feed the float unit into the wing tank and hold the gauge in place with 2 screws.
Page 285 Jabiru J450 Constructors Manual Post-Paint>Wings>Prepare wings for fitting Fuel lines and fittings There are 3 fuel lines that need to be connected in the wing root: the bottom 2 carry fuel to the header tank while the top line is the breather for the header tank. These fuel lines were cut to the approximate length in the Pre-Paint>Fuselage>Interior>Fuel System...
Page 286 Jabiru J450 Constructors Manual Post-Paint>Wings>Prepare wings for fitting Fit the vent tubes to the fuel filler caps The fuel filler caps came partly assembled on the card and were fitted to the fuel filler opening on the wing in the Pre-Paint>Wings>Prepare wing root...
Page 287: Post-Paint>Wings>Fit Wings
Jabiru J450 Constructors Manual Post-Paint>Wings>Fit wings 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 into place more easily. This task will discuss the fitting of one wing at a time.
Page 288 Jabiru J450 Constructors Manual Post-Paint>Wings>Fit wings Each AN4-14A wing attach bolt should be fitted with one AN960-416 washer under the head of the bolt and one AN960-416 washer under the nut. It will be necessary to gently tap the AN4-14A bolts into place – tap in until the head of the...
Page 289: Post-Paint>Wings>Connect Ailerons
Jabiru J450 Constructors Manual Post-Paint>Wings>Connect ailerons 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 position the ailerons and one to make the adjustments.
Page 290 Jabiru J450 Constructors Manual Post-Paint>Wings>Connect ailerons 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.
Page 291 Jabiru J450 Constructors Manual Post-Paint>Wings>Connect ailerons Set the aileron deflections Once the aileron cables have been adjusted to length with the ailerons in the neutral position and the stick centred, the full travel deflections can be set. In the kit there is an aileron deflection template. Place this template on top of the wing and set...
Page 292: Post-Paint>Wings>Connect Wing Tanks
Jabiru J450 Constructors Manual Post-Paint>Wings>Connect wing tanks 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 lines will have been routed through the front conduits during the wing fitting task and will now be labelled and hanging down inside the cabin.
Page 293 Jabiru J450 Constructors Manual Post-Paint>Wings>Connect wing tanks 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 suitable terminal to the bottom of each wire and fit to the common earth connection –...
Page 294: Post-Paint>Wings>Fit Flaps
Jabiru J450 Constructors Manual Post-Paint>Wings>Fit flaps 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 as the flap is too long for one person to handle and there is a risk of damaging the painted surface of the flap and the wing.
Page 295 Jabiru J450 Constructors Manual Post-Paint>Wings>Fit flaps 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...
Page 296: Post-Paint>Wings>Fit Fairings
Jabiru J450 Constructors Manual Post-Paint>Wings>Fit fairings 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. Wing root fairing The wing root fairing comes in 3 parts: 2 upper and 1 lower.
Page 297 Jabiru J450 Constructors Manual Post-Paint>Wings>Fit fairings Lower strut/main gear fairing Right hand side strut/main gear fairing from below (top photo) and side on (above) 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.
Page 298: Testing>General
Jabiru J450 Constructors Manual Testing>General Testing>General Here we are: the Construction phase has been completed and the task in hand is to thoroughly check the aircraft in preparation for flight and then, finally, test fly the aircraft for first time.
Page 299: Testing>Weight And Balance
Jabiru J450 Constructors Manual Testing>Weight and balance 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 then various loading scenarios are be tested to see if any rebalancing of the aircraft is required.
Page 300 Jabiru J450 Constructors Manual Testing>Weight and balance 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.
Page 301 Jabiru J450 Constructors Manual Testing>Weight and balance Weigh the aircraft The weighing part of this procedure should be conducted in a closed hangar with a level floor. Because the aircraft is very light any wind will adversely affect the weights, so a closed building, without any doors being opened during the procedure, is required.
Page 302 Jabiru J450 Constructors Manual Testing>Weight and balance Examples of calculation Below is an example calculation showing typical values: Item Weight Distance to Datum Moment (kg) (mm) (kg/mm) - 780 - 58,500 Nose wheel Left main wheel + 475 + 51,300...
Page 303: Testing>Rigging Check
Jabiru J450 Constructors Manual Testing>Rigging check 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 deflections set as part of the appropriate fitting task, so this final check is just to verify that nothing was missed during assembly.
Page 304 Jabiru J450 Constructors Manual Testing>Rigging check Ailerons Check the control stick with the ailerons in the neutral position Set the ailerons to the neutral position: a straightedge held under the wing must touch the front and back of the wing and the back of the aileron as shown arrowed in the photo above.
Page 305 Jabiru J450 Constructors Manual Testing>Rigging check Elevator Check the elevator travel Use the supplied deflection templates to check the up and down travel of the elevator. DOWN elevator template Hold the control stick all the way forward (have someone help you) and check the amount of down deflection and adjust the cable length (by screwing the rod ends in or out an equal amount at each end of the cable) until the down deflection is correct.
Page 306: Testing>Calibrate Fuel Gauges
Jabiru J450 Constructors Manual Testing>Calibrate fuel gauges 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 will be working with flammable fuel and you should take precautions such as having a suitable fuel extinguisher close to hand and no naked lights of any kind nearby.
Page 307 Jabiru J450 Constructors Manual Testing>Calibrate fuel gauges Calibrate the fuel gauges Fit the fuel gauge calibration decal around each wing tank gauge opening in the wing root with the Zero indication on the decal placed against the fuel gauge needle – at this point there is no usable fuel in either wing tank.
Page 308: Testing>Registration Markings
Jabiru J450 Constructors Manual Testing>Registration markings 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 Australia either the Recreational Aircraft Association (RAA) for recreational registration or the Civil Aviation Safety Authority (CASA) for general aviation registration controls the allocation of aviation registration markings.
Page 309: Testing>Final Inspection Checklist
Propeller: Jabiru / Sensenich Propeller Size: Propeller Serial No: Propeller Bolts  1 Check torque (Jabiru prop 7 ft/lbs, Senenich prop 12ft/lbs)  2 Check tip tracking is accurate to < 2mm, adjust if required  3 TorqueSeal the propeller nuts ...
Page 310 Jabiru J450 Constructors Manual Testing>Final inspection checklist 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) ...
Page 311 Jabiru J450 Constructors Manual Testing>Final inspection checklist 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 ...
Page 312 Jabiru J450 Constructors Manual Testing>Final inspection checklist 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 right ...
Page 313 Jabiru J450 Constructors Manual Testing>Final inspection checklist 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 to header tank inlets ...
Page 314 Jabiru J450 Constructors Manual Testing>Final inspection checklist 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”...
Page 315 Jabiru J450 Constructors Manual Testing>Final inspection checklist 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 ...
Page 316 Jabiru J450 Constructors Manual Testing>Final inspection checklist 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 ...
Page 317 Jabiru J450 Constructors Manual Testing>Final inspection checklist 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 ...
Page 318 Jabiru J450 Constructors Manual Testing>Final inspection checklist 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: ...
Page 319 Jabiru J450 Constructors Manual Testing>Final inspection checklist 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] ...
Page 320 Jabiru J450 Constructors Manual Testing>Final inspection checklist 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 ...
Page 321 Jabiru J450 Constructors Manual Testing>Final inspection checklist 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 ...
Page 322 Jabiru J450 Constructors Manual Testing>Final inspection checklist 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 Elevator ...
Page 323 Jabiru J450 Constructors Manual Testing>Final inspection checklist 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 ...
Page 324: Testing>Flight Testing
Well, this is what it all comes down to: you have built your own Jabiru, you have painted it and assembled it and checked and tested every part of it to your satisfaction and now it is time...
Page 325 The nearest flat piece of land may not necessarily be the best or safest place and you may have to consider transporting your new Jabiru by road to a suitable airfield for the flight testing sequence.
Page 326 The Test Sequence in this task is based on the Test Schedule used by Jabiru Aircraft on factory-built models and is supplied as reference material as a part of the construction data for this kit.
Page 327 Jabiru J450 Constructors Manual Testing>Flight testing Sequence #1 – First start, ground run and taxi Print and use the Flight Testing form Sequence #1 for this sequence. Locate the aircraft on a suitable run-up area with no gravel or small stones in the area under the propeller, point the nose of the aircraft into wind and chock the main wheels.
Page 328 Jabiru J450 Constructors Manual Testing>Flight testing Run up and full power check Re-start the engine and smoothly increase the engine speed to 2000 rpm. Check that all temperatures and pressures are in the green part of the range. Check each magneto individually: the maximum permissible rpm drop is 200 rpm but it is typically much less.
Page 329 Jabiru J450 Constructors Manual Testing>Flight testing 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.
Page 330 Jabiru J450 Constructors Manual Testing>Flight testing Sequence #2 – First flight and rigging tests Pre-flight Print and use the Flight Testing form Sequence #2 for each test flight in this sequence. Recording Use a kneeboard or clipboard to hold the Flight Test forms and record details of each test flight, however the first priority must always be to fly the aircraft so write things down only when it is safe to do so.
Page 331 Jabiru J450 Constructors Manual Testing>Flight testing Flight testing Takeoff and climb Use the full length of the available runway, which should be into wind. Apply full power in a positive manner over a count of 4. Check engine rpm indication and ASI function on the roll and abort if either is incorrect.
Page 332 Jabiru J450 Constructors Manual Testing>Flight testing Rigging corrective actions It is particularly important that any rigging problems are dealt with in the correct sequence. Use the flowchart below to work your way through any rigging problems: it may be necessary...
Page 333 Jabiru J450 Constructors Manual Testing>Flight testing 1. Adjusting the Rudder Pedal Pushrods If the rudder pedals are displaced fore and aft when the aircraft is in straight and level flight, adjust the rudder pedal pushrods that connect the rudder pedals to the steering yoke until the pedals sit level.
Page 334 Jabiru J450 Constructors Manual Testing>Flight testing Test fit the eccentric bush into the wing lug dry, using a gently tapered object such as an old round file through the centre of the bush to screw the bush into the lug, ending when the bush is centred in the lug with offset hole facing UP to test the threads.
Page 335 Jabiru J450 Constructors Manual Testing>Flight testing Sequence #3 – Performance and handling Print and use the Flight Testing form Sequence #3 for each test flight in this sequence. If all of the rigging corrections in Sequence #2 have been done correctly and all equipment performs correctly then this sequence will usually only require one flight.
Page 336 Well done! Please drop us a line here at Jabiru and tell us all about it, we would love to know. We are sure that you will have many enjoyable hours of flying your very own Jabiru aircraft and we are equally sure that you will enjoy the low operating costs as well as the pleasurable flying characteristics that all Jabiru‟s share.
Page 337: 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 sequences. The first form,...
Page 338 Jabiru J450 Constructors Manual Testing>Forms Aircraft Identification Aircraft Identification Phone Phone Owner Owner Address Address Mobile Mobile Model Model Registration Registration Kit # Kit # Engine Serial number Engine Serial number : Jabiru / Sensenich : Jabiru / Sensenich Propeller...
Page 339 Jabiru J450 Constructors Manual Testing>Forms Sequence #1 – Ground run Sequence #1 – Ground run Date Date WIND WIND Engine hours start Engine hours start Pilot Pilot Run up - 2000 rpm Run up - 2000 rpm rpm drop rpm drop...
Page 340 Jabiru J450 Constructors Manual Testing>Forms Sequence #2 – Rigging Sequence #2 – Rigging Date Date WIND WIND P. ALT P. ALT Engine hours start Engine hours start 1013.2 hPa 1013.2 hPa Loading Loading Full power climb at 80 KIAS Full power climb at 80 KIAS...
Page 341 Jabiru J450 Constructors Manual Testing>Forms Sequence #3 – Performance & handling Sequence #3 – Performance & handling page 1 of 3 page 1 of 3 Date Date WIND WIND Engine hours start Engine hours start Loading Loading Loading rules - either:...
Page 342 Jabiru J450 Constructors Manual Testing>Forms Sequence #3 – Performance & handling Sequence #3 – Performance & handling page 2 of 3 page 2 of 3 Trim test Trim test Cruise power, clean Cruise power, clean Cruise power, clean Idle, full flap...
Page 343 Jabiru J450 Constructors Manual Testing>Forms Sequence #3 – Performance & handling Sequence #3 – Performance & handling page 3 of 3 page 3 of 3 Equipment Equipment VHF Comm #1 VHF Comm #1 VHF Comm #2 VHF Comm #2 operation...

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