Jabiru J160 Construction Manual

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Jabiru J160 Constructors ManualGeneral>Constructors manualPost-Paint>Fuselage>Firewall forward>Fit propeller and spinner .......................................... 259Post-Paint>Fuselage>Fit wheel spats ..................................................................................... 263Post-Paint>Wings>Install aileron cables................................................................................ 264Post-Paint>Wings>Fit stall warning ...................................................................................... 266Post-Paint>Wings>Prepare wings for fitting .......................................................................... 268Post-Paint>Wings>Fit wings ................................................................................................. 272Post-Paint>Wings>Connect ailerons ..................................................................................... 274Post-Paint>Wings>Connect wing tanks ................................................................................. 277Post-Paint>Wings>Fit flaps................................................................................................... 278Post-Paint>Wings>Fit fairings .............................................................................................. 280Testing>General ................................................................................................................... 282Testing>Weight and balance ................................................................................................. 283Testing>Rigging check ......................................................................................................... 287Testing>Calibrate fuel gauges ............................................................................................... 290Testing>Registration markings .............................................................................................. 292Testing>Final inspection checklist ........................................................................................ 293Testing>Flight testing ........................................................................................................... 308Testing>Forms ...................................................................................................................... 321Wednesday, April 7, 2010 6 of 327
Direction referencesJabiru J160 Constructors ManualGeneral>Constructors manualIn 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 tobe sitting in the pilot‟s seat facing towards the front of the aircraft.“Lateral” means something that it is oriented from side to side in relation to the aircraft.“Longitudinal” or “Fore and aft” means something that it is oriented from the front to theback of the aircraft.PreparationWe suggest that you get as much preparation done as possible before starting your build.Start with your workshop: give it a good clean out and consider upgrading the lighting andpower with plenty of strip lights and extra sockets for power tools. Paint the walls and ceilinga light colour to provide as light a work area as possible. This will also help if you plan toprepare the aircraft for painting preparation (filling/primer) and also the topcoat if you feelyou are capable of doing so.In preparation for storing the vacuum-sealed Build Cards that pack many of the small partsinto convenient groups we suggest that you construct a large wallboard that you can place theBuild Cards on, preferably in numerical order (each Card is numbered) – you will find thatthis is much easier and more pleasant than sorting through a box or pile of Build Cards!For items such as fairings and instrumentation prepare as much protected shelf space as youcan find (some shelving under a workbench can be particularly useful in this instance) andalso make a vertical bin in a cooler corner of the workshop to stand long items like elevator,rudder and flaps in while building the relevant parts of the aircraft. Reserve an out-of-the-wayarea for windows and other fragile parts.In our factory we use large mobile bench/racks that contain all of the parts for an aircraft andthat rack stays with that aircraft all the way through production.If you're going to do any painting, try to keep equipment and parts off the floor as much aspossible so that you can sweep/vacuum/hose the place out thoroughly in order to minimisedust before you start any painting.Get all of the tools and equipment on the list that starts on the next page.Read this manual from start to finish to familiarise yourself with the work to come.Consider getting extra insurance cover for your kit during the build to cover any risks(fire/damage/theft, etc). Most aircraft insurers will quote for this and many builders considerthat the cost is worth it for the peace of mind that it brings.Cold climate considerationsIf you are building in a colder climate/during winter, some extra heating and insulation inyour workshop will help, as well as keeping the humidity levels up to acceptable levels forepoxy work. Clearly, all workshops are different and your build inspector will advise.Get a large roll of bubble wrap packaging sheet (1.5m x 15m) from your local garden centreor packaging company (usually cheaper). In low temperature environments you will use thisto create an insulated tunnel by draping it over the work you've bonded/flocked and, with thecareful application of warm air from a fan heater, you'll easily achieve the 24°C (or so) youneed for a good epoxy cure.Wednesday, April 7, 2010 7 of 327
Page 1 and 2: JabiruJ160ConstructorsManualfrom ki
Page 3 and 4: General>Constructors manualWelcome
Page 5: Jabiru J160 Constructors ManualGene
Page 9 and 10: Optional tools and equipmentJabiru
Page 11 and 12: General>GlossaryJabiru J160 Constru
Page 13 and 14: General>Unpacking and supportJabiru
Page 15 and 16: Epoxy measuring and mixingQuality a
Page 17 and 18: General>Aircraft grade bolts and lo
Page 19 and 20: General>Rod endsJabiru J160 Constru
Page 21 and 22: Pre-Paint>Fuselage>Fit ventral fin
Page 23 and 24: Finish the ventral finJabiru J160 C
Page 25 and 26: Vertical fin stubJabiru J160 Constr
Page 27 and 28: Fit the header tank enclosureJabiru
Page 29 and 30: Jabiru J160 Constructors ManualPre-
Page 33 and 34: Assemble the brake calipersIn this
Page 35 and 36: Assemble the brake and wheelFirstly
Page 41 and 42: Pre-Paint>Fuselage>Firewall forward
Page 43 and 44: Fit the firewall plateJabiru J160 C
Page 47 and 48: Cabin heaterJabiru J160 Constructor
Page 49 and 50: Electrical componentsJabiru J160 Co
Page 55 and 56: Fit the nose leg housingJabiru J160
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Jabiru J160 Constructors ManualPre-
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Fit the engine to the engine mountJ
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Set the engine angle of incidenceJa
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Clean and prepare the screws and hu
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Pre-Paint>Fuselage>Fit windscreenJa
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Use a wire hook to pull the static
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Take care not to let the fin just s
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Fit the static probe assemblyJabiru
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Fit the elevator end capsJabiru J16
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Fit the stabiliserJabiru J160 Const
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Pre-Paint>Fuselage>Empennage>Fit ru
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Fit the rudder cable bracket clampJ
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Pre-fit the cowl hingesYou will nee
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Fit the hinge pin guidesJabiru J160
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Fit the cabin air inlet flangeJabir
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Fit the bearing blocksJabiru J160 C
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Fit the bushes to the consoleFit th
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Align the templateand mark the brac
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Pre-Paint>Fuselage>Interior>Fuel sy
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Pre-Paint>Fuselage>Interior>Fit sea
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Pre-Paint>Fuselage>Pre-fit doorsObj
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Final fit the doorJabiru J160 Const
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Pre-Paint>Fuselage>Fit windowsJabir
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Pre-Paint>Fuselage>Wheel alignmentO
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Pre-Paint>Fuselage>Pre-fit wheel sp
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Now both halves of the spat can be
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Pre-Paint>Wings>Fit fuel tank fille
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Pre-Paint>Wings>Cut aileron cable o
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Now look into the hole that you hav
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Take your time and get each flap ex
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Pre-Paint>Wings>Fit aileronsObjecti
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Pre-Paint>Wings>Test fit wingsObjec
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The important thing at this stage i
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Pre-fit the strut/main gear to fuse
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Sandpaper:Jabiru J160 Constructors
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Paint>Surface preparationJabiru J16
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Post-Paint>GeneralObjectives of thi
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Jabiru J160 Constructors ManualPost
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Post-Paint>Fuselage>Assemble instru
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Fit digital instrumentationJabiru J
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Post-Paint>Fuselage>Electrical wiri
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Post-Paint>Fuselage>Interior>Fit up
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Engine wiringJabiru J160 Constructo
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Wire the fuel pumpJabiru J160 Const
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Connect the multi pin connectorsJab
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Connect the VHF antenna cableJabiru
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Fit the steering yoke and pushrodsJ
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Connect the rudder cableJabiru J160
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Locate and fit the throttle cableJa
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Connect the elevator cableFit the d
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Pre-fit the spinnerJabiru J160 Cons
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Post-Paint>Fuselage>Fit wheel spats
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Connect the aileron cableJabiru J16
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Fit the fuel gaugesJabiru J160 Cons
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Fit the vent tubes to the fuel fill
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Set the aileron cable lengthsJabiru
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Tape the flap into position with a
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Testing>Weight and balanceObjective
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Weigh the aircraftJabiru J160 Const
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Testing>Rigging checkObjectives of
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Jabiru J160 Constructors ManualTest
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Calibrate the fuel gaugesJabiru J16
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Testing>Final inspection checklistJ
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Instrument panelJabiru J160 Constru
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Airfield selectionJabiru J160 Const
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Sequence #1 - First start, ground r
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Compass swingJabiru J160 Constructo
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Flight testingTakeoff and climbUse
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1. Adjusting the Rudder Pedal Pushr
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Sequence #3 - Performance and handl
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Testing>FormsObjectives of this tas
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EquipmentVHF Comm #1VHF Comm #2oper
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Jabiru J160 Construction Manual

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