Lower Fuselage Assembly. Controls

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Norah Karin Jackson
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1 Lower Fuselage Assembly Jabiru Aircraft Controls Lower Fuselage Assembly

2 Assemble & Fit Control References: Drawings and 93000K4/1 see (10.12) Photo 10.11(a) to 10.11(i) Parts Required: N Tube Handle Pivot Input Drive Plate Horizontal Tube Output Yoke Aileron Drive 3000C84 Spacer Control Pivot 3000A94 Nylon Washer (2) AN3-13A Bolt (3) AN3-15A Bolt AN3-20A Bolt MS Nut (5) AN Washer (10) AN Washer PM0039N Rubber Handgrip Material Required: LC3600 Resin LC3600 Hardener Fibreflock Procedure: 1. Ensure Bush Control Column (2) fit factory pre-drilled holes in Lower Fuselage Main Beam. 2. Using Horizontal Tube as the guide for the alignment, with the output Yoke Aileron Drive attached on the back as a mounting point for the jig. Attach the input drive plate on the front so now you should have an assembled control shaft to set up the end float. 3. Mix resin/hardener & fibre-flock & apply to the control bushes. Slide bush on one end of the shaft then put through the centre consol & put the other nylon bush then repeat step 2. Note: Wax or lightly grease horizontal tube to prevent bonding to bushes by excess resin/flock. 4. Smooth off flock using your brush with Epoxy resin and allow to cure. Note: Resin/Flock can be given a smooth finish by wetting and smoothing with a mixing stick dipped in resin. When mixing flock it is a good practice to keep some resin aside for this purpose. 5. Remove horizontal tube from bushes after resin has cured. 6. Install and clamp elevator cable. Refer to Proc Page 2 and Photo 10.11(a). 7. Clean, Lubricate and reinstall horizontal tube. 8. Assemble control handle as per drawing and Photo 10.11i. * 1 CAUTION: Ensure elevator cable clamp is secure in the groove. Assemble & Fit Control

3 Elevator anchor point. Using AN3-6a bolts Photo 10.11(a) - Control Column Assy Right Side showing Elevator Cable in Position Assemble & Fit Control

4 Photo 10.11(b) - Control Column Assy Left Side Assemble & Fit Control

5 Horizontal Tube Control Column Nylon Control Bushes Spacer Control Pivot AN3-13A Bolt Photo 10.11C Input Drive Plate Assy Photo 10.11D Control Column Assy Photo 10.11E Control Column Assy Assemble & Fit Control

6 Nylon Control Column Bush Photo 10.11F Output Yoke Aileron Drive Assy Assemble & Fit Control

7 Tube Handle Pivot Nylon Washer Spacer Control Pivot AN3-13A Bolt Photo 10.11H Control Handle Assy Photo 10.11I Control Assy Assemble & Fit Control

8 Assemble & Fit Control

9 Assemble & Fit Control

Fit Main Control Stops Reference: Drawings 5011094/2, 3107094/1, 93000K4/1 Photos 10.12(a), 10.

Washer (2) Materials Required: 5 min Araldite Fibre Flock Procedure: 1. Manufacture Jig in accordance with Drawing 3107094/1 and locate on Aileron Drive Plate (Ref: Drawing 93000K4/1 2.

10 Fit Main Control Stops Reference: Drawings /2, /1, 93000K4/1 Photos 10.12(a), 10.12(b) Parts Required: Plate Aileron Control Stud Aileron Control Main Control Stop - Front Nut Hex 1/4 BSW Nut Nyloc 1/4 BSW AN3-5A Bolt (2) MS Nut (2) AN Washer (2) Materials Required: 5 min Araldite Fibre Flock Procedure: 1. Manufacture Jig in accordance with Drawing /1 and locate on Aileron Drive Plate (Ref: Drawing 93000K4/1 2. Fit Plate Aileron Control to 3/16 holes located by Jig in rear of Undercarriage Beam, using AN3-5A Bolts as per Photo 10.12(b & c). 3. Fit Stud Aileron Control and Nut Nyloc and Nut Hex to Plate Aileron Control as per drawing /2. Note: The precise location of the Stops is set at a later stage when wings are on & ailerons are being fitted. PTT Switch Front Main Control Stop Fit Press to talk wire through console & up through control column Photo 10.12(a) - Position of Main Control Stop - Front Photo 10.12(b)- Aileron Control Stops Fit Main Control Stops

11 Photo 10.12(c)- Aileron Controle Stops Fit Main Control Stops

12 4. Bond the Main Control Stop - Front into position as shown by Photo 10.12(b). Note: This stop will be trimmed later to achieve required travel on elevator. Fit Main Control Stops

13 Fit Main Control Stops

14 Fit Main Control Stops

Fit Rudder, Elevator and Trim Cables Reference: Photo 10.13(a), 10.13(b), 10.13 (c), 10.13(d), Drawing 3103083/2 (Refer Procedure 10.

15 Fit Rudder, Elevator and Trim Cables Reference: Photo 10.13(a), 10.13(b), (c), 10.13(d), Drawing /2 (Refer Procedure Page 3) Parts Required: PC00394 Rudder Cable (Green Sheath) PC00194 Elevator Cable (Green Sheath) PC00494 Trim Cable (Black Sheath) PC0089N Cable Clamp (1) PC0099N Cable Anchor (1) AN3-10A Bolt (1) AN Washer (1) AN Washer (1) Procedure: Rudder Cable (Green Sheath, 3700mm long) 1. Route cable through pre-drilled holes in lower fuselage Cross Ribs. 2. Route cable through main beam to exit top slotted hole in LS Main Beam. See Photo 10.13(a). Note: Do not anchor cable at this stage. See Procedure Elevator Cable (Green Sheath, 3050 long SK) / (3655mm Long UL & SP) Use top cutout for Rudder cable & bottom slot for throttle cable. Photo 10.13(a)- Rudder Cable Entry Point 1. Route cable through pre-drilled holes in lower fuselage Cross Ribs. Entry through the Main Undercarriage Cross Beam is via the top hole in the beam. (refer to Photo 10.13(c) 2. Locate and clamp at control handle end, using Cable Clamp and Cable Anchor with AN3-5A Bolts. Secure cable ends with clamp & shim. Fit Rudder, Elevator & Trim Cables

IMPORTANT We have had one kit builder think that he should drill a hole through the main carry through beam under the seats, in order to keep the rudder cable straight.

16 IMPORTANT We have had one kit builder think that he should drill a hole through the main carry through beam under the seats, in order to keep the rudder cable straight. This is the main beam that provides carry through loads from the wing struts and MUST NOT be drilled. The cable is routed above the beam. VHF coax cable Wrap cables with foam & secure with zip ties. Trim Cable (Black Sheath) 1. Route cable through pre-drilled holes in lower fuselage Cross Ribs. Exit hole in lower rear fuselage. Tape cable to fuselage with masking tape, or similar, to prevent possible damage through rubbing during manufacture. 2. Route cable through main beam and through 30mm hole in master cylinder mount plate to exit predrilled hole in front of seat pan, see Photo 10.13(b). Anchor cable at this stage. to centre console using TLR rivets. You will need to make a spacer to pack out the trim cable to route it in a straight line. See Procedure Paragraph 5. Note: Mount master cylinder to mount plate and place in position. See Procedure Photo 10.13(b) Trim Cable entry point After all of the cables are routed and secured, tie all the cables together (including static tube) with a shock absorbent material and cable tie securely. Refer Photo 10.13(d). Fit Rudder, Elevator & Trim Cables

Trim cable Shim Trim Cable Clamp 26 layer plate spacer trim clamp, shape

through the Fuel Photo 10.13(c) - Elevator cable entry.

17 Trim Anchor point. Make it as close to the seat radius as possible & rivet with 7/32 TLR Trim cable Shim Trim Cable Clamp 26 layer plate spacer trim clamp, shape to radius of center console & glue with 5 min Araldite Elevator cable through the Fuel Photo 10.13(c) - Elevator cable entry. Note: Smaller hole above and right of hole Photo 10.13(d) - Installed cables, including static line Fit Rudder, Elevator & Trim Cables

18 Fit Trim Assembly to Extension Trim Horn Reference: Parts Required: Drawing Trim Assy Photos Material Required: Procedure: 1. Assemble the Trim System as per drawing /2 and with reference to Photos. 2. Bolt the assembly to the Trim Plate on the fuselage. 3. Attach Trim Cable to predrilled holes as per drawing and with reference to Photos. 4. When the Elevator Cable, Trim Cable and Trim System is finally assembled, there must be complete freedom of movement in all travel positions and accurate alignment so as to ensure ease of operation. With the Elevator in the full up position the front spring must be just of coil bound. Fit Brake Master Cylinder & Handbrake

19 Note: Ensure all ball ends have freedom of movement in all positions and are not binding on washers in any way. Also due to the amount of variables in the positioning it may be necessary to set you alignment a little different to the photos or drawing. Basically you need to set the trim system to the alignment is straight & not binding. Photo - Trim Assembly from the left hand side Fit Brake Master Cylinder & Handbrake

20 Fit Brake Master Cylinder & Handbrake

21 Fit Brake Master Cylinder & Handbrake

22 Fit Brake Master Cylinder and Handbrake Reference: Drawing /2 Photos 10.15(a), 10.15(b), 10.15(c), 10.15(d). Parts Required: Lever Input Brake Cam Handbrake Brake Knob Short Brake Knob Long Spacer Spacer Sleeve Mount Plate Master Cylinder Push Rod Brake Master Cylinder Aluminium Spacer Nylon Washer (2) AN4-24 Bolt (Drilled) AN310-4 Nut Castle MS Pin AN Washer (3) AN3-10A Bolt (2) MS Nut (4) AN Washer (6) PH0429N M/Thread Br SH 3/16 x 50 - Cut to 40 long PH0319N Nut BSW 3/16 Nyloc PD0039N Brake Master Cylinder AN3-7A Bolt (2) AN970-4 Washer PH0059N Rivet (4) PB0009N Ball End Male AN316-3 Nut Lock PZ0039N Nipple Materials Required: 5 min Araldite Fibreflock Procedure: 1. Attach Nipple to Brake Master Cylinder. 2. Attach Mount Plate Master Cylinder to Brake Master Cylinder as per drawing /2. 3. Insert 3/8" x 3/4" Grommet into 3/4" hole beside brake master cylinder. Note: This grommet is to carry trim cable. 4. Fit the Master Brake Cylinder assembly to Main Beam using rivets as per Photo 10.15(b) 5. Fit Brake Knob Short and Brake Knob Long to Lever Input Brake as per drawing /2. 6. Fit Cam Handbrake to Lever Input Brake as per drawing /2. Fit Brake Master Cylinder & Handbrake

7. Fit this assembly to Main Beam factory drilled holes as per drawing 9009093/2 and Photo 10.15(c) Note: Spacer and aluminium spacer are bonded to main beam with 5 min Araldite/Flock. 8.

23 7. Fit this assembly to Main Beam factory drilled holes as per drawing /2 and Photo 10.15(c) Note: Spacer and aluminium spacer are bonded to main beam with 5 min Araldite/Flock. 8. Fit Rod End and Nut Lock to the Push Rod Brake Master Cylinder. Refer Photo 10.15(a) Note: Ensure that the stem of the Rod End is visible through the inspection hole in the Push Rod. 9. Fit this assembly to the Master Cylinder Brake and the Lever Input Brake as per drawing. Camhandbrake Brake Stop: Screw with 8g x ¾ & glue with epoxy LC3600 8g x ¾ self tapper AN4-23 pivot bolt Photo 10.15(a) -Brake Lever Assembly Note: Ensure the AN Washer is used outside the Rod End to provide security should the bearing in the Rod End fail. Fit Brake Master Cylinder & Handbrake

24 Photo 10.15(b) - Brake Master Cylinder Installation Details Photo 10.15(c) - Brake Master Cylinder Fit Brake Master Cylinder & Handbrake

25 Photo 10.15(d) - Master Cylinder showing trim cable passing through master cylinder mount plate. Fit Brake Master Cylinder & Handbrake

26 Fit Brake Master Cylinder & Handbrake

27 Fit Brake Hoses Reference: Drawing 91009K4/1 Parts Required: PZ0049N Tee Brake Line 950 OA (2) N Brake Line 460 OA Material Required: Nil Procedure: 1. Using Loctite 569 Hydraulic Sealant on all threads 2. Connect Brake Lines 950 OA to both of the top of the tee. 3. Connect Brake Line 460 OA to other end of tee. 4. Connect other end of Brake Line 460 OA to the nipple on the Brake Master Cylinder via the bottom rear hole in the main beam. 5. Pass the 950 OA Brake Lines through the holes in the fuel tank supports and down the holes near the undercarriage attachment points. 6. Connect to Piston Body on the brake assembly. Note: The reservior has yet to be filled with brake fluid and the brake lines will need to be bled. Fit Brake Hoses

28 Fit Trim Control Assembly Reference: Drawings /2 (Proc Page 3) and /1 Photo Parts Required: Trim Lever Knob Trim Lever T Trim Lever Stops (2) Spacer Main Beam Aluminium Spacer (2) N Friction Plate Inner N Friction Plate Outer Spacer Friction Pad AN4-23Bolt (Drilled) MS Nut AN Washer (2) AN3-10A Bolt (2) MS Nut (2) AN Washer (2) PH0359N M/Thread M4 x 25 PH0209N Nut M4 Nyloc MS Pin AN310-4 Nut Castle PC0089N Cable Clamp PC0099N Cable Anchor Plate Material Required: Procedure: 5 min Araldite Fibre Flock 1. Manufacture Jig in accordance with Dwg /1 and position on trim lever pivot bolt. Note: Pivot bolt hole pre-drilled. Refer to Photo Using 5 min. Araldite/Fibreflock fit Trim Lever Stops in position after sanding joining areas. 3. Fit Knob Trim Lever 4. Fit Trim Lever to factory cut holes in Main Beam as per drawing /2 and Photo Note: Main beam spacer, aluminium spacer and inner friction plate are bonded with 5 min Araldite/flock. Outer friction plate and aluminium spacer are bonded together. Note: Trim Cable has been pre-fitted. 5. Use Cable Clamp, Anchor Plate and Trim Cable Packer to secure Trim Cable with 2 x TLR rivets. Ensure correct alignment of Cable with Trim Lever attachment by sanding Trim Cable Packer to correct width. Note: Cable packer is cut from 26 layer glass and shaped to cable anchor plate. Bond to main beam when riveting. Fit Trim Control Assembly

29 Photo Trim Control Assembly Fit Trim Control Assembly

Fit Rudder Pedals Reference: Drawing 3011092/2 Photo 10.

30 Fit Rudder Pedals Reference: Drawing /2 Photo Parts Required: Bearing Block (2) Clamp Plate (2) End Stop (4) LS Rudder Pedal Assembly RS Rudder Pedal Assembly AN Washer (2) MS Nut (2) AN4-23A Bolt (2) Jabiru Aircraft PH0019N Rivet 73 AS 4-2 (4) Materials Required: Nil Procedure: 1. Locate Rudder Pedals through hole at front of main beam with right hand pedals to the front of aircraft. Refer to Photo Lubricate and fit Rudder Pedals to Bearing Blocks ensuring smooth movement. Note: There must be no friction, as they will not centre properly. Release the AN4-23 bearing block mount if necessary. 3. Position pedal shafts so that approximately 2-3mm protrudes through bearing blocks and pedals are centred above bearing blocks. Photo Rudder Pedal Installation 4. Fit End Stops to each end of both Rudder Pedal Assemblies at the inner side of each bearing block to prevent the Rudder Pedal Assembly moving laterally in the blocks. Drill 1 x 1/8" hole in each Rudder Pedal Assembly as per drawing and fit End Stops with rivets supplied. Ref Photo Fit Rudder Pedals

31 Note: This can be achieved by holding stopper against inside of bearing block and drilling through stopper with hand drill. Fit Rudder Pedals

32 Fit Rudder Pedals

33 Fit Bellcrank Assembly and Steering Reference: Drawings /2, /4 and /3 Photo Parts Required: Mount Plate (1) Spacer-Steering Bellcrank (1) Drive Plate (1) N Pushrod RS Rudder (1) N Pushrod LS Rudder (1) N Pushrod Steering (1) N Cable Assembly Spring Balance includes: PR0029N Cable (.35m) (1) PH0279N Cable Eye (3) PH0289N Ferrel (3) - (Factory pre-assembled) AN4-14A Bolt (1) PB0078N Bearing (2) Bearing Retainer (1) PH0029N Rivet 73MS4-6 (6) PH0119N Rivet TLR (4) AN Washer (1) MS Nut (1) AN4-17A Bolt (1) AN3-12A Bolt (1) AN3-14A Bolt (2) AN3-10A Bolt (3) AN3-7A Bolt (2) AN Washer (12) MS Nut (2) PX0009N Spring Steering Balance (1 pre-assembled) MS Nut (10) PB0009N Rod End Male (6) PB0019N Rod End Female (2) MS /32 Nut Lock (2) Spacer 4mm (1) Spacer 4mm (2) N Spacer 3mm (2) Spacer 7mm (2) AN Washer (6) PC0089N Cable Clamp (2) PC0099N Cable Anchor Shim (2) PH0119N Rivet TLR (2) Material Required: 5 Min. Araldite Fibreflock Procedure: Note: It is easier to fit drive plate to mount plate before mounting to main beam. 1. Assemble Steering Bellcrank Assembly as per drawing /3. Note: The AN3-10A bolt for the nose wheel pushrod ball end must be installed before bolting drive plate to mount plate. Refer Section AA drawing /2. 2. Sand back of Mount Plate and joining area on Main Beam adjacent to factory pre-drilled holes to provide a bonding key. 3. Mix 5 Min. Araldite and fibreflock. Fit Bellcrank Assembly &

4. Fix Mount Plate to Main Beam with Araldite/fibreflock. 5. Attach Mount Plate to Main Beam with TLR rivets. 6. Fit Steering Balance Assembly as per drawing 3102084/3. 7.

34 4. Fix Mount Plate to Main Beam with Araldite/fibreflock. 5. Attach Mount Plate to Main Beam with TLR rivets. 6. Fit Steering Balance Assembly as per drawing /3. 7. Assemble Pushrods as per drawing /2. 8. Fit Pushrod Assemblies as per drawing /3. Note: Rudder Pedals must form a straight line when pushrods are connected to bellcrank, which has been positioned by the spring steering balance. Note: Ensure AN Washer is used on the outside of each Rod End to provide protection in the event of a bearing failure. This washer is allowed to float freely over 1/4 O.D. spacer. Photo Bellcrank Assembly and Steering CAUTION: It is most important that balljoints have free movement at all pedal positions. If there is any obstruction, then fitting a AN washer or washers between 1/4" diameter spacer and rudder pedal will provide extra clearance. Do not place washer between 1/4" spacer and ball end as it will restrict movement of ball end. See note at Step 8 re fitting AN washers on outside of Rod Ends. Note: Attachment of Pushrod Steering to Nose wheel Steering Link is completed at a later stage. 9. Measure and mark centre of travel of inner rudder cable. 10. Mount rudder cable ball end to rudder pedals as per drawing /3 Section CC. 11. Ensuring rudder pedals remain centred move rudder cable outer case to align with centre of travel mark. 12. Mount Rudder Cable to Main Beam using TLR rivets, cable clamp and anchor. Refer to Photo Note: Ensure cable forms a straight line with rudder pedals centred. Fit Bellcrank Assembly &

35 Fit Bellcrank Assembly &

36 Fit Bellcrank Assembly &

37 Fit Bellcrank Assembly &

Fit Throttle Assembly Reference: Drawing 3068033/2 Photo Parts Required: 3022094 Input Lever (2) 3067234 Cross Shaft Throttle (1) 3024094 Knob Throttle (2) 5010094 Backing Plate Throttle (2) 3067134

38 Fit Throttle Assembly Reference: Drawing /2 Photo Parts Required: Input Lever (2) Cross Shaft Throttle (1) Knob Throttle (2) Backing Plate Throttle (2) Output Lever AN3-11A Bolt (3) MS Nut (3) AN Washer (9) PH0439N M/Thread Br SH 3/16 x 50 (6) PH0319N Nut 3/16 BSW Nyloc (6) PZ0059N Tube Clamp (2) - 4 pieces Material Required: 5 min Araldite Epoxy & flock Procedure: 1. Fit output lever to shaft with bolt. 2. Mask output lever and paint cross shaft. 3. Fit Left hand side input leaver & knob. Refer photo & drawing. 4. Manoeuvre part assembled cross shaft into position sliding the tube in through the centre console from the left hand side. Refer to photo 5. Fit left hand input lever. 6. Fit tube clamps as bearings as per drawing /2 to centre console. Things to check before drilling:- Check you have no end float between left & right input leaver. Check that you have the output leaver as close to the centre console as possible. Check that the leaver assembly is level measuring up from the floor. Note: Throttle Cable is fitted in later procedure. Throttle stop bonded in position after Engine has Throttle lever Knob Throttle Input lever Bearing block Throttle shaft Throttle output lever RIGHT HAND SIDE OF AIRCRAFT LEFT HAND SIDE OF AIRCRAFT been installed. 7. When pre-fitting bearing blocks to seat pans, you will need to cut a 3 hole into the seat pan. This hole is determined by Projecting a line up from the bearing block bolt holes to obtain a center line for the hole. 8. Drill 3/16 holes for bearing blocks. Fit Throttle Assembly

39 Out put lever Input lever Photo - Throttle Assembly Throttle leaver installed Fit Throttle Assembly

40 Fit Throttle Assembly

1. Ensure Bush Control Column (2) fit factory predrilled holes in Lower Fuselage Main Beam.

1. Ensure Bush Control Column (2) fit factory predrilled holes in Lower Fuselage Main Beam. Assemble & Fit Control References: Drawings 3000092-7 and 93000K4/1 Photo 10.11(a), 10.11(b) Parts Required: 310408N Tube Handle Pivot 3000594 Input Drive Plate 3000394 Horizontal Tube 3100084 Output Yoke