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

Transcription

1 Assemble & Fit Control References: Drawings and 93000K4/1 Photo 10.11(a), 10.11(b) 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 LC3600 Resin Hardener Fibreflock Procedure: 1. Ensure Bush Control Column (2) fit factory predrilled 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. Refer photo 11.2I for assembly procedure. Now take assembly apart. 3. Mix resin/hardener/fibreflock & 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 pratice 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). Assemble and Fit Control Column

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

3 Photo 10.11(b) - Control Column Assy Left Side Assemble and Fit Control Column

4 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 and Fit Control Column

5 Nylon Control Column Bush Photo 10.11F Output Yoke Aileron Drive Assy Assemble and Fit Control Column

6 Tube Handle Pivot Nylon Washer Spacer Control Pivot AN3-13A Bolt Photo 10.11H Control Handle Assy Photo 10.11I Control Ass Assemble and Fit Control Column

7 Assemble and Fit Control Column

8 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: Procedure: 5 min Araldite Fibre Flock 1. Manufacture Jig in accordance with Drawing /1 and locate on Aileron Drive Plate (Ref: Drawing 93000K4/ 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 Fit Main Control Stops

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

10 2. 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

11 Fit Main Control Stops

12 Fit Main Control Stops

13 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 Use top cutout for Rudder cable & bottom slot for throttle cable. Photo 10.13(a) - Rudder Cable Entry Point Elevator Cable (Green Sheath, 3050 long SK) / (3655mm Long UL & SP) 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) 3. Locate and clamp at control handle end, using Cable Clamp and Cable Anchor with AN3-5A Bolts. 4. Secure cable ends with clamp & shim. Fit Rudder, Elevator & Trim Cables

14 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. 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 pre-drilled 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. Trim Ankor point. Make it as close to the seat radius as possible & rivet with 7/32 TLR Note: Mount master cylinder to mount plate and place in position. See Procedure Photo 10.13(b) Trim Cable entry point Fit Rudder, Elevator & Trim Cables

15 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). Elevator cable hole Main hole into center console Photo 10.13(c) - Elevator cable entry. Note: Smaller hole above and right of hole Wrap cables with foam & secure with zip ties VHF coax cable Photo 10.13(d) - Installed cables, including static line Fit Rudder, Elevator & Trim Cables

16 Fit Trim Assembly Reference: Drawing /2 Photos 10.14(a), 10.14(b) Parts Required: Spring Retaining Rod Mounting Plate Trim Assy PC0089N Cable Clamp (3) PC0099N Cable Clamp Shim (3) PB00194 Rod End Female (3) PB0009N Rod End Male AN310-4 Nut Lock AN4-13A Bolt (2) AN218-4 Bearing PH0199N Rivet (6) Pivot Block Sleeve Pivot Block Spacer Rod End Bearing Pivot Block AN3-12A Bolt AN3-7A Bolt AN3-11A Bolt PH0219N Washer PX00594 Spring (2) AN Washer (2) PC00494 Trim Cable Assembly Material Required: LC3600 LC3600 AF303 Resin Hardener Glass Coth Fibre Flock Procedure: 1. Assemble the Trim System as per drawing /2 and with reference to Photos 10.14(a) and 10.14(b). 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 10.14(a) and 10.14(b). 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. Note: Ensure all ball ends have freedom of movement in all positions and are not binding on washers in any way. Fit Trim Assembly

17 Photo 10.14(a) - Trim Assembly from the right hand side. Elevator cable Trim cable Spring balance trim Pivot bolt trim AN4- Photo 10.14(b) - Trim Assembly from the left hand side Note: 3 AN washers over sleeve pivot block and between pivot block and bearing pivot block. Fit Trim Assembly

18 Fit Trim Assembly

19 Fit Brake Master Cylinder and Handbrake Reference: Drawing /2 Photos 10.15(a), 10.15(b), 10.15(c). 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

20 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

21 Photo 10.15(b) - Brake Master Cylinder Installation Details Photo 10.15(c) - Master Cylinder showing trim cable passing through master cylinder mount plate. Fit Brake Master Cylinder & Handbrake

22 Fit Brake Master Cylinder & Handbrake

23 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

24 Fit Trim Control Assembly Reference: Drawings /2 (Proc 10.4 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 AN4-23 Bolt (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 predrilled. 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

25 Photo Trim Control Assembly Fit Trim Control Assembly

26 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) 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 friciton 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 Fit Rudder Pedals

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

28 Fit Rudder Pedals

29 Fit Bellcrank Assembly and Steering Reference: Drawings /2, /3 and /2 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 preassembled) 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 Fit Bellcrank Assembly & Steering

30 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 /2. Note: The AN3-10A bolt for the nosewheel 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 predrilled holes to provide a bonding key. 3. Mix 5 Min. Araldite and fibreflock. 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 /2. 7. Assemble Pushrods as per drawing /2. 8. Fit Pushrod Assemblies as per drawing /2. 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 Nosewheel Steering Link is completed at a later stage. Fit Bellcrank Assembly & Steering

31 9. Measure and mark centre of travel of inner rudder cable. 10. Mount rudder cable ball end to rudder pedals as per drawing /2 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 centered. Fit Bellcrank Assembly & Steering

32 Fit Bellcrank Assembly & Steering

33 Fit Bellcrank Assembly & Steering

34 Fit Bellcrank Assembly & Steering

35 Fit Throttle Assembly Reference: Drawing /2 Photo Parts Required: Input Lever (2) Cross Shaft Throttle 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: Nil Procedure: 1. Clamp tube clamps together and drill out to 1/2". 2. Fit output lever. Mask output lever and paint cross shaft. 3. Manoeuvre part assembled cross shaft into position. Refer to photo Fit right hand and left hand input lever. 5. Fit tube clamps as bearings as per drawing /2. Photo Throttle Assembly Fit Throttle Assembly

36 Note: Throttle Cable is fitted in later procedure. Throttle stop bonded in position after floor cover installation. 6. The throttle stop must be bonded into position with 5 min araldite and flock. (Left Seat only) Fit Throttle Assembly

37 Lower Fuselage Assembly Firewall Lower Fuselage Assembly 10.0/C

38 Fit Front Moulded Skin and Top Stiffeners Reference: Photo 10.21(a), 10.21(b), 10.21(c) Parts Required: N Moulded Skin Front N Stiffener RS Top Stiffener LS Top To determine left from right Note: Top of Stiffener is straight and bottom inclined to skin. Material Required: LC 3600 LC 3600 AT 313 Resin Hardener Fibreflock 75mm Glass Tape Procedure: 1. Trial fit L/S and R/S top stiffeners between doorframe and firewall and over join line. (Ref Photo 10.21(a) 2. Unscrew and remove moulded skin from firewall. Lightly sand firewall joining areas. 3. Locate pre-cut fibreglass pieces labelled (Firewall Skin) Note: There are 2 layers of 75mm glass tape for front of firewall. 2 Layers (12 pieces) of 303 glass pre-cut for the inside area forward of the front door pillar and 2 layers of 303 (4 pieces) for front join line. 4. Mix Resin/Hardener and separate Resin/Hardener/Fibreflock. 5. Apply Resin/Hardener/Fibreflock to firewall and door frame (Photo 10.21(B) joining areas and secure moulded skin using the pre-drilled holes. 6. Smooth out flock on inside rear between firewall and moulded skin, radius forward join area between skin and firewall with bead of flock. Fill join line on inside with flock. Ensure outside of skin is flush, pull into line with a piece of ply and self tapping screws. If necessary, ensure there is a lip for top of cowl. Fit Front Moulded Skin & Top Stiffeners

39 Photo 10.21(a) Fitting Top Stiffeners 7. Use 2 layers of AT 313 glass tape to join the front of the firewall to the moulded skin. Cut each length of 75mm tape into 3 pieces for easier handling. Make cuts at point of maximum radius. 8. Glass area between firewall and door frame using 6 pieces of 303 glass on each side. (200 x 70 firewall to skin, 180 x 70 door frame to skin, Photo 10.21(c), 70 x 70 join line between firewall and door frame). 9. Apply Resin/Hardener/Fibreflock to the joining surfaces of both top stiffeners and locate over join line between the door frame and firewall on each side of the fuselage. 10. Glass join line forward of firewall using 2 layers of 303 cloth (140 x 100). Ensure cloth goes approx 40mm past front of moulded firewall skin. 11. Place flock on the flanges of top stiffeners and fit stiffeners in position. Hold in place with self tapping screw. Fit Front Moulded Skin & Top Stiffeners

40 Photo 10.21(b) - Flocking Firewall and Door Frame Photo 10.21(c) - Glassing Moulded Firewall Skin to Door Frame and Firewall Fit Front Moulded Skin & Top Stiffeners

41 Fit Firewall Metal Sections Reference: Drawing /1 and /1 Photo Parts Required: Stainless Steel Section LS Stainless Steel Section RS PH0049N Rivet 73 As 5-8 (80) PH0219N Washer Com 5/32 (50) Material Required: Silicon Sealant Procedure: Note: To seal ply, paint any bare areas with epoxy resin (Front Only). 1. Bend up rear section of pre-drilled firewall sections as per drawing /1 and /1. Note: To have overlap line in centre L/H side must be fitted first. (Under R/H side). Bend at rear will fit better if it has a radius. 2. Position L/H section and mark position of front bend. (Ref Photo 10.22) 3. Bend front of L/H section down, refit and trim edge to fit if necessary. 4. Holding L/H section in position, drill 5/32" holes into firewall. Note: A long shanked 5/32" drill will be necessary to drill edge holes. These rivets fit at an angle and do not pull up flush. Do not pull up rivets until all holes are drilled and wood shavings removed from behind metal section. 5. Rivet in place using 5/32" brass washers or ply. The top horizontal row of rivets are riveted with the heads on the inside to provide a smoother interior finish. The vertical row is behind instrument panel and can be installed from front. 6. Repeat steps 2 to 5 to fit R/H section. 7. The rudder pedals stops and top centre housing suspension leg holes have been predrilled through firewall, ensure these holes are drilled through metal sections. 8. Seal all joints and surround with silicone sealant. Fit Firewall Metal Sections

42 Photo Marking Front Bend Left Hand Side Fit Firewall Metal Sections

43 Fit Firewall Metal Sections

44 Fit Firewall Metal Sections

45 Fit Housing Suspension Leg Reference: Photo Parts Required: Housing Suspension Leg Assembly (1) N Plate Backing (1) AN3-10A Bolt (3) AN3-11A Bolt (5) MS Nut (8) AN Washer (8) AN Washer (8) Material Required: Nil Procedure: 1. Position the housing and bolt in place with the backing plate inside the fuselage, using the pre-drilled top hole. Note: Ensure that the assembly is vertical with the fuselage centreline. Ref Photo Drill the remaining holes inserting the bolts, as holes are drilled. The top three bolts are AN3-10A, remainder AN3-11A to allow for extra thickness of glass on firewall. Place AN washers 1/4" under bolt heads. 3. A small rectangular aluminium backing plate is used inside centre beam for bottom bolt. Use AN washers 3/16" behind nuts. Photo Noseleg Housing Suspension Bracket Installation Fit Housing Suspension Leg

46 Fitting-out the Firewall Reference: Photo Refer Procedure Photo Refer Procedure Photo Refer Procedure Drawing 30070J1/1 Drawing /1 Parts Required: PW0009N Grommet 1-1/8 (3) Fuel Bulkhead Fitting PH0069N Rivet 73 AS (15) PH0219N Washer Com 5/32 (15) Battery Box Battery Tie Down Lug (2) N Earth Bracket AN3-5A Bolt MS Nut AN Washer (2) N Firewall Steering Grommet PH0359N Rudder Pedal Stop (4) PH0239N Nut 1/4 BSW (8) Material Required: Silicon Sealant Procedure: 1. Cut holes (3) for Firewall Grommets as marked on Zinc Sheet. 2. Locate Grommets in holes. 3. Drill Hole for Fuel Bulkhead Fitting as per drawing /1. 4. Attach Fuel Bulkhead Fitting to Firewall with rivets, backing up with washers and sealing with Silicon. 5. Attach Battery Box with rivets, backing up with washers as per drawing. 6. Attach Battery Restraints as per drawing with rivets, backing up with washers. 7. Fit Firewall Earth as per drawing /1 with bolt. 8. To cut the hole for Steering Pushrod use Jig 30070J1/1, refer to drawing 30070J1/1. Position the jig over the Housing Suspension Leg and drill the hole. 9. Fit Firewall Steering Grommet to Firewall as per photo Seal with Silicon and back up rivets with washers. 10. Drill holes for Rudder Pedal Stops as per drawing / Fit Rudder Pedal Stops with Nut each side of Firewall. Note: The exact positioning of these stops is set at a later stage. Fitting-out the Firewall

47 Fitting-out the Firewall

48 NOTE: It may be necessary to put this step in the firewall so the Carburettor clears. Fitting-out the Firewall

49 Fitting-out the Firewall

50 Fit Upper Instrument Panel Mount Brackets and Panel Reference: Photo 10.25(a), 10.25(b) Parts Required: Bush Mount Lower Panel (2) Tube Mount Instrument Panel (1) Mount Bracket Top LS (1) N Mount Bracket Top RS (1) PH0049N Rivets (4) Upper Instrument Panel (1) PW0009N Grommets (4) AN Cotter Pins (2) Materials Required: Nil Procedure: 1. Identify pre-drilled upper instrument panel mount bracket holes. Refer to Photo 10.25(a) Note: Only one hole is provided for each mount to correspond with the top inside hole of brackets when mounted with slotted holder to inside. Refer to Photo 10.25(a) for orientation of brackets. File a radius or bevel on front corner of holder slot. This will help guide top panel into slot. 2. Drill 5/32" hole through firewall metal and rivet mount brackets into position. Note: Riveting from front will look neater in engine bay. 3. Use a straight edge across top front of mounts to align, drill and rivet lower outside hole. 4. Locate four 3/4" mount holes in upper instrument panel and insert grommets (two top inside and two bottom outside). 5. Insert mount rod into top inside grommets and set in place using split pins. Insert lower bush mount into grommets ( ). Note: A little rubber grease will help mount rod slide into grommets. 6. Hang upper instrument panel on mounts and check alignment. Refer Photo 10.25(b). Note: If panel requires adjustment the bottom of the mount brackets can be filed with a round file. Fit Upper Instrument Panel Mount Brackets & anel

51 Photo 10.25(a) - Instrument Panel Mount Brackets. Photo 10.25(b) - Upper Instrument Panel in Position Fit Upper Instrument Panel Mount Brackets & anel

52 10.25(c)Helicopter Instrument Panel in Position (d) 3 piece Instrument Panel in Position Fit Upper Instrument Panel Mount Brackets & anel

53 10.25 (e) VLA Instrument Panel in Position Fit Upper Instrument Panel Mount Brackets & anel

54 Drawing (3 piece panel) Mount Bracket Centre Dash Panel Fit Upper Instrument Panel Mount Brackets & anel

55 Drawing (3 piece panel) Mounting Rod R&L Dash Panels Fit Upper Instrument Panel Mount Brackets & anel

56 Drawing (3 piece panel) Mounting Rod Centre Dash Panel Fit Upper Instrument Panel Mount Brackets & anel

57 Drawing Mount Bracket Top L.S. for helicopter (Mount Bracket bottom for 3 piece panel) Fit Upper Instrument Panel Mount Brackets & anel

58 Drawing (3 piece panel) Moulded Dash LS Sub Assy Fit Upper Instrument Panel Mount Brackets & anel

59 Drawing (3 piece panel) Moulded Dash RS Sub Assy Fit Upper Instrument Panel Mount Brackets & anel

60 Drawing (3 piece panel) Moulded Dash Centre Sub Assy Fit Upper Instrument Panel Mount Brackets & anel

61 Drawing (3 piece panel) Dash Panel Assy Fit Upper Instrument Panel Mount Brackets & anel

62 Fit Lower Instrument Panel Reference: Photo 10.25(a), 10.25(b), Parts Required: Lower Instrument Panel (2) PH0049N Rivets AS 5-8 (4) PH0399 Rivets AS 3-3 (4) M Anchor Nuts 3/16" (2) Materials Required: 2mm Spacing Material Procedure: 1. Place 2mm spacer behind to lower forward edge of top panel to provide clearance for firewall carpeting. 2. Temporarily fit lower panel to upper panel by clamping together with 2mm spacer between. Note: Ensure top panel is correctly positioned on top mount brackets and lower panel centred between top panel lower mount brackets. 3. Ensure flanges on front of lower instrument panel are flush on firewall and lower panel is level. Photo Drill and rivet lower instrument panel in place using four AS 5-8 rivets. Photo 10.25(a). 5. With clamps still in place drill 3/16" hole into lower panel through lower mount bush in top panel. 6. Remove top panel and rivet 3/16" anchor nuts on inside of lower panel, over holes. Photo Spacing Lower Instrument Panel Fit Lower Instrument Panel

63 10. Lower Fuselage Assembly Undercarriage Lower Fuselage Assembly 10.0/D

64 Jabiru Undercarriage Configurations There are four combinations of tyres available, utilising two sets of hubs (standard and heavy duty) and rim reinforcements with two different bolt combinations. Refer to Photo 10.27(a). The 400/4 and 500/6 nose tyres use a shorter noseleg and a larger nose leg yoke. Undercarriage Configuration Description Tyre Rim Hub Rim Reinforcements Standard Nose 260/4 4" STD Nil Main 400/4 4" STD Nil Medium A Nose 400/4 4" STD Nil Main 500/6 6" HD 2 (4 Bolts) Medium B Nose 500/6 6" HD 2 (4 Bolts) Main 500/6 6" HD 2 (8 Bolts) BigFoot Nose 500/6 6" HD 2 (4 Bolts) Main 600/6 6" HD 2 (8 Bolts) Photo 10.27(a) - Rims, Hubs, Reos and Tyres Assemble Main Hubs, Rims, Tyres & Brake Disc

65 Assemble Main Hubs, Rims, Tyres and Brake Disc Reference: Drawing /2, /3 Photo 10.27(a), 10.27(b) Parts Required: Standard Medium A and B BigFoot Description Qty Brake Disk (2) Wheel Hub (2) N N Rim - Main Wheel (4) AN4-6A AN4-10A AN4-10A Bolt - Wheel Halves (8) MS MS MS Nut - Wheel Halves (8) AN AN AN Washer - Wheel Halves (8) PB0029N PB0029N PB0029N Bearing (4) AN3-6A AN3-6A AN3-6A Bolt - Disk Brake (8) MS MS MS Nut - Disk Brake (8) AN AN AN Washer - Disk Brake (8) PU0019N(400/4) PU0099N (500/6) PU0079N (660/6) Tyre (2) PU0029N (400/4) PU0109N (500/6) PU0089N (600/6) Tube (2) N/A Plate Reinforcements (4) N/A AN3-10A AN3-10A Bolt - Reinforcements (16) N/A MS MS Nut - Reinforcements (16) N/A AN AN Washer - Reinforcements (16) Material Required: Nil Procedure: 1. Press 2 bearings (PB0029N) into each hub ensuring they are properly bottomed. Note: The outer bearing will be 1-2mm inside hub, not flush. 2. Insert tube into tyre and inflate lightly to avoid pinching in rim halves. 3. (a) Assemble tyre tube and wheel laves to hubs as per drawings /1 (standard), /3 (Med A, Med B and BigFoot). Refer to Photo 10.27(b). 3. (b) Med A, Med B and BigFoot only - Bolt rim reinforcements to both sides of rims as per drawing /3. Refer to Photo 10.27(b). Note: Four 3/16" holes will have to be drilled in rims. 4. Bolt brake disc to hubs as per drawing /2 and /3. Assemble Main Hubs, Rims, Tyres & Brake Disc

66 Photo 10.27(b) - BigFoot showing Rim Reo Assemble Main Hubs, Rims, Tyres & Brake Disc

67 Assemble Main Hubs, Rims, Tyres & Brake Disc

68 Assemble Main Hubs, Rims, Tyres & Brake Disc

69 Assemble Main Undercarriage Brakes and Wheels References: Drawing /2 Photo 10.28(a) and 10.28(b) Parts Required: Extension Axle Stub (2) AN3-12A Bolt (2) Axle Stub (2) Mounting Plate Inner (2) PX0029N Spring (4) AN4-16A Bolt (4) Piston Body Arm (2) Piston Disk Brake (2) PD0049N Piston Seal (2) Nipple (2) Nipple (2) Piston Body (2) Brake Pad (4) PD0029N Rivet (6) PD0019N Rivet (6) Mounting Plate Outer (2) AN4-16A Bolts (4) AN4-17A Bolts (4) MS /16" Nyloc Nuts (10) MS /4" Nyloc Nuts (8) AN Metal Lock Nuts (4) Suspension Leg LS (1) N Suspension Leg RS (1) Mount Bracket Spat (2) Preassembled Main Wheel Assembly (1) Materials Required: Anti-seize or grease Rubber Grease Loctite Pipe Sealant Procedure: 1. Using shorter rivets, attach brake pads to both inner mounting plates, also using longer rivets attach brake pads to both outer mounting plates. 2. Using two AN4-16A bolts on top holes and two AN4-17A bolts on bottom holes, insert bolts through inner mounting plate, axle and main undercarriage (suspension) leg, ensuring inner brake pad is in front of the axle. As per Drawing /2 refer Photo (a) and (b). Note: Left and right undercarriage legs must be properly identified as they are not interchangeable. The mount plate is on the outside of axle flange (not between flange and leg) and facing forward. Assemble Main Undercarriage Brakes & Wheels

70 3. Fit spat mount bracket on bottom AN4-17A bolts and bolt axle assembly together. Refer to photo 10.28(a) and 10.28(b). 4. Assemble outer brake pad mounting plate by inserting two AN4-16A bolts and placing return spring (PX0029N) on each bolt. Lightly grease axle, fit preassembled wheel assembly onto axle while installing outer brake pad mounting plate assembly at the same time. Refer Drawing /2 and Photo 10.28(a). 5. Secure wheel assembly by mounting extension stub axle to end of axle using AN3-12A Bolt. Refer Drawing /2 and Photo 10.28(b). 6. Thoroughly clean brake piston body, place piston body through piston body arm. 7. Screw in brake hose nipple using thread sealant. 8. Screw in bleed nipple, locking up tight several times to bed seal. 9. Grease piston seal and piston with rubber grease and insert into piston body as per drawing /2. Note: Use care when inserting piston into piston body as it can mark piston body if not aligned properly. 10. Mount brake piston body and arm assembly to main undercarriage as per drawing Connect brake hose to piston body nipple. Photo 10.28(a) - Main Undercarriage showing brake and axle assembly Assemble Main Undercarriage Brakes & Wheels

71 Photo 10.28(b) - Main Undercarriage showing Axle Extensions on standard and BigFoot configuration Assemble Main Undercarriage Brakes & Wheels

72 Fit Undercarriage Backing Plates References: Drawings (Proc 10.30) Photo 10.29(a) Parts Required: Backing Plate - Rad (2) Backing Plate - Rec (4) Materials Required: LC3600 Resin LC3600 Hardener Fibre Flock 2" x 5/16" Steel Rod or Tube (6) Procedure: 1. Sand and trim area around the six predrilled 5/16" undercarriage mount holes in preparation for backing plates. Note and Caution: A flatter area around the top of undercarriage hole will ensure a lower fitting backing plate and removal of some glass may be desirable. However strength in this area is important and any glass removal must be kept to a minimum. 2. Grease 5/16" steel rods and insert in undercarriage holes. 3. Trial fit undercarriage backing plates over steel rods to sit as low as possible. Radiusing edges and reshaping of undercarriage plates may be necessary. Sand backs of undercarriage plates to provide bond key. Note: The four rectangular undercarriage plates fit over holes in front of seat backs (Photo 10.29(a)) and two radiused undercarriage plates fit over holes behind seat backs. Refer to Photos 10.29(a) and Drawing Mix epoxy resin/hardener/fibreflock and place sufficient amount around steel rods to form a bed. Press undercarriage backing plates into position. Shape flock bed and smooth off with resin/hardener mix. 5. Cure and remove steel 5/16" rods. Fit Undercarriage Backing Plates

73 Photo 10.29(a) - Showing Front (rec) Undercarriage Backing Plate Fit Undercarriage Backing Plates

74 Fit Main Undercarriage Legs Reference: Drawing Photo 10.30(a) and (b) Parts Required: Suspension Leg Rear LS N Suspension Leg Rear RS Materials Required: Nil Procedure: Bush Suspension Leg (4) Washer Undercarriage (2) Clamp Bar Undercarriage (2) N Rubber Strip (2) AN5-26A Bolt - Leg Inner (2) AN5-31A Bolt - Leg Outer Rear (2) AN5-33A Bolt - Leg Outer Front (2) MS Nut Nyloc (6) Washer (as required) 1. Run a 5/16 drill through Undercarriage mount holes to make sure they are clear. 2. Position suspension legs using AN5-26A bolt, undercarriage washer and two suspension leg bushes in inner leg hole. The outer leg is held in place using clamp bar, AN5-31A bolt front, AN5-33A bolt rear, and rubber strip between leg and fuselage. Refer to Drawing assembly details. Photo 10.30(a) shows the rubber strip and undercarriage clamp bar in place. Note: The length of bolts required to mount suspension legs may vary, depending how undercarriage backing plates have been positioned. If more than three washers on each bolt is required, a shorter bolt is recommended. Fit Main Undercarriage Legs

75 Photo 10.30(a) - Undercarriage Leg Attachment Details Note: A better fit of outter clamp to undercarriage leg can be obtained by placing some resin/fibreflock mix between clamp and undercarriage leg. Photo 10.30(b) - Inner Undercarriage Mount Note: Suspension bush flange between suspension leg and undercarriage washer to be compressed to approximately half original thickness. Bolts on undercarriage clamp bar (outer mount) must be sufficiently tightended to stop later bending. Fit Main Undercarriage Legs

76 Fit Main Undercarriage Legs

77 Bleed Brake Cylinders Reference: Photo Parts Required: Nil Material Required: Brake Fluid Procedure: 1. Close bleed nipples, (Photo 10.31) and fill brake master cylinder reservoir to full mark. 2. Open one of either nipples, depress brake handle and hold depressed. 3. Close open nipple and release brake handle. 4. Repeat steps 2 and 3 until all air has been removed from line. 5. Repeat procedure for both sides. Note: Ensure master cylinder level does not drop to low during bleeding process. Photo Brake Bleed Nipple Bleed Brake Cylinders

78 Assemble Nose Wheel and Hub References: Drawing , Photo Parts Required: Standard Med A Med B Description PU0009N (260 x 4) PU0019N (400 x 4) PU0099N (500/6) Tyre (1) PU0029N (260 x 4) PU0029N (400 x 4) PU0109N (500/6) Tube (1) N Rim (2) Hub (1) PB0029N PB0029N PB0029N Bearing (2) Spacer Bearing Hub (2) Front Axle (1) Materials Required: Loctite 480 Procedure: 1) Press Bearings into Hub 2) Loctite 480 Bearing Spacers ( Standard) ( Med A, Med B, Big Foot) into Bearings 3) Loctite 480 Front Axle ( Standard) ( Big Foot, Med A, Med B) into Bearing Spacers ensuring axle end flush with, or protruding slightly from spacers. (Ref Drawing Section AA, Section AA, Standard), ( Med A, Med B, Photo Big Foot). Note: If spacers protrude past axle, bearings will be side loaded and bind when wheel is mounted in yokes. Spacers must be ground back to make a flush surface with axle if necessary. 4) Assemble rims, tyre and tube on hub as per Drawing Standard, Med A, Med B and Big Foot. Assemble Nose Wheel & Hub

79 Photo Med A, Med B, Big Foot, Hub and Axle Assemble Nose Wheel & Hub

80 Assemble Rubber Spacer Set References: Drawing Parts Required: Suspension Rubber Domed End (1) Suspension Rubber w/o Pilot (8) Suspension Rubber with Pilot (1) Washer Aluminium 1mm thick (9) Washer Aluminium 3mm thick (1) Materials Required: Loctite 480 Rubber Grease Acetone or Similar Solvent 200mm x 10mm Bolt and Nut Large washer with 10mm centre Procedure: 1) Remove Spiggot Ends from all suspension rubbers excluding one for top of set. Re: Drawing Note: The domed rubber will be at the bottom of set and a spiggoted rubber second top to locate in nose leg top mount. A further flat rubber is positioned above nose leg top mount. 2) Shape a 1mm Aluminium Washer to fit domed rubber end and curved suspension bracket washer Ref Proc Step 7. 3) Prepare all rubbers and washers for bonding by washing 1mm aluminium washers in Acetone or similar solvent and roughing up all bonding surfaces. 4) Clamp 200mm x 10mm bolt in vice to create a jig with sufficient length to hold nine rubbers and 1mm washers. Grease bolt with rubber grease. Assemble rubber spacer set on bolt as per Drawing bonding all surfaces with loctite 480. When assembled, clamp together with nut and washer on bolt using enough pressure to compress rubbers slightly. Cure. Assemble Rubber Spacer Set

81 Note this has been replaced with a one piece rubber set Assemble Rubber Spacer Set

82 Top rebound Rubber A775 4 cylinder pre-formed compreshion rubbers Top Rebound Rubber A775 6 cylinder pre-formed compression rubbers Photo nose leg 6 cylinder compression rubbers Assemble Rubber Spacer Set

83 Assemble and Fit Nose Leg References: Drawing (Big Foot, Med A, Med B) Drawing (Standard) Photo (a), (b) Parts Required: Standard Med A, Med B, Big Foot Description Quantity MS MS Nut (3) N/A MS Nut (4) AN3-22A AN3-22A Bolt (2) Retaining Collar Leg (1) Suspension Leg w/assy (1) Tube Suspension Rubber (1) Retaining Collar Suspension (1) Steering Link (1) AN3-6A AN3-6A Bolt (1) MS MS Bolt (1) Shaft Suspension Tensioner (1) N/A Suspension Bracket Washer (1) AN4-53A AN4-63A (AN4-72A spats) Bolt Axle (1) AN AN Washer (3) N/A AN4-7A Bolt (4) MS MS Nut (2) AN310-4 AN310-4 Castled Nut (1) AN AN Cotter Pin (1) N Bush Suspension (1) AN5-31 AN5-42 Bolt Yoke Pivot (1) Wheel Yoke RH (1) N Wheel Yoke LH (1) AN4-42A AN4-42A Bolt (1) N N Bush Suspension (1) Pre Assembled Parts Required: Proc Nose Wheel and Hub (1) Proc Rubber Spacer Set (1) Materials Required: Grease Rubber Grease Loctite 480 Fit Steering Link & Firewall Steering Grommet

84 Procedure: 1) Grease and insert nylon front pivot bush into mount tube, welded into bottom of leg. Note: Standard Bush 50mm long, Med A, Med B, and Bigfoot, 75mm long with 5/16" hole. Bush must be able to pivot freely in mounts, some reaming of mounts may be necessary. 2) Attach yokes to front pivot bush using AN5-32 bolt standard and AN5-42 Bolt Med A, Med B and Bigfoot use castle nut. Do Not Tighten. Ref Drawings , and Photos (a), (b). Note: For Med A, Med B, and Bigfoot, Yoke Spacer ( ) is bolted between yokes at this stage. Redrilling of 3/16" mount holes may be necessary due to distortion during bending of yoke. Do Not Tighten Bolts. Ref Drawing Photo (b). 3) Assemble rubber suspension tube into suspension shaft tensioner ( ) as per Drawings and Note: Long end to hole of suspension tube goes into suspension shaft tensioner. 4) Grease and insert suspension tensioner bush into suspension tensioner (75mm long with 1/4" hole). Note: Ensure free movement, ream tensioner if necessary. 5) Bolt suspension tensioner to yokes leaving bolt untightened. 6) Fit preassembled nose wheel to yokes. Tighten all bolts. Remove nose wheel. 7) Place curved suspension bracket washer ( ) and rubber spacer set on suspension tensioner shaft. Clamp bottoms of yokes in vice and using a lever on top of nose suspension leg compress rubber spacers to fit top suspension rubber, 3mm washer and retaining collar. Retaining collar held in place with AN3-6A bolt. Ref Drawings and Re fit nose wheel, fit retaining collar ( ). 8) Re fit nose wheel, fit retaining collar ( ). 9) Fit nose leg into suspension leg housing, fit steering link onto top of leg. Note: Only one hole is provided in steering link. The second one must be drilled in situe. 10) With upward pressure on nose leg and downward pressure on steering link, drill 3/16" hole through collar. Note: A series of holes 1mm off set is provided in bottom retaining collar to provide adjustment. Increments of 0.55mm are available by inverting collar. 11) Remove nose leg, lubricate, re assemble. Fit Steering Link & Firewall Steering Grommet

85 Photo (a) - Noseleg Assembly (Right Side) Standard Photo (b) Noseleg Assembly (Med B) Showing Yoke Spacer ( ) Fit Steering Link & Firewall Steering Grommet

86 Fit Steering Link & Firewall Steering Grommet

87 Fit Steering Link & Firewall Steering Grommet

88 Fit Steering Link & Firewall Steering Grommet

89 Fit Steering Link & Firewall Steering Grommet

90 Fit Steering Link and Firewall Steering Grommet Reference: Photo 10.23, Drawing (Proc 10.19, Page 4), 300J051 (Proc 10.24) Parts Required: N Firewall Steering Grommet (1) N Steering Push Rod (1) PB0009N Male Ball End (2) AN316-3 Nut Lock (2) AN3-12A Bolt (1) AN Washer 3/16" (2) AN Washer 1/4" (2) Spacer 3/16" ID x 3mm (1) Rivets (6) Washer 1/8" (8) Material Required: Silicon Sealant 240mm x 150mm x 4mm Ply Procedure: Note: This procedure completed after procedure Fitting Firewall Metal Sections and procedure Fit Housing Suspension Leg. 1. Cut out drilling jig from 4mm ply as per drawing 30070J1 (Proc 10.24) 2. Place drilling jig over top of nose leg housing and against firewall. Mark and drill 3/16" pilot hole for steering pushrod. Drill out pushrod hole to 3/4". 3. Assemble ball ends and locknuts to steering pushrod. Insert pushrod through firewall and bolt to bellcrank and steering link. Ref Drawing Photo Note: Spacer is used on bellcrank to provide clearance from bearing flange. AN /4" washers used on top of ball ends to provide security in case of ball end failure. 4. Move rudder pedals through full range of travel to ensure pedals are not fouling pushrod and pushrod is not fouling on firewall. Elongation of hole in firewall will probably be necessary. 5. Punch 3/8" hole in centre of steering grommet. Fold grommet in half over hole and insert 1/8" rivets using washer either side top and bottom of grommet, approx, 10mm back from front and 10mm in from edges. Ref sketch & photo 10.35a&b 6. Remove pushrod from nose leg steering link, place grommet over pushrod with loose ends to firewall. Refit pushrod to steering link. 7. Spread grommet ends onto firewall, drill 1/8" holes through four corners into firewall. Note: A long shank drill will be necessary. Cut a gap in grommet to fit over rudder stop. Rivets do not go through firewall. Seal gap between grommet and firewall with silicon and rivet into position with washers under rivet heads. Ref sketch Photo Fit Steering Link & Firewall Steering Grommet

91 Sketch10.35 Fit Steering Link & Firewall Steering Grommet

92 Photo 10.35a Steering pushrod cover Photo 10.35b Steering pushrod cover Fit Steering Link & Firewall Steering Grommet

93 Fit Auxiliary Fuel Pump Reference: Photo 10.3, Parts Required: PM0029N Fuel Pump PZ0069N Hosetail (2) MS Machine Screw (2) AS Tinnerman Washer (2) MS Nut (2) AN Washer (2) Material Required: Fuel Resistant Thread Sealant Procedure: 1. Attach hosetails to the fuel pump using Loctite 262 or a fuel resistant product. 2. Fit Male electrical terminals to wires. 3. Using the base of the fuel pump as a template mark the position of the bolt holes on the lower fuselage approximately 160mm back from undercarriage radius and central between LH mount and spine. Ref Photo 10.36b&c. 4. Drill and countersink 3/16" holes. Attach fuel pump to lower fuselage using machine screws, tinnerman washers, nuts and AN washers as per Photo 10.36b&C. Note: Tinnerman washers under screw heads. Ensure flow direction of pump is forward. 5. Seal hosetail ends to prevent the entry of foreign bodies to the fuel pump. Masking tape is adequate. FRONT OF AIRCRAFT Underneath view of Fuel pump screws MS24693C51 & tinniminum washers. #A Photo 10.36a Installation of the Auxiliary Fuel Pump Fit Auxiliary Fuel Pump

94 FRONT OF AIRCRAFT Fuel Pump Note: Make sure direction of flow is facing forward Photo 10.36b Fuel Pump Pisition FRONT OF AIRCRAFT Photo 10.36C Fuel Pump Position Fit Auxiliary Fuel Pump

95 Fit Fuel Lines, Filter, Fuel Tap and Tap Cover Reference: Photo Parts Required: PT0019N Fuel Hose PV0019N Hose Clamp (6) PM0009N Fuel Filter (1) Cover Fuel Tap (1) Mount Bracket Fuel Tap (1) PM0019N Fuel Tap (1) PZ0019N Hose Tail 1/4 BSP - 1/4 (2) PH0199N Screw Phillips Pan Head 6g x 1/4 (10) Material Required: Fuel Resistant Thread Sealant Loctite 262 Procedure: 1. Run fuel hose from auxiliary pump through large hole behind seat backs and through 5/8" holes predrilled in seat pan on left hand side of main centre beam. Finish hose 90mm from front hole where fuel line re-enters main beam (Ref Photo 10.37). Connect fuel line to pump. Note: Ensure fuel line is of sufficient length to lie freely. Do not over tighten clamps. 2. Fit hosetails to tap using thread sealant and remove handle. 3. Fit tap to hose from auxiliary pump. 4. Run hose from tap through front beam and exiting rear of two 5/8" holes in top of beam. Note: Position clamps on tap to top of line. This will help secure tap behind mount. 5. Fit fuel filter between main beam and firewall fuel bulkhead fitting. (Ref Drawing ). 6. Drill and file hole to fit fuel tap mount bracket over tap handle shaft and position tap as far forward as possible (Ref Photo 10.37). Secure tap mount with 6g x 1/4" self tapping screws. 7. Refit tap handle using loctite Fit tap cover with handle in upright (OFF) position, using 6g x 1/4" self tapping screws (Ref Photo 10.37, Drawing ). 9. Ensure both ends of fuel system are sealed. Note: The connection to the Fuel Tank and to the Firewall Bulkhead Fitting are completed at a later stage. Fit Fuel Lines, Filter, Fuel Tap & Tap Cover

96 Fit Fuel Lines, Filter, Fuel Tap & Tap Cover

97 Fuel Tap Cover Fuel Tap Mount plate ¼ I.D. Fuel Line Fuel Tap 6g x ¼ self tappers Photo 10.37a Fuel Tap Cover and Fuel Tap Fuel Filter Fuel hose Note: leave enough hose in console so it can be pulled out to change filter. Photo 10.37b Fuel filter Fit Fuel Lines, Filter, Fuel Tap & Tap Cover

98 Photo 10.36C Fuel tap Cover Photo 10.36D Fit Fuel Lines, Filter, Fuel Tap & Tap Cover