Jabiru

8. Assembly

Overview As with any assembly a certain amount of preparation is necessary to expedite the building process in other areas. It is easier to PREFIT the elevator to the horizontal stabiliser and the to the vertical fin before the stabiliser and fin are fitted to the

Photo 8.0a - Elevator/Stabiliser

Photo 8.0b - and Rudder/Fin awaiting assembly

PROCEDURE NAME PROC NO. ISSUE DATE PAGE Empennage Assembly 8.0 2 230399 1 Jabiru Aircraft

Fit Rudder to Vertical Fin

Reference: Drawing 20020K2/1, 2065092-2 2064092-2, 2068002-1 Photo 8.1(a), 8.1(b) and 8.1(c)

Parts Required: 2064092-1 Vertical Fin 2068002-1 Rudder 2001394 Hinge - Aluminium (4) 2001H94 Hinge Pin 1/8 (3) 2001594 Hinge Pin Retainer (3) PH0059N Rivet 3/16” (12) TAPK 3-3 Rivet 3/32” (6) MS35206-245 Screw (3) MS21078-3 Anchor Nut (3)

Materials Required: LC3600Resin LC3600Hardener Fibreflock

Retained Nut MS21078-3 Aluminum Hinge leaf

TAPK 6-6 Rivet

Photo 8.1(a) - Positioning of the retaining cap nuts

PROCEDURE NAME PROC NO. ISSUE DATE PAGE Fit Rudder to Vertical Fin 8.1 2 230399 1 Jabiru Aircraft

Procedure:

Hinges

Note: This procedure to be completed after fin is bonded to joined fuselage. 1. Trial fit hinges to both the rudder and the fin stabiliser by inserting bolts in the rivet holes. 2. Mount the rudder on the fin and insert the hinge pins. Check for hinge alignment, full movement and parallel gap between fin and rudder. Note: If it is necessary, holes can be elongated as the resin/flock used to secure hinge will take up any gaps. 3. Disassemble 4. Rivet the retaining nuts into position using TAPK 3-3. Refer to Photo 8.1(a) 5. Lightly sand the joining surfaces 6. Mix epoxy/fibreflock and apply to the hinge leaf. 7. Refit hinges using 2 bolts in each hinge leaf. 8. Remount the rudder on the fin and insert the hinge pins

TAPK 3-3 rivet MS21078 Retained Nut

Photo 8.1(b) - Fitting the hinge leaves

9. Rivet hinge leaves into position using remaining 2 holes. 10. Remove hinge pins and remove rudder. 11. Remove bolts and replace with rivets. Refer to Photo 8.1(b). 12. Remount the rudder on the fin and insert the hinge pins.

PROCEDURE NAME PROC NO. ISSUE DATE PAGE Fit Rudder to Vertical Fin 8.1 2 230399 2 Jabiru Aircraft

13. Locate the hinge pin retaining studs. 14. Leave to cure. (24 hours)

Photo 8.1(c) – Finished Product

PROCEDURE NAME PROC NO. ISSUE DATE PAGE Fit Rudder to Vertical Fin 8.1 2 230399 3 Jabiru Aircraft

PROCEDURE NAME PROC NO. ISSUE DATE PAGE Fit Rudder to Vertical Fin 8.1 2 230399 4 Jabiru Aircraft

PROCEDURE NAME PROC NO. ISSUE DATE PAGE Fit Rudder to Vertical Fin 8.1 2 230399 5 Jabiru Aircraft

PROCEDURE NAME PROC NO. ISSUE DATE PAGE Fit Rudder to Vertical Fin 8.1 2 230399 6 Jabiru Aircraft

PROCEDURE NAME PROC NO. ISSUE DATE PAGE Fit Rudder to Vertical Fin 8.1 2 230399 7 Jabiru Aircraft

Fit Horizontal Stabiliser and Elevator Hinges.

Reference: Drawing 20010K1/1 & 2001G94 Photo 8.2(a) to 8.2(H)

Parts Required: 2001L9N Horizontal Stabiliser 2001M9N Elevator 2001G94 Hinge - Stainless Steel (4) 2001H94 Hinge Pin 1/8 (4) 2001594 Hinge Pin Retainer (4) PH0109N CS Rivet 73AS6-6 (32) MS35206-245 Screw (4) PH0409N Anchor Nut (4) PH9929N CS Rivet 73AS3-3 (8)

Materials Required: LC3600Resin LC3600Hardener Fibreflock

Photo 8.2(a) - Fitting the hinge leaves

PROCEDURE NAME PROC NO. ISSUE DATE PAGE Fit Horizontal Stabiliser & 8.2 2 230399 1 Elevator Hinges Jabiru Aircraft

Procedure: Hinges

15. Drill stainless steel hinges as per drawing 2001G94. 16. Mark and drill hinge mount holes in horizontal stabiliser and elevator as per drawing 20010K1/1. Note: As hinges will be hand drilled it may be necessary to mark holes in stabiliser and elevator using holes in individual hinges. Keep hinges identified with the position they were marked in. 3. Trial fit hinges to both the elevator and horizontal stabiliser by inserting 3/16 bolts in the rivet holes. Note: File a recess in stabiliser where hinge pin sits to allow full up travel. 4. Fit elevator to stabiliser and insert the hinge pins. Check for hinge alignment, full movement and parallel gap between stabiliser and elevator. Note: If it is necessary, holes can be elongated as the resin/flock used to secure hinge will take up any gaps. 5. Disassemble 6. Lightly sand the joining surfaces 7. Mix epoxy/fibreflock and apply to the hinge leaf. 8. Refit hinges using 2 bolts in outside holes of each hinge leaf. 9. Remount elevator stabiliser and insert the hinge pins.

Rivet

Hinge Leaf Retained Nut MS21069-L08

Photo 8.2(b) – Positioning of the retaining nuts

10. Countersink two inside rivet holes and rivet hinge leaves into position. Ref photo 8.2(a) 11. Remove hinge pins and remove elevator. 12. Remove bolts countersink and replace with rivets. Refer to Photo 8.2(a) & 8.2 (b) 13. Remount the elevator on the stabiliser and insert the hinge pins. 17. With hinge pins positioned in recess, use lock tab (hinge pin retainer) to mark and drill position of anchor nut. 18. Use anchor nut as jig to mark and drill mount holes ref. Proc. 10.8 steps 1 to 3. Note: Position retainer nut at 45 degrees angle to hinge line to keep rear rivet hole in from edge. 19. Countersink anchor nut mount holes and rivet anchor nuts in position using 3-3 CS rivets.

PROCEDURE NAME PROC NO. ISSUE DATE PAGE Fit Horizontal Stabiliser & 8.2 2 230399 2 Elevator Hinges Jabiru Aircraft

Photo 8.2C Taking Peel Cloth of Elevator

Photo 8.2D on to Elevator

PROCEDURE NAME PROC NO. ISSUE DATE PAGE Fit Horizontal Stabiliser & 8.2 2 230399 3 Elevator Hinges Jabiru Aircraft

3 Layers of AF303 around radius

Photo 8.2E Fibreglass Glass

Photo 8.2F Trim Tab & End Plug onto Elevator

PROCEDURE NAME PROC NO. ISSUE DATE PAGE Fit Horizontal Stabiliser & 8.2 2 230399 4 Elevator Hinges Jabiru Aircraft

8.2 G & H

PROCEDURE NAME PROC NO. ISSUE DATE PAGE Fit Horizontal Stabiliser & 8.2 2 230399 5 Elevator Hinges Jabiru Aircraft

PROCEDURE NAME PROC NO. ISSUE DATE PAGE Fit Horizontal Stabiliser & 8.2 2 230399 6 Elevator Hinges Jabiru Aircraft

PROCEDURE NAME PROC NO. ISSUE DATE PAGE Fit Horizontal Stabiliser & 8.2 2 230399 7 Elevator Hinges Jabiru Aircraft

Fit Static Tube and Hose

Reference: Drawing 1048094/2 Photo 8.3 (a)

Parts Required: 2001L9N Vertical Fin 104519N Static Tube PV0029N PVC Hose

Materials Required: 5-min Araldite Fibreflock Procedure: 1. Drill a 1.50mm hole back 65mm from the tip of the Static tube (as per dwg 1048094/2). 2. Drill a 3/8" hole in the top centre of the fin. 3. Fit PVC hose onto static tube, fit wire tie and insert through 3/8" hole. 4. Position the tube as per dwg 1048094/2 5. Mix 5-min Araldite with Flock and bond the tube into place. 6. Allow the Araldite to dry then build-up the 'bullet nose' as shown in photo 8.3(a).

215mm

Photo 8.3(a) - Fitting the Static Tube.

7. Fit the PVC sleeve on the static tube as per drawing 1048094/2.

PROCEDURE NAME PROC NO. ISSUE DATE PAGE Fit Static Tube & Hose 8.3 2 230399 1 Jabiru Aircraft

PROCEDURE NAME PROC NO. ISSUE DATE PAGE Fit Static Tube & Hose 8.3 2 230399 2 Jabiru Aircraft

Fit Horizontal Stabiliser End Caps

Reference: Drawing 20010K/1 and 20010K1A/1 Photo 8.4(a) and (b)

Parts Required: 2001L9N Horizontal Stabiliser 2001F9N End Caps - Horizontal Stabiliser (2) Self-Tapping Screws

Materials Required: LC3600Resin LC3600Hardener Fibreflock

Procedure:

1. Locate predrilled end cap to match corresponding side. 2. Lightly sand the bonding surfaces. 3. Mix Epoxy and Flock. 4. Bond Caps into position, refer to photo 8.4(a) and (b). 5. Use the self-tapping screws to hold the caps in position until cured then remove.

Photo 8.4(a) - Bonding on the Horizontal Stabiliser End Caps

PROCEDURE NAME PROC NO. ISSUE DATE PAGE Fit Horizontal Stab End Caps 8.4 2 230399 1 Jabiru Aircraft

Photo 8.4 (b) - End Cap

PROCEDURE NAME PROC NO. ISSUE DATE PAGE Fit Horizontal Stab End Caps 8.4 2 230399 2 Jabiru Aircraft

PROCEDURE NAME PROC NO. ISSUE DATE PAGE Fit Horizontal Stab End Caps 8.4 2 230399 3 Jabiru Aircraft

Fit Elevator Trim Tabs

Reference: Drawing 20010K1B/1 Photo 8.5(a)

Parts Required: 2001M9N Elevator 2001N9N Trim Tab (2) PH0039N Rivet (6) PH0219N Washer 1/8 (6)

Materials Required: LC3600Resin LC3600Hardener Fibreflock Procedure: 1. Locate predrilled trim tabs to match corresponding side. 2. Position the trim tabs according to drawing 20010K1B/1 on the topside of the elevator. 3. Lightly sand the bonding surfaces. 4. Mix Epoxy and Flock. 5. Bond Tabs into position on the top of the elevator, refer to photo 8.5(a) and rivet using 1/8 washer on bottom.

Photo 8.5(a) - Bonding and riveting the Trim Tabs into position.

Note: Ensure 1/8 rivet is of suitable length to hold washers.

PROCEDURE NAME PROC NO. ISSUE DATE PAGE Fit Elevator Trim Tabs 8.5 2 230399 1 Jabiru Aircraft

PROCEDURE NAME PROC NO. ISSUE DATE PAGE Fit Elevator Trim Tabs 8.5 2 230399 2 Jabiru Aircraft

Fit Elevator End Plugs

Reference: Photo 8.6(a)

Parts Required: 2001M9N Elevator 2001094 End Plug (2) Self-Tapping Screws

Materials Required: 75mm x 100mm 303 Cloth (4) LC3600Resin LC3600Hardener Fibreflock

Procedure:

1. Fit elevator to horizontal stabiliser and locate predrilled end plugs to match corresponding side. Refer to Photo 8.6(a) Note: Check end plug alignment and fit with horizontal stabiliser end caps. 2. Lightly sand end plug bonding surface. 3. Mix epoxy and flock. 4. Force flock between foam and skin on elevator 5. Apply flock to end plug. 6. Bond end plug to elevator and hold in place with self-tapping screws. 7. Sand bonding surface and glass (75mm x 100mm) 303 cloth along front of elevator and side of end plug (2 per side). 8. Cure, trim and remove screws. 9. Fit elevator to horizontal stabiliser and check for correct deflections up and down (the slot near the end plug may need adjusting).

Photo 8.6(a) – End Plug fitted showing slot to allow correct down deflection

PROCEDURE NAME PROC NO. ISSUE DATE PAGE Fit Elevator End Plugs 8.6 2 230399 1