Nynja Build manual Version 1.4c 1 Nynja Build Manual 1.4b Figure 1 tube numbering scheme. 2 Nynja Build Manual 1.4b Figure 2 Basic frame (Skyranger). 3 Nynja Build Manual 1.4b Figure 3 uncovered Skyranger frame. 4 Nynja Build Manual 1.4b Figure 4 Uncovered Nynja frame Figure 5 Nynja fuselage with rear fairings removed 5 Nynja Build Manual 1.4b Figure 6 Nynja fuselage with rear fairings removed – rear view Figure 7 simply assemble thus! 6 Nynja Build Manual 1.4b Contents Introduction ............................................................................................................. 10 1.1 How to Build Your Aircraft .................................................................................................... 10 1.2 The BMAA Homebuilt Aircraft System ....................................................................................... 12 1.3 General Assembly Notes ........................................................................................................... 14 1.4 Finish .......................................................................................................................................... 18 1.5 Weight ........................................................................................................................................ 20 2. Forward Fuselage ............................................................................................ 21 2.1 Tube Numbering .................................................................................................................. 21 2.2 Fuselage frame assembly overview ........................................................................................... 23 2.3 Lower Cabin Triangle .................................................................................................................. 25 2.4 Upper Cabin Triangle ................................................................................................................. 30 2.5 Rear Cabin Frame ................................................................................................................ 33 2.6 Rear cabin frame bracing. .................................................................................................... 34 2.7 Engine Supports ................................................................................................................... 37 2.8 Floor ..................................................................................................................................... 46 2.9 Rudder Pedals ..................................................................................................................... 48 2.10 Control Stick Assembly ........................................................................................................ 49 2.11 Finishing the Forward Fuselage ........................................................................................... 52 3 Rear Fuselage .................................................................................................. 54 3.1 Tail End ................................................................................................................................ 54 3.2 Bracing Frame ............................................................................................................................. 56 3.3 Front End.............................................................................................................................. 57 3.4 Fuselage bracing cables ............................................................................................................. 58 3.5 Tailplane Front Mounting ..................................................................................................... 63 3.6 Fuel Tank Support and Flap Handle ........................................................................................... 64 Not Tightening the Bolts and cables! ................................................................................................ 66 4 Undercarriage .................................................................................................. 67 4.1 Wheels ................................................................................................................................. 67 4.2 Main Undercarriage .............................................................................................................. 69 4.3 Nose Gear ................................................................................................................................... 73 4.4 Brakes .................................................................................................................................. 77 5. Tail Surfaces ....................................................................................................... 80 5.1 Tensioning the Rear Fuselage ............................................................................................. 80 5.2 Elevator Trim Tab ................................................................................................................. 81 5.3 Tailplane ...................................................................................................................................... 83 5.4 Rudder .................................................................................................................................. 87 5.5 Control Cables ..................................................................................................................... 90 6 Fitting the Rear Fuselage Fairings ............................................................... 100 6.1 Preparing the rear fuselage fairings ................................................................................... 100 6.2 Fitting the rear fuselage fairings ......................................................................................... 101 7. Engine Installation Rotax 912UL/912ULS .................................................... 105 8. Wings .............................................................................................................. 110 8.1 Wing Frame ........................................................................................................................ 110 8.2 Aileron Horn Assembly ....................................................................................................... 119 8.3 Attaching the Wings to the Fuselage ................................................................................. 121 8.4 Aileron Control Cables ....................................................................................................... 122 8.5 Flaps ................................................................................................................................... 126 8.6 Covering the Wings ............................................................................................................ 128 8.7 Inserting the Battens .......................................................................................................... 135 9. Windscreen Frame and Throttles ................................................................. 138 9.1 Windscreen Frame ............................................................................................................. 138 9.2 Throttles ............................................................................................................................. 143 7 Nynja Build Manual 1.4b 10. Floor pan, firewall and cowlings .................................................................. 147 10.1 Floor pan ............................................................................................................................ 147 10.2 Firewall and scuttle moulding ............................................................................................. 150 10.3 Engine cowlings ................................................................................................................. 153 11. Engine Ancillaries ......................................................................................... 158 11.1 CKT twin outlet exhaust fitting ........................................................................................... 158 11.2 Oil cooling ................................................................................................................................ 160 11.3 Water cooling ..................................................................................................................... 164 12 Fuel System ................................................................................................... 167 12.1 Fuel lines and connections ...................................................................................................... 167 12.2 Engine compartment ............................................................................................................... 168 12.3 Fuel Tanks............................................................................................................................... 169 12.4 Fitting instructions for HADS Optional Mod 33 – Large diameter balance pipe between fuel tanks ................................................................................................................................................ 170 Overview ......................................................................................................................................... 170 Parts: ..............................................................................................................................................