Backcountry Super Cubs PA‐18 Builder’s Manual Index Rev # 1.1 –Page # i Assembly Information Guide Disclaimer Definition of Terms The use of the word “Information” includes any and all information contained within this Backcountry Super Cubs Builder’s Manual, including, but not limited to text, images, graph‐ ics, diagrams, and references. “Guide” means this Backcountry Super Cubs Builder’s Manual. “User” means any individual or entity who utilizes this Guide for any purpose. ACKNOWLEDGEMENT OF INHERENT RISKS By using the Guide, User acknowledges the inherent risks associated with experimental and amateur‐built aircraft and aviation, including bodily injury or death. Backcountry Super Cubs, LLC and its members, officers, directors, agents, employees, and their heirs, succes‐ sors and assigns (collectively, “BCS”) has no control over, and assumes no responsibility for, User’s ability to successfully construct and test the User’s completed aircraft, with or with‐ out the use of the Guide. User acknowledges that the FAA and/or other knowledgeable persons should inspect the aircraft at construction intervals, as well as the completed project, prior to flight and that User should work with his local FAA representative regarding the construction and licens‐ ing of the aircraft. User, on behalf of itself and its successors and assigns, agrees to comply with all FAA regulations regarding the construction, licensing, and operation of the com‐ pleted aircraft, including but not limited to obtaining and maintaining all appropriate li‐ censes and ratings prior to operating the completed aircraft. NO WARRANTY ANY USE WHATSOEVER OF INFORMATION CONTAINED IN THE GUIDE IS AT USER’S OWN RISK. THE INFORMATION IS INTENDED TO BE SOLELY EDUCATIONAL AND REC‐ REATIONAL IN NATURE, AND IS PROVIDED “AS IS” WITHOUT WARRANTY OF ANY KIND, TO THE MAXIMUM EXTENT PERMITTED BY APPLICABLE LAW. BCS EXPRESSLY DISCLAIMS ALL WARRANTIES AND CONDITIONS, EITHER EXPRESS OR IMPLIED, IN‐ CLUDING, BUT NOT LIMITED TO, ANY IMPLIED WARRANTIES OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE, NONINFRINGEMENT, STRUCTURAL INTEG‐ RITY, PERFORMANCE, FLIGHT CHARACTERISTICS, OR SAFETY OF THE USER’S COM‐ PLETED AIRCRAFT AND ITS COMPONENT PARTS, WITH OR WITHOUT USE OF THE GUIDE. THE ENTIRE RISK ARISING FROM USE OF ANY INFORMATION IN THE GUIDE RE‐ MAINS WITH THE USER. Backcountry Super Cubs PA‐18 Builder’s Manual Index Rev # 1.1 –Page # ii Assembly Information Guide Disclaimer (continued) NO ENDORSEMENT ANY USE WHATSOEVER OF THE INFORMATION CONTAINED IN THE GUIDE IS AT USER’S OWN RISK. THE INFORMATION IS PROVIDED “AS IS” WITHOUT ENDORSEMENT OF ANY KIND EITHER EXPRESSED OR IMPLIED, INTENTIONAL OR UNINTENTIONAL BY BCS. NO LIABILITY FOR CONSEQUENTIAL DAMAGES. TO THE MAXIMUM EXTENT PERMITTED BY APPLICABLE LAW, IN NO EVENT SHALL BCS BE LIABLE FOR ANY SPECIAL, INCIDENTAL, INDIRECT, OR CONSEQUENTIAL DAM‐ AGES WHATSOEVER (INCLUDING, WITHOUT LIMITATION, EMOTIONAL DAMAGES, DAMAGES FOR LOSS OF BUSINESS PROFITS, BUSINESS INTERRUPTION, LOSS OF BUSINESS INFORMATION, OR ANY OTHER PECUNIARY OR EQUITABLE LOSS) ARISING OUT OF THE USE OF OR INABILITY TO USE THE GUIDE. LIMITATION OF LIABILITY BCS’s ENTIRE LIABILITY AND USER’S EXCLUSIVE REMEDY FOR ANY DAMAGES ARISING FROM USE OF THE GUIDE SHALL NOT EXCEED THE ACTUAL AMOUNT PAID BY USER FOR THE GUIDE. Backcountry Super Cubs PA‐18 Builder’s Manual Index Rev # 1.1 –Page #1 Chapter # Page # Revision # Creation Date #1 Introduction Unpacking & inventory Required Tools & Work Area July 2008 Techniques & Torque values 12 1.0 Construction standards 13 1.0 May 2009 May 2009 #2 Airframe Assembly Trim System Jack screw sub‐assembly 18‐20 1.2 Jack screw install 20‐21 1.2 April 2009 Rear trim indicator pulley 35 April 2009 Trim cable 21 Trim system fairleads 22 1.2 Trim plate 23‐24 1.2 April 2009 Trim handle & front pulleys 25 1.2 April 2009 Trim indicator cable 26 1.2 April 2009 Trim indicator 27 1.2 April 2009 April 2009 Balance cable sub‐assembly 23‐25 1.0 Rudder –Cleaning bushings 26 1.0 April 2009 Rudder –Bushing install 27 1.0 April 2009 Rudder –Temporary install 28‐30 1.0 April 2009 April 2009 Stringers Top 34 1.0 Bottom & sides 36 1.0 April 2009 Vertical fin 39 1.0 April 2009 Elevator balance cable bracket 33‐35 1.0 April 2009 Vertical fin radius (Saddle) 39 1.0 April 2009 April 2009 Floor boards Board Map 36 1.2 Rear & front baggage 37 1.0 May 2009 Front seat fitting 38 1.0 May 2009 Torque tube thread cleaning 38 1.0 May 2009 Front floor boards 40‐41 1.0 May 2009 April 2009 Backcountry Super Cubs PA‐18 Builder’s Manual Index Rev # 1.1 –Page #2 Chapter # Page # Revision # Creation Date Rudder Controls Pedals install 39‐41 1.0 April 2009 Pulleys & cables 43‐44 1.0 April 2009 Flap cables 42 1.0 April 2009 Elevator cables 43 1.0 April 2009 Torque tube 45‐46 1.0 April 2009 Rudder cable s to pedals 47 1.0 April 2009 Fair leads 48 1.0 April 2009 Lift strut pulleys 48 1.0 April 2009 Brake System Brake reinforcement plate 49 1.0 April 2009 Pedals 49‐50 1.0 April 2009 Connecting pedals together 51 1.0 April 2009 Master cylinder install 51‐52 1.0 April 2009 Reservoir 52‐53 1.0 April 2009 Gear legs 54‐57 1.2 May 2009 Fuel System Fuel system switch modification 58‐59 1.2 May 2009 Fuel line routing 60‐63 1.0 May 2009 Electrical System 1.1 May 2009 Battery cables & ground wires 64‐66 1.0 May 2009 Wiring Map 67 1.0 May 2009 Interior panels 68‐75 #3 Wing Assembly Introduction 76 1.0 April 2009 Removing flaps & ailerons 76 1.1 June 2008 Fuel tanks 77‐80 1.0 April 2009 Landing lights 80‐85 1.1 November 2007 Wiring 86‐88 1.1 November 2007 Fuel lines & auxiliary pump 89‐90 1.0 April 2009 Pitot line 91 1.0 April 2009 Drilling for rivets 92‐93 1.0 May 2009 Flap & aileron install Backcountry Super Cubs PA‐18 Builder’s Manual Index Rev # 1.1 –Page #3 Chapter # Page # Revision # Creation Date #4 Fabric Covering Map #5 After paint assembly Landing gear 94‐97 Tail wheel 97‐99 Stabilizer 100‐109 Tail brace wires 110‐115 Elevators 116‐120 Rudder 120‐122 Tail control cables 123‐127 Instrument panel Glass installation 128‐137 Main wheels & brakes 137‐146 Brake lines 147‐148 #6 Firewall forward Engine install Video Cowling Video Baffling 149‐151 Other items firewall forward #7 Wing install Lift struts & tie down rings Jury struts Flaps & Ailerons Connecting Flaps & Ailerons Connecting Fuel & Pitot lines #8 Finishing Trim Interior panel trim Wiring outside of panel Wing root fairings Inspection cover plates “N” Number & Required Placards #9 Before Flight Information Log Books Weight & Balance Ground Run & Taxi Test Safety equipment FAA Inspection How to break‐in a new engine Backcountry Super Cubs PA‐18 Builder’s Manual Index Rev # 1.1 –Page #4 Chapter # Page # Revision # Creation Date #10 First Flight What to expect Fine tune your rigging Phase 1 flight testing Backcountry Super Cubs PA‐18 Parts Inventory Rev # 1.0 –Page #5 Fuselage Group Fuselage Group Part # Description Amount Part # Description Amount F1 Fuselage Assembly (welded & Power Coated) 1 F46 Windshield 1 F2 Jack Screw 1 F47 Windshield Trim Strips 2 F3 Jack Screw Yoke 1 F47B Rear Side window front trim strips 2 F4 Jack Screw Tube 1 F48 Windshield side Trim Strips 2 F5 Jack Screw Pulley (Large 2 Groove) 1 F48B Skylight front & rear trim strip 2 F6 Jack Screw Key 1 F48C L21 rear upper side glass trim strip 2 F7 Trim Cable Rear Idler Pulley Bracket (1 3/4) 1 F49 Throttle Cover (Single Door Only) 1 F8 Trim Cable Front Drive Pulley (2 Groove) 1 F50 Throttle Handles 2 F9 Trim Indicator Fairleads 5 F50B Throttle Handle Balls 2 F10 Trim Cable Front Idler Pulley F51 Throttle Connecting Rod 1 Bracket 1 3/4" (Dual Door) 1 F52 Flap Lever Assembly 1 F11 Top Elevator Cable Connecting Link 1 F53 Flap Lever Pivot Shaft 1 F12 Lower Elevator Cable Connecting Link 1 F54 Flap Cam Detent 1 F16 Oil Light Bushings (12 small & 6 long) 1 F56 Instrument Panel 1 F17 Hinges Engine‐side Cowls (2" x 26") 2 F57 Engine Mount Saddles 4 F18 Bag Door Hinges (1 1/2" x 24") 1 F58 Engine Mount (Check options) 1 F19 Control Stick Torque Tube 1 F59 Engine Cowl Support Channels 4 F20 Control Stick connecting Rod 1 F60 Side‐Cowl Doors 2 F21 Control Sticks 2 F61 Side Cowl Door Formers 2 F22 Control Stick Pivots 2 F62 Nose Bowl 1 F23 Hardware Bolt Kit (Airframe) 1 F63 Top Cowl 1 F25 Rudder Pedals 4 F64 Bottom Cowl 1 F26 Rudder Pedal Saddles 8 F64B Air scoop (check options) 1 F27 Brake Pedals 2 F64C small air scoops (air exit) 2 F28 Brake Pedal Saddles 4 F65 Entrance step (2 for double door) 1 F29 Brake Pedal Blocks 4 F66 Upper Door (check options) 1 F30 Brake Reinforcement Plate 1 F67 Lower Door (check options) 1 F31 Floor Board 2 Hole Mount Plate 14 F68 Trim Cable Tensioned Spring 1 F32 Set Floor Boards (4 pc) 1 F69 Elevator Balance Cable Spring 1 F33 Front Seat Assembly (Top & Bottom) 1 F70 Trim Handle & Bearing Kit 1 F35 Lower Aileron Cable Connecting Link F73 Brake Master Cylinder (check options) 2 (At the Control Stick) 2 F74 Fuel Site Gauges (check options) 2 F36 Upper Aileron Cable Connecting Link 2 F75 Carb Heat Air Box (check options) 1 F37 Brake Interconnect Rods (24 1/2" threaded) 2 F76 Torque Tube Caps 2 F37B Rod Ends & Jam Nuts (XM3) for F37 4 F77 Flap Button 1 F38 Large Fairleads 19 F78 Tail Brace Wire Set 1 F39 Rear seat Crossbar 1 F79 Vertical fin radius fairing ( Saddle ) 1 F40 Baggage Door 1 F80 Kit Assembly Manual (Book + CD) 1 F41 Fuselage Stringers 6 F42 1 3/4" Pulleys 12 F43 2 3/4" Pulleys 5 F44 1" Pulleys (5 with upper rear baggage door) 3 F15 Front Elevator Cable Pulley (3") 1 F45 Boot Cowl w/reinforcements, instrument panel tabs (6) 1 Engine Cowl Angle Mounts (4) F45B Side Cheeks (just behind boot cowl) left & right 2 Backcountry Super Cubs PA‐18 Parts Inventory Rev # 1.0 –Page #6 Part # Description Amount Part # Description Amount Fuselage Group Cont.