Builders Manual Index

  New Manual Old Manual
A    
Access panels for aileron bellcranks 8-17 8-16
Access panels for fuel tank fittings 17-1 10-24A
Access panels in rear fuselage 24-3 NA
Aileron quick-connect system 14-1 10-39
    Aileron initial setting up procedure 14-9 10-47
    Bellcranks 14-1 10-39
    Fuselage mounted quick-connect bellcranks 14-7 10-45
    Mounting belleranks to wing spar 14-2 10-40
    Mounting quick-connect bellcrank brackets in cockpit module 14-7 10-45
    Push-rods 14-3 10-41
Ailerons 8-1 8-1
    Adjustment 14-10 10-48
    Attaching the hinges 8-7 8-6
    Bellcranks 7-3 7-2
    Bellcrank access hole 8-17 8-16
    Checking for balance 8-16 8-15
    Close-out layups 8-4 8-4
    First layup 8-2 8-1
    Fitting anchor nuts to hinges 8-11 8-8
    Fitting the aileron to the wing 8-10 8-7
    Initial setting up procedure 14-9 10-47
    Lateral push-rod 8-22 8-19
    Leading edge layup 8-4 8-3
    Link-rod 8-22 8-19
    Mass balance arm and weight attachment 8-12 8-12
    Mass balance arm templates 8-24 8-21
    Mass balancing 8-12 8-12
    Mass balance layup 8-15 8-14
    Push-rod installation 8-21 8-18
    Root close-out 8-5 8-4
    Second layup 8-3 8-2
    Setting up procedure 14-9 10-47
    Tip close-out 8-7 8-5
    Wing cut-out layup for mass balance 8-14 8-13
Anti-servo trim tab 5-1 5-1
    Attaching the hinges 5-4 5-2
    Flettner strips 5-7 NA
    Leading edge and root rib layup 5-2 5-1
    Preparation for leading edge layup 5-1 5-1
Antenna for comm radio 37-2 Annex C
    Cable fitting 24-1 10-73
Avionics – See also Electrical system 27-7 NA
B    
Battery – See also Electrical system 27-5 10-129
Brake master cylinder 12-1 10-79
    Brake bleeding 32-4 10-121
    Brake lever 12-1 10-79
    Mounting 12-2 10-80
Brake installation – See also Main landing gear 32-3 10-120
Bungee cord – See also Main landing gear 32-4 10-121
C    
Ceiling panel – See also Fuselage 24-3 10-76
Choke control 26-3 10-90
Cockpit module    
    Aileron quick connect system – See also Aileron quick connect 14-1 10-39
    Bonding into fuselage 17-1 10-53
        Access panels for fuel tank fittings 17-1 10-24A
        Aileron quick-connect bracket reinforcement 17-5 10-55
        Bonding cockpit module in place 17-4 10-54
        Cockpit seat pans 17-5 NA
        Control column boots 17-5 NA
        Preparation for bonding 17-4 10-54
        Rudder cable pulleys / seat belt attachment 17-3 10-53
        Taping rear bulkhead to fuselage 17-5 10-55
        Taping to firewall 17-5 10-55
    Fitting flying controls – See also Flying controls 13-1 10-7
    Headrest storage area 11-5 10-8
    Rear bulkhead access D panel 11-3 10-2
    Spar pin reinforcement pads 14-10 10-48
    Spar sockets and alignment bushes See also Wing spars 14-3 10-41
    Thigh support ribs 11-3 10-8
    Wheel well bulkhead 34-3 NA
Comm radio antenna 37-2 Annex C
    Cable fitting 24-1 10-73
Control stick – See also Flying controls 13-10 10-16
D    
Door fitting 36-1 10-92
    Gas struts 36-6 10-97
    Glass fitting 36-5 10-96
Door latches 35-1 10-26
    Cover plates 35-3 10-28
    Cut outs 35-4 10-29
    Fitting latch plate covers 35-1 10-26
    Shoot bolt guide installation 35-8 10-33
E    
Electrical System 27-1 10-128
    Alternator 27-5 NA
    Avionics 27-7 NA
    Battery 27-5 NA
    Circuit breakers 27-2 NA
    Connectors 27-4 NA
    Load calculations 27-10 NA
    Master switch / solenoid 27-10 NA
    Pitch trim 27-7 NA
    Switches 27-1 NA
    Wiring – current rating 27-3 NA
    Wiring standards 27-2 NA
Elevator push rod – See also Pitch See also Tailplanes 18-7 10-38
Engine cowlings 25-1 10-124
F    
Fin 2-1 2-1
    First layup 2-4 2-2
    Foam core preparation 2-1 2-1
    Second layup 2-6 2-4
Fin and rudder attachment 28-1 10-109
    Bonding the fin to the fuselage 28-2 10-113
    Comm radio antenna 28-2 10-111
    Drainage holes 28-8 NA
    Fin trailing edge close-out 28-6 10-116
    Push-rod attachment socket 28-4 10-113
    Rudder attachment 28-3 10-112
    Rudder push-rod 28-5 10-114
Finishing the flying surfaces 38-1 NA
    Colour 38-1 NA
    Sanding 38-4 NA
    Weight build up 38-6 NA
Firewall 33-1 10-132
Flap control system 31-1 10-98
    Cross tube hinge arms / brackets 31-6 10-102
    Flap actuating horn 31-10 10-106
    Flap root extension 31-12 10-108A
    Guide plate rubbing strip 31-4 10-101
    Mounting the cross-tube 31-5 10-102
    Pins – See also Wing lift/drag pins 29-3 10-68
    Push-rod 31-9 10-105
    Retraction lever guide plate 31-3 10-100
    Retraction lever installation 31-1 10-98
    Rubbing strip 31-4 10-101
    Safety latch 31-5 NA
Flaps 9-1 9-1
    Bottom skin lay-up 9-2 9-2
    Close-out layups 9-7 9-5
    Co-ordinates for incidence template 9-12 9-9
    Flap attachment 9-11 9-8
    Flap connector plates attachment 9-15 9-11
    Hinge plates 7-21 7-13
    Installing hinge plates 9-5 9-4
    Joining cores together 9-1 9-1
    Root close-out lay-up 9-8 9-6
    Setting flat angle 9-23 9-13
    Setting flap angle 31-10 10-107
    Tip close-out lay-up 9-9 9-7
    Top skin lay-up 9-4 9-3
Floor panels – See also Rudder system 23-1 10-62
Flying controls 13-1 10-7
    Aileron controls 13-1 10-9
    Aileron torque tube 13-4 10-11
    Bearing installation 13-8 10-14
    Control stick 13-10 10-16
    Control stick movement 13-10 10-16
    Control system assembly 13-1 10-9
    Push-rods 13-8 10-14
    Rear bearing 13-5 10-11
Fuel filler hose and vent lines 34-2  
    Fuel filler 34-1 NA
    Fuel selector valve 34-2  
    Fuel sight gauge 34-3 Engine
    Fuel system vents 34-1 Fitting
    In-line restrictor 34-4 Kit
Fuel system 34-1 NA
    Wheel well bulkhead 34-3 NA
Fuel tank 16-1 10-49
    Brackets 16-3 10-51
    Fittings 16-4 10-52
    Spacers 16-5 10-52A
    Installation into cockpit module 16-1 10-49
Fuselage 10-1 10-1
    Access panels for fuel tank fittings 17-1 10-24A
    Access panels in rear fuselage 24-3 NA
    Bottom moulding set-up 11-5 10-2
    Fitting the cockpit module – See also Cockpit module 17-1 10-53
    Preparing the mouldings 11-1 10-1
        Cockpit module rear bulkhead access panel 11-3 10-2
        Fuselage bottom moulding set-up 11-6 10-2
        Headrest storage area 11-5 10-8
        Thigh support ribs 11-3 10-8
    Rear bulkhead 18-1 10-3
    Top moulding bonding on 24-1 10-73
        Access panel in rear fuselage 24-3 NA
        Bonding and taping 24-5 10-77
        Ceiling panel 24-3 10-76
        Cockpit frames 24-2 10-76
        Pitch control stop upper brackets 24-6 10-78
        Trial fit of the top moulding 24-4 10-75
        Trim servo wiring and antenna cable 24-1 10-73
        Upper pitch control stop 24-6 10-78
H    
Headrest storage area – See also Cockpit module 11-5 10-8
I    
Instrument panel module 26-1 10-88
    Choke control 26-3 10-90
    Engine instruments 26-3 10-89
    Flight instruments 26-4 10-91
    Instrument layout 26-2 10-89
    Mounting 26-1 10-88
    Pitch trim and indicator 26-3 10-90
L    
Landing gear mounting frame 22-1 10-56
    Drilling attachment bolt holes 22-2 10-57
    Final installation 22-4 10-59
    Preparation for installation 22-1 10-56
    Retraction arm installation 22-3 10-58
    Retraction shaft bush installation 22-3 10-58
Lift pin socket/root fairings/spar pin latch 30-1 10-82
    Bonding the sockets 30-4 10-85
    Front stiffener 30-5 10-86
    Initial wing set-up 30-1 10-82
    Rear stiffener 30-4 10-85
    Spar pin latches 30-8 10-87B
    Wing root fairings 30-7 10-87A
M    
Main landing gear 32-1 10-118
 Brake bleeding 32-4 10-121
 Bungee cord 32-4 10-121
 Main wheel and brake installation 32-3 10-120
 Main wheel assembly 32-2 10-119
 Shock absorber 32-1 10-118
Mass balance system – See also Tailplane mass balance 21-1 10-69
Master cylinder – brakes 12-1 10-79
O    
Outrigger assembly 9-21 9-12
P    
Pip pin recess – See also Tailplanes 6-4 6-2
Pitch control lower stop – See also Tailplane mass balance 21-3 10-71
Pitch control upper stop – See also Tailplane mass balance 24-6 10-78
Pitch push rod 18-7 10-38
Pitch torque tube 15-1 10-34
    End caps 15-1 10-34
    Installation 15-3 10-36
    Support brackets 15-2 10-35
Pitch trim system 19-1 10-17
    Bellcrank assembly and mounting 19-2 10-18
    Indicator 26-3 10-90
    System check 19-7 10-23
    Tab link-rod 19-6 10-20
    Servo 19-5 10-20
    Servo wiring 24-1 10-73
Pitot system 7-10 NA
Q    
Quick connect aileron system – See also Aileron quick connect 14-1 10-39
R    
Rudder 3-1 3-1
    Attachment to fuselage – See also Fin & rudder 28-1 10-109
    First skin layup 3-2 3-2
    Hinge attachment 3-8 3-6
    Hinge flange 3-6 3-4
    Preparation 3-1 3-1
    Second skin layup 3-5 3-3
Rudder system 23-1 10-62
    Aft pedals 23-6 10-65C
    Cable adjustment 23-5 10-65B
    Cable guides and rubbing blocks 23-7 10-65C
    Cable pulleys 17-3 10-53
    Cables 23-4 10-65A
    Cables in centre tunnel 23-7 10-65C
    Floor panels 23-1 10-62
    Forward pedals 23-6 10-65C
    Installing floor panels 23-4 10-65A
    Pedal installation 23-2 10-64
    Pedal lateral alignment 23-3 10-64
    Pedal reinforcement 23-2 10-63
    Pedal tension springs 23-6 10-65B
    Pulley installation 23-4 10-64
    Push-rod 28-5 10-114
    Push rod hole above tailwheel bracket 20-2 10-61
S    
Seat harnesses 37-1 10-126
    Tunnel attachment point 17-3 10-53
Shock absorber – See also Main landing gear 32-1 10-118
Spar preparation – See also Wings 7-1 7-1
Static air system 24-1 10-73
Swinging arm installation – See also Main landing gear 32-2 10-119
T    
Tailplane mass balance and control stops 21-1 10-69
    Lower pitch control stop 21-3 10-71
    Mass balance arm installation 21-1 10-69
    Pitch control stop / Push-rod containment 21-3 10-71
    Push-rod containment bulkhead 21-4 10-72
    Upper control stop brackets 24-6 10-78
    Upper pitch control stop 24-6 10-78
    Weights 21-3 10-71
Tailplane torque-tube 18-1 10-5
    Bonding in the tailplane bushes 18-6 10-5
    Fitting the torque tube 18-5 10-5
    Fuselage rear bulkhead 18-1 10-3
    Pitch push-rod 18-7 10-38
    Tab drive pins 18-3 10-21
    Tailplane torque tube securing 18-6 10-6
Tailplanes 4-1 4-1
    Assembly 6-1 6-1
    Close-outs 4-19 4-13
    Cutting off the anti-servo trim tabs 4-16 4-11
    First skin layup (bottom surface) 4-11 4-8
    First skin layup (bottom surface) preparation 4-10 4-7
    Joining the cores together 4-9 4-6
    Laying up the outboard rib 4-6 4-4
    Pip pin recess 6-4 6-2
    Pressure relief holes 4-2 4-1
    Second skin layup (top surface) 4-15 4-10
    Second skin layup (top surface) preparation 4-13 4-9
    Tab drive pins 18-3 10-21
    Tailplane tip 4-2 4-1
    The outboard rib 4-4 4-3
Tailwheel 20-1 10-60
    Main fitting attachment 20-2 10-61
    Rudder push-rod hole 20-2 10-61
Trim system – See also Pitch trim system 19-1 10-17
W    
Wheel assembly – See also Main landing gear 32-2 10-119
Wheel well bulkhead – See also Cockpit module 34-3 NA
Windscreen fitting 36-5 10-96
Wing lift/drag pin & flap drive pin installation 29-1 10-66
    Drilling and tapping 29-2 10-67
    Flap pins 29-3 10-68
    Pin installation 29-3 10-68
    Pin installation preparation 29-1 10-66
Wings 7-1 7-1
    Aileron bellcrank housing and link-rod channel 7-18 7-10
    Aileron close-out 7-27 7-16
    Aileron mass balance cut-out layup 8-14 8-13
    Bonding L.E. cores to the spar 7-8 7-5
    Bonding T.E. cores to the spar 7-23 7-13
    Close-out layups 7-27 7-17
    Flap close-out 7-26 7-16
    Flap plates 7-21 7-13
    Foam Cores 7-5 7-3
    Incidence board 7-16 9-8
    Jigging for the trailing edge layup 7-19 7-11
    Lateral push-rod channel 7-18 7-11
    Leading edge ribs layups 7-8 7-5
    Leading edge skin layup 7-12 7-72
    Pitot system 7-10 NA
    Root close-out rib 7-30 7-19
    Root fairings 30-7 10-87A
    Spar jigging 7-4 7-2
    Spar preparation 7-1 7-1
    Spar alignment bush bonding 14-6 10-44
    Spar pin latches 30-8 10-87B
    Spar sockets and alignment bushes 14-3 10-41
        Preparation and trial setup 14-5 10-43
        Preparation for bonding 14-4 10-42
    Tip block attachment 9-16 8-9
        Cutting to shape 9-17 8-9
        First layup 9-18 8-10
        Second layup 9-19 8-10
        Trailing edge bottom skin layup 7-24 7-15
Trailing edge close-out 7-26 7-15
    Trailing edge cores preparation 7-17 7-9
    Trailing edge rib layups 7-21 7-12
    Trailing edge top skin layup 7-29 7-18
Workshop and tools 1-2 1-2