Jabiru j160 Instructions for use

Jabiru Construction Manual
Pre-Paint>Fuselage>Empennage>Fit horizontal stabiliser
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Pre-Paint>Fuselage>Empennage>Fit horizontal stabiliser
Issue Revision Table
Issue
Date:
Change(s):
Issued by:
2
16/11/2021
Adopt “Section Only” Manual System, Add Issue Revision Table and
model applicability.
Horizontal stabiliser incidence angle 1.5 degrees (was 3)
AS
Model Applicability
Aircraft Model
J-160
J-170
J-230
J-430
Document Applicability
Yes
Yes
Yes

Jabiru Construction Manual
Pre-Paint>Fuselage>Empennage>Fit horizontal
stabilizer>Procedure
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Pre-Paint>Fuselage>Empennage>Fit horizontal stabilizer>Procedure
Objectives of this task:
To fit the horizontal stabiliser to the fuselage and glass it in place. Note that the elevator hinges should
have been fitted in another task Pre-Paint>Fuselage>Empennage>Fit elevator.
Materials required:
•Epoxy resin and flock
•Glass fibre cloth and peel cloth in the bag labelled: “Horizontal Stabiliser”
Steps
1. Level the aircraft
2. Fit the stabiliser
3. Glass the tail-cone (if required)
4. Glass the stabiliser
Level the aircraft
The aircraft should be fixed in a “wings level” attitude prior to fitting. Place a 3” block on the top of
each front wing mounting lug and place a spirit level across the top of the cabin so that it rests on both
blocks. Pack the main wheels as required to level the aircraft.
Clamp a straightedge (a 2 or 3 metre length of aluminium angle works well) across the back of the door
frames at the height of the fuselage join line: ensure that the straightedge is level. This will be your
main reference for aligning the horizontal stabiliser.

Jabiru Construction Manual
Pre-Paint>Fuselage>Empennage>Fit horizontal
stabilizer>Procedure
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Fit the stabiliser
These instructions only apply to installing tailplanes with part number 2A109A0D (for the J230 kit) or
2A032D0D (for the J170 kit). Older tailplanes require different instructions.
These fitting instructions also apply to the special short horizontal stabiliser (P/No 2A109F0N, for the
J230 kit) which is about 300mm shorter then 2A109A0D and uses large end caps to make up the
difference.
Note: It is important that you determine which horizontal stabiliser
you have.
Prepare the stabiliser by taping up the inboard elevator hinges to prevent any resin getting into the
hinge pins barrels. From the previous task you will have a marked centreline on the stabiliser: test fit
the stabiliser to the rear of the fuselage using the stabiliser centreline as a lateral location guide against
the fuselage centreline.
Push the stabiliser fully forward into the rear of the fuselage and check that each end of the stabiliser is
an equal distance back from the straightedge –use 2 tape measures as shown circled above, one each
side, and carefully move the stabiliser until the measurements are exactly the same. Sight along the
fuselage from the rear and confirm that the stabiliser is level and lined up with the straightedge. The
chord line of the stabiliser is to be angled down 1.5 degrees at the leading edge. Make any adjustments
necessary.
When the stabiliser is aligned correctly, secure the stabiliser to the fuselage with self-tapping screws,
using 10 screws per side. These screws will be removed after the stabiliser has been finally fitted. Run a
pencil line around the stabiliser along the fuselage join.
Remove the stabiliser from the fuselage and remove the peel cloth from the rear of the fuselage, then
lightly sand all the surfaces to be joined –the pencil line on the stabiliser will act as a guide for where
to sand and where to coat with resin.

Jabiru Construction Manual
Pre-Paint>Fuselage>Empennage>Fit horizontal
stabilizer>Procedure
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Flocking in Horizontal Stabiliser
Before flocking in the stabiliser it is important to identify which fuselage you have in your kit and
whether a ‘tail-cone’ is required or not. The following identifies the difference in fuselage flange
attachment.
Fuselages without a rear
flange DO require a tail-
cone (follow the
instructions listed in the
‘glass the tail cone section’
Fuselages with a rear
flange DO NOT require a
tail-cone and need only be
flocked in along the side
and rear fuselage flanges

Jabiru Construction Manual
Pre-Paint>Fuselage>Empennage>Fit horizontal
stabilizer>Procedure
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Mix a batch of resin and divide into 2 parts. Coat all the surfaces to be joined. Add flock to one part of
the resin and apply a layer to the rear of the fuselage then slide the stabiliser in to place, pushing it
fully forward. Open the join and use a mixing stick to force flock into the sides and rear of the join,
working from the inside of the empennage through the hole in the top, then smooth the flock along
the outside. Fix the stabiliser in place with the self-tapping screws, do a final check of the alignment
and leave overnight to cure.
Next day, remove the self-tapping screws that were used to temporarily fix the stabiliser in place. If
they are difficult to remove heating each screw with a soldering iron will help.
Lightly sand the surface around the root of the join between the leading edge of the horizontal
stabiliser and the fuselage, then mix a small batch of resin and coat the surfaces where the glass fibre
cloth will be placed. Cut a small square of glass fibre cloth to cover the root of the join as shown below
and brush it into place. Note that this root join glass is required for both fuselage configurations.
This completes the Pre-Paint>Fuselage>Empennage>Fit horizontal stabiliser task if you have Horizontal
Stabiliser P/N 2A109A0D, 2A109F0N (for J230 kits) or 2A023D0D (for J170 kits), if your P/N is
2A069A0D then continue.

Jabiru Construction Manual
Pre-Paint>Fuselage>Empennage>Fit horizontal
stabilizer>Procedure
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Glass the tail-cone
First ensure if this step is necessary (check the previous comparison between fuselages to see whether
you need to glass in a Tail Cone or not.
In this step you will apply 3 layers of 320 x 200mm glass fibre cloth to the tailcone, starting at the top
and wrapping the glass cloth behind the stabiliser and under the tailcone.
First cut a piece of foam 225mm long, 57mm high & 27mm deep and fit it to the rear of the stabiliser,
tapering it towards the bottom as shown in the photo above left, and cut a thin strip of foam to fill the
void under the stabiliser.
Mix a batch of resin and coat the tailcone and the foam blocks and flock them into place. Place the first
sheet of glass fibre cloth centrally on the tailcone and brush it on, then down over the foam blocks, cut
to clear the elevator stop and brush under the tailcone taking care to avoid any bubbles or gaps.
The second layer of glass cloth is placed offset to the right as
shown above and brushed on in a similar manner, followed by the
third layer, which is offset to the left by the same amount.
For reduce sanding then apply peel cloth over all the glassed
surfaces and brush on carefully to ensure a smooth finish.
This completes the Pre-Paint>Fuselage>Empennage>Fit horizontal
stabiliser task.