Jabiru J450 User manual

Jabiru
J450
Constructors
Manual
from kit/serial number 659

Jabiru J450 Constructors Manual
General>Introduction
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General>Introduction
Welcome to the Jabiru family, and a family it is.
Jabiru is a small aircraft and aero-engine manufacturer located in Bundaberg, Queensland,
Australia. The city has a population of 60,000 and until recently its most renowned export has
been the famous (or infamous) Bundaberg Rum. The Jabiru factory is located on the airport at
the Western edge of town where a staff of 55 craftsmen turns out these fine aircraft and
engines.
We are not just another kit manufacturer; we also build certified aircraft, engines and
propellers and have a quality assurance program fully approved by the Australian Civil
Aviation Safety Authority (CASA); as far as we know we are the only company doing so.
All of our products are original and have been designed, prototyped and produced in house, so
we can support you like no other kit manufacturer can.
Our distributors are fully supported by us and are a ready source of spares and free advice.
You need not have a degree in electrical engineering, an intimate knowledge of hydraulics or
a garage full of tools to complete this aircraft. There are no complex or complicated systems
on this aircraft. The gear stays down, the prop pitch is fixed and a simple switch operates the
flaps. The brakes are hydraulic and the simplicity will delight you.
Your Jabiru kit is designed to be simple to complete and finish, and will provide you with
many years of enjoyable flying.
Once completed you will find the aircraft extremely economical with operating costs more
associated with a car than an aeroplane, and the ease of maintenance will increase your flying
time.
If you're ever in our area call in for a coffee, we'll show you what we're up to and how we
make our aircraft and engines.
Safe Aviating and Happy Landings.
Rodney Stiff, Managing Director

Jabiru J450 Constructors Manual
General>Constructors manual
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General>Constructors manual
Welcome to the Constructors Manual!
In this Manual you will find all the instructions that you will need to build your very own
Jabiru, one step or task at a time. Each task in this Manual stands alone, with the intention that
each task will be completed before you move on to the next task. There are many good
reasons for this approach: you can easily keep track of where you are in the build; it forms a
checklist to ensure that nothing gets overlooked; and in many cases a task will be dependant
on the completion of a previous task, and if the sequence shown in the Table of Contents is
followed there will be no issues of this kind.
The Table of Contents of this Manual is also the Build Sequence.
We suggest that you print the Table of Contents out and keep it on the wall in your workshop.
As each task is completed mark it off - in this manner you can accurately track your progress
while ensuring that nothing gets overlooked.
The manual has been arranged into 2 major Sections plus General and Painting sections:
Pre-Paint
Post-Paint
Which have been further Grouped by:
Fuselage
Wings
Each Group is then broken down into Stage, Task and Step as required.
In the main the only sets of tasks that can be done without relation to each other are those
under the Group headings: Fuselage and Wings. Tasks in one group may be worked on
independent of tasks in the other group but the individual sequences under each group really
need to remain intact.
This Manual details the procedures that we have refined over many years of certified factory
builds, all combined with the experience of many kit builders to produce a document that
combines the best of both worlds: efficient, proven factory techniques throughout, but
arranged into a build sequence that meets the needs of kit builders.
For example: the first objective for most kit builders is to get the fuselage up onto its wheels
and mobile as quickly as possible so that the fuselage can be moved around the workshop/out
of the way of the wife‟s car/outside for cleaning/etc. By way of contrast, in the factory the
fuselage remains in a floor-mounted jig for the majority of the Pre-Paint tasks, which is not
usually an option for most kit builders.
Each task contains photographs of the work in progress in our factory, often in a step-by-step
manner in the case of the more complex tasks. While the Manual is formatted in A4 size you
may wish to print some pages in A3 size (if you have a suitable printer) for a clearer view
should that be required. Each task starts on a new page so you can print out single tasks.
As you work through this manual, and we suggest that you read it right through from start to
finish before you start your build, if something is not completely clear please call your dealer
or e-mail us for clarification: it may be that we can better explain something for the benefit of
future kit builders at the same time as helping you.
Enjoy your build!

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Table of Contents
General
General>Introduction................................................................................................................2
General>Constructors manual ...................................................................................................3
General>Tools and equipment...................................................................................................8
General>Glossary ...................................................................................................................11
General>Registration and certification ....................................................................................12
General>Reference documentation..........................................................................................12
General>Unpacking and support .............................................................................................13
General>Composite standard procedures.................................................................................14
General>Aircraft grade bolts and lock nuts..............................................................................17
General>Rod ends...................................................................................................................19
General>Health and safety......................................................................................................20
Pre-Paint>Fuselage>Underbody penetrations ..........................................................................21
Pre-Paint>Fuselage>Fit ventral fin and trim horn ....................................................................23
Pre-Paint>Fuselage>Prepare the fuselage................................................................................26
Pre-Paint>Fuselage>Undercarriage>Assemble main wheels....................................................32
Pre-Paint>Fuselage>Undercarriage>Assemble main gear........................................................34
Pre-Paint>Fuselage>Undercarriage>Fit main gear...................................................................40
Pre-Paint>Fuselage>Firewall forward>Fit firewall..................................................................44
Pre-Paint>Fuselage>Firewall forward>Firewall fittings...........................................................48
Pre-Paint>Fuselage>Firewall forward>Assemble and fit nose gear..........................................54
Pre-Paint>Fuselage>Firewall forward>Fit engine mount and engine .......................................61
Pre-Paint>Fuselage>Firewall forward>Fit propeller flange extension......................................65
Pre-Paint>Fuselage>Firewall forward>Fit oil cooler ...............................................................67
Pre-Paint>Fuselage>Firewall forward>Fuel pump fittings.......................................................73
Pre-Paint>Fuselage>Firewall forward>Fit ram air cooling ducts..............................................75
Pre-Paint>Fuselage>Fit windscreen ........................................................................................79
Pre-Paint>Fuselage>Fit control cables and lines......................................................................82
Pre-Paint>Fuselage>Empennage>Fit vertical tail fin...............................................................85
Pre-Paint>Fuselage>Empennage>Fit elevator .........................................................................94
Pre-Paint>Fuselage>Empennage>Fit horizontal stabiliser .......................................................98
Pre-Paint>Fuselage>Empennage>Fit rudder..........................................................................103
Pre-Paint>Fuselage>Fit cowling............................................................................................108
Pre-Paint>Fuselage>Fit flap drive shaft bearing blocks .........................................................116
Pre-Paint>Fuselage>Interior>Console>Pre-fit handbrake......................................................118
Pre-Paint>Fuselage>Interior>Console>Pre-fit trim control....................................................121

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Pre-Paint>Fuselage>Interior>Console>Fit control stick.........................................................125
Pre-Paint>Fuselage>Interior>Fit rudder pedal mount blocks .................................................129
Pre-Paint>Fuselage>Interior>Fit aileron cable brackets.........................................................131
Pre-Paint>Fuselage>Interior>Fuel system.............................................................................136
Pre-Paint>Fuselage>Interior>Fit seatbelt anchors..................................................................141
Pre-Paint>Fuselage>Interior>Fit rear seat .............................................................................144
Pre-Paint>Fuselage>Pre-fit doors..........................................................................................146
Pre-Paint>Fuselage>Fit windows..........................................................................................150
Pre-Paint>Fuselage>Wheel alignment...................................................................................152
Pre-Paint>Fuselage>Pre-fit wheel spats.................................................................................154
Pre-Paint>Wings>General.....................................................................................................157
Pre-Paint>Wings>Fit fuel tank filler body.............................................................................158
Pre-Paint>Wings>Prepare wing root .....................................................................................162
Pre-Paint>Wings>Cut aileron cable openings........................................................................166
Pre-Paint>Wings>Fit quick drain sumps ...............................................................................169
Pre-Paint>Wings>Mount flaps..............................................................................................171
Pre-Paint>Wings>Fit wing tips .............................................................................................178
Pre-Paint>Wings>Fit ailerons ...............................................................................................180
Pre-Paint>Wings>Fit pitot tube to strut.................................................................................186
Pre-Paint>Wings>Fit vibration damper to strut......................................................................188
Pre-Paint>Wings>Test fit wings............................................................................................190
Paint>General.......................................................................................................................195
Paint>Masking......................................................................................................................197
Paint>Surface preparation.....................................................................................................198
Paint>Topcoat.......................................................................................................................199
Post-Paint>General...............................................................................................................200
Post-Paint>Fuselage>Fit panel mounted throttle....................................................................201
Post-Paint>Fuselage>Assemble instrument panel..................................................................204
Post-Paint>Fuselage>Electrical wiring diagrams ...................................................................216
Post-Paint>Fuselage>Interior>Fit upholstery 1......................................................................222
Post-Paint>Fuselage>Install electrical wiring ........................................................................225
Post-Paint>Fuselage>Interior>Fit console controls................................................................237
Post-Paint>Fuselage>Interior>Controls>Fit rudder pedals.....................................................242
Post-Paint>Fuselage>Interior>Fit flap drive motor................................................................249
Post-Paint>Fuselage>Interior>Fit instrument panel housing..................................................252
Post-Paint>Fuselage>Interior>Engine control cabling...........................................................255
Post-Paint>Fuselage>Interior>Fit the instrument panel..........................................................258
Post-Paint>Fuselage>Interior>Fit upholstery 2......................................................................259