Pipistrel Sinus Manual

K i t M a n u a l f o r P i p i s t r e l S i n u s a n d V i r u s A i r c r a f t
Pipistrel
Sinus & Virus
Kit Build Manual
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K i t M a n u a l f o r P i p i s t r e l S i n u s a n d V i r u s A i r c r a f t
Table of Contents
What do you need?......................................................................................................................................4
Preparing the uselage .............................................................................................................................. 5
Preparing the undercarriage.....................................................................................................................10
itting the undercarriage to the aircraft...................................................................................................18
irewall setup ............................................................................................................................................ 21
Mounting the engine to the firewall..........................................................................................................22
Sound dampening material ...................................................................................................................... 23
Painting the fuselages interior (part 1) ................................................................................................... 25
General touch ups and painting the fuselage (part 2)............................................................................27
Lining the fuselage interior with carpet and mounting the fuel taps....................................................29
itting the cockpit carpet .......................................................................................................................... 32
Installation of the heat duct, oil tank bracket and wire bundle fittings.................................................33
Cutting the slots for the fuel gauge ......................................................................................................... 34
itting the throttle assembly and the flap handle ................................................................................... 34
itting the ballistic chute (part 1) ............................................................................................................. 37
itting the ballistic chute (part 2) ............................................................................................................. 43
itting the lower fuel system .................................................................................................................... 49
itting the Velcro for the seats..................................................................................................................54
Rudder pedal preparation ......................................................................................................................... 55
Seat belt preparation..................................................................................................................................56
Drilling the rudder cable holes..................................................................................................................58
Running the rudder cable outers..............................................................................................................58
Mounting the pedals ................................................................................................................................. 61
itting the rudder cables .......................................................................................................................... 69
Mounting the upper flaperon pushrod bracket.......................................................................................70
Mounting the electrical panel ................................................................................................................... 71
itting the rudder assembly ..................................................................................................................... 72
Horizontal stabilizer preparation..............................................................................................................81
Preparing the elevator / rudder ................................................................................................................ 83
itting the horizontal stabilizer ................................................................................................................ 88
Installation of the sliding elevator trim knob .......................................................................................... 93
itting the trim system .............................................................................................................................. 95
The Control System .................................................................................................................................. 98
Mounting the control system..................................................................................................................102
Nose wheel cable preparation ................................................................................................................ 107
inishing the rudder cables ................................................................................................................... 109
itting the rudder .................................................................................................................................... 110
itting the brake lines ............................................................................................................................. 111
Mounting the fuel lines in the cabin ...................................................................................................... 117
itting the windscreen ............................................................................................................................ 118
Installation of the strobes ....................................................................................................................... 123
itting the engine (part 1) ....................................................................................................................... 126
itting the engine (part 2) ....................................................................................................................... 167
itting the dashboard ............................................................................................................................. 175
itting the front cowls ............................................................................................................................. 178
itting the cowling around the exhaust and final cowl touch ups ...................................................... 187
Propeller setup ........................................................................................................................................ 191
itting the nose wheel ............................................................................................................................ 196
Wing preparation ..................................................................................................................................... 197
Assembling the airbrakes........................................................................................................................215
Mounting the wings ................................................................................................................................ 223
itting the Wheel Spats ........................................................................................................................... 229
itting the nose wheel spat .................................................................................................................... 233
itting the luggage rack and headsets...................................................................................................234
Mounting the Autopilot System..............................................................................................................237
Automatic nose wheel and rudder centering systems ........................................................................ 245
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K i t M a n u a l f o r P i p i s t r e l S i n u s a n d V i r u s A i r c r a f t
Congratulations on your purchase or evaluation of the Pipistrel Sinus or Virus aircraft kit.
The Sinus and Virus are unique aircraft providing exceptional performance unparalleled
flying qualities and astonishing economy.
The building procedures explained in this manual are aimed towards the abilities of an average
person with basic tools. Most of the precision manufacture has been performed at the factory
under controlled conditions and this will provide the homebuilder with an aircraft which should
be every bit as good as a factory manufactured plane.
Most of the construction can be performed by the builder alone but you will require additional
assistance for some tasks. Possibly a friend or partner could assist you with some of the
construction. In situations where you need to rotate the fuselage or fit the wings you may
need three people.
By following these simple instructions and the accompanying photographs we expect that you
will need around 250 to 400 hours of enjoyable construction to finish the aircraft. Should you
have any questions with this manual or the construction techniques please contact Pipistrel USA
for clarification. If you aren't used to the metric system be sure to check Appendix 1 where we
have added a conversion table to help you with certain measurements.
As this is a new version of the kit manual for Pipistrel's Sinus and Virus rcraft we would like your
feedback and suggestions on the different tasks so we may improve the manual for future
customers. Please email [email protected]m with any of your questions
They say a picture is worth 1000 words... so we have tried to incorporate this in our manual and
let the pictures do the talking. With over 1000 deruddered images to select from and print out
you will probably find many answers to your questions in the photos and accompanying text.
Time to build..... Lets start !!
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K i t M a n u a l f o r P i p i s t r e l S i n u s a n d V i r u s A i r c r a f t
What do you need?
Space
Pipistrel Sinus aircraft have a wingspan of just under 15 meters while Virus aircraft have
approximately 12.5. In order to work the wings comfortably you're going to need a work space
that is at least 9 meters long because Sinus wings measure approximately 8 meters long. This
would give you a little space at each end to move around a little more if you're making a Virus.
Work Conditions
Working with epoxy requires that the components epoxy and work space need to be around 21
degrees Celsius until the epoxy completely cures. For all other steps and procedures you aren't
required to heat your workspace.
Work Conditions
Here is a list of tools that will definitely come in handy when making your Pipistrel aircraft:
Vapor mask Tape measure
Variable spee rill Swaging tool
Set of metric rill bits (longer ones if possible) Work lamp (one that you can hang in the aircraft if
nee be)
Metric threa taps Scissors or clippers
Metric step rill Paint brushes
Stan ar metric open-en wrenches Dremel han rill
Stan ar metric ratchet sockets Dremel san ing rill bits
Stan ar metric Allen wrenches Heat gun
Special NutSert installation tool Various files for san ing, grin ing an polishing
Right angle han rill (or rill angle attachment) Felt-tip marker (erasable)
Jigsaw Drill bits for countersinking
De-burring tool Vernier caliper set
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K i t M a n u a l f o r P i p i s t r e l S i n u s a n d V i r u s A i r c r a f t
Materials
Here is a list of materials that you will definitely need when making your Pipistrel aircraft:
Loctite 243
Loctite 262
Sheets of plastic for masking while painting (3M
Painter's Masking Tape Pre-Tape Drop Cloth is highly
recommen e )
Grease (SKF bearing grease or Xintex)
Silicon (black if possible)
WD-40
San paper (80 an 100 granulation)
Electrical tape
Two-si e tape
Rubber gloves
Preparing the uselage
Support the fuselage on a suitable stand and support the rudder on a piece of foam to
protect it from damage.
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K i t M a n u a l f o r P i p i s t r e l S i n u s a n d V i r u s A i r c r a f t
Mask the elevator pushrod with masking tape to keep out dust and debris from the
pushrod bearings during the early fuselage preparation phases.
Sand the cockpit openings smooth to remove the sharp edges from manufacture
Sand the windscreen edge to ensure a good fit of the Lexan windscreen paying particular
attention to the section marked with ovals in the photos below. The key is to make sure
the edges around the windscreen are smooth and not sharp.
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K i t M a n u a l f o r P i p i s t r e l S i n u s a n d V i r u s A i r c r a f t
The sections highlighted below need a little extra material taken off the inside edge to
make sure the windscreen seats perfectly. Be sure to do both sides.
With a marker pen mark the center of the fuselage halves above the firewall section.
Look for the strip of raised plastic on the fuselages surface which is a result of the
fuselages manufacturing process. This will assist you in finding the center position which
in turn will be used to locate the windscreen brace.
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K i t M a n u a l f o r P i p i s t r e l S i n u s a n d V i r u s A i r c r a f t
Clean the windscreen mounting areas with thinners or alcohol removers to ensure they
are clean and will bond properly. Blow them with compressed air and a vacuum to
ensure they are totally clean.
Drill holes in the floor for the cables flaps and the trim slot. Use the Dremel tool to cut
the holes and then sand smooth with a file and sandpaper. The same goes for the flap
handle area and also the throttle nutserts. The factory will already have these positions
marked for you in marker pen. Look at Appendix 2 3 and 4 for hole diagrams with exact
dimensions.
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K i t M a n u a l f o r P i p i s t r e l S i n u s a n d V i r u s A i r c r a f t
Dremel the holes and slots use a vacuum cleaner to keep the dust under control when
cutting.
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K i t M a n u a l f o r P i p i s t r e l S i n u s a n d V i r u s A i r c r a f t
Preparing the undercarriage
Drilling the main axle hole:
NOTE: The main axle hole most likely has already been drilled for you.
•The main axle hole is drilled half way in from both sides to avoid drifting
•The use of a reamer drill is recommended
•The tighter the fit the better therefore drill cautiously. The last thing you want to do is
drill a hole that is too big.
Placement of the main axle and endplates:
•Place the endplates - be sure to align the plates correctly as shown in the pictures below.
If aligned the wrong way drilling the holes could cause perforation of the undercarriage's
upper edge. When the plates are aligned correctly the holes are drilled further away
from the edge and will not cause perforation of the undercarriage.
•Slide the axle through and fix the assembly with the washer and the non-machined nyloc
nut - apply Loctite 243 to the axle's threads before assembling the washer and nyloc nut
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K i t M a n u a l f o r P i p i s t r e l S i n u s a n d V i r u s A i r c r a f t
Now we have to to drill the holes for the brake pins.
The goal is to drill a hole that is just deep enough so that the pin once placed sticks out
exactly 1 cm from the brake assembly resting plate. This can be done by marking the
drill.
Insert the pins and tap them in with a hammer
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K i t M a n u a l f o r P i p i s t r e l S i n u s a n d V i r u s A i r c r a f t
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K i t M a n u a l f o r P i p i s t r e l S i n u s a n d V i r u s A i r c r a f t
Placement of the brake assembly:
First check to see that the brake pad fits nicely into the brake assembly housing. It
should slide in and out of the housing smoothly without being hindered or getting stuck.
If needed lightly grind the brake pad's two alignment pegs with a file until the pad slides
in and out of the housing nicely. This is very important in order for the brakes to function
properly.
Slide the brake assembly on and ensure that it is properly seated on the resting plate. If
necessary use a piece of pipe to tap it flush on the resting plate.
Note that there is a left and a right brake; they must be fitted so the hydraulic nipple is
pointing to the front of the aircraft on both sides of the plane.
Fit washer and clean brake – NOTE: FOR ALL VIRUS AND SIRUS MODELS WITH SERIES
NUMBER 277 AND GREATER IT IS NOT NECESSARY TO PLACE A WASHER BETWEEN THE
BRAKE ASSEMBLY AND THE WHEEL. THESE MODELS HAVE AN ALTERED BRAKE
ASSEMBLY WITH A BIGGER FLANGE AND THUS DO NOT REQUIRE THE WASHER.
Brake assembly WITH washer
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K i t M a n u a l f o r P i p i s t r e l S i n u s a n d V i r u s A i r c r a f t
Wheel placement:
Place wheel on the axle
Thoroughly grease the bearing and the wheel hub
Place the bearing and apply even more grease around the bearing afterwards
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K i t M a n u a l f o r P i p i s t r e l S i n u s a n d V i r u s A i r c r a f t
Fit the dust cover on the axle after thoroughly greasing it.
Fit the nyloc nut - note there is no washer as the nut is especially machined to fit
Tighten the nut up so that the wheel still turns freely - do not over tighten the nut or the
wheel may bind
Wipe off excess grease
Fit the wheel spat spacer but first apply Loctite 243 to the axle's threads
When tightening the spacer be sure not to also tighten the locknut. Brace the locknut
while tightening the spacer as shown below.
Check one last time to ensure that the wheel turns freely and quietly.
Also grab the wheel with two hands and check to see that there is no free movement of
the wheel along the axis.
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K i t M a n u a l f o r P i p i s t r e l S i n u s a n d V i r u s A i r c r a f t
Go to other side of axle and tighten the other locknut torque setting 6 Newton meters.
Mark all nuts with red paint. Repeat for other side.
Check tire pressures at 32 psi or 2.2 atmospheres
Modification of the landing gear for the aircraft with a nose wheel:
Aircraft with a nose wheel have a different way to run the brake lines and it is necessary to
make modification to the tops of the landing gear legs. Normally the brake lines come from the
brakes and travel up the inside of the legs and enter into the cabin. If the aircraft has a nose
wheel it is necessary to modify the exit hole so the line actually travels the normal route goes
back into the landing gear leg and exits on the bottom where it then enters the cabin on the
front side of the leg.
Drill a hole at a 45 degree angle directly beside pre-drilled hole located on top of the
undercarriage's legs. Do the same for the other side. Check to make sure no sharp
edges remain.
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K i t M a n u a l f o r P i p i s t r e l S i n u s a n d V i r u s A i r c r a f t
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K i t M a n u a l f o r P i p i s t r e l S i n u s a n d V i r u s A i r c r a f t
itting the undercarriage to the aircraft
For aircraft equipped with a nose wheel the undercarriage is attached to the fuselage with bolts
and special washers.
These washers require a recessed hole to be drilled in the cockpit floor. Use an
appropriate drill bit.
It is important that the washer is seated properly; if you make the hole too big it will
allow the undercarriage to move around excessively and if you make the recess too small
the bolt and washer wont be seated properly. If by chance the holes are drilled too big
be sure to fill them in with epoxy.
Note: for aircraft without a nose wheel there is no recess. There are just normal bolts
mounted with locknuts and a plate to hold the undercarriage in place.
Setup for aircraft without a nose wheel
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K i t M a n u a l f o r P i p i s t r e l S i n u s a n d V i r u s A i r c r a f t
Put a fair amount of epoxy around the top of the holes in the cockpit. This makes the
large locating washers sit perfectly in the holes.
Then put a light smear of grease around the bottom of the washer and around the bolt
shaft to stop the epoxy from sticking to the metal parts. It is important to have the
washers seated properly to avoid future damage to the structure
Cover the tops of the landing gear leg with silicone before mounting as shown below
Place undercarriage bolts into floor of fuselage and fit undercarriage leg. You'll need
someone to lift the front of the plane to do this as its not so light.
Tighten the nylocs on the undercarriage to 5.5 Newton meters. Apply Loctite 243.
Wipe up any excess epoxy and grease. After 24 hours it is necessary to retighten the
bolts again to 5.5 Newton meters to allow for the epoxy to come out while it is curing.
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K i t M a n u a l f o r P i p i s t r e l S i n u s a n d V i r u s A i r c r a f t
The last step is to prepare the fuselage for the brake lines. Position yourself under the
fuselage so that you're looking directly at the undercarriage and your legs are pointing
towards the engine.
Locate the center mark of the undercarriage's groove and drill two holes. Each hole
should be approximately 3 cm from the center mark.
Dremel the opening in the side of the aircraft for the brake lines to run from the pedals to
the wheels. The position is already marked in marker pen by the factory.
Be careful not to go to deep or you can go through the outer shell of the aircraft then
clean up with a drill and sandpaper
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