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Jabiru J450 User Manual

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Jabiru
J450
Constructors
Manual
from kit/serial number 659

Table of Contents

Other manuals for Jabiru J450

Questions and Answers:

Jabiru J450 Specifications

General IconGeneral
BrandJabiru
ModelJ450
CategoryAircrafts
LanguageEnglish

Summary

General

General > Introduction

Overview of Jabiru aircraft and company history, located in Bundaberg, Australia.

General > Constructors manual

Guide to building procedures, manual structure, and build sequence for the kit.

General > Tools and equipment

List of essential and optional tools required for the build process.

General > Glossary

Definitions of common composite and aircraft terms used throughout the manual.

General > Registration and certification

Information on aircraft registration options and requirements in Australia.

General > Unpacking and support

Instructions for unpacking the kit, inspecting parts, and available after-market support.

General > Composite standard procedures

Guidelines for preparing and bonding composite surfaces, including peel cloth usage.

General > Aircraft grade bolts and lock nuts

Identification and proper use of aircraft-grade fasteners, including bolt identification.

General > Rod ends

Correct method for connecting rod ends, emphasizing cable and drive connections.

General > Health and safety

Important safety precautions when working with composites, chemicals, and dust.

Pre-Paint

Pre-Paint > Fuselage > Underbody penetrations

Making required penetrations and fitting fairings to the fuselage underside.

Pre-Paint > Fuselage > Fit ventral fin and trim horn

Fitting the ventral fin, trim horn, and cutting rear fuselage penetrations.

Pre-Paint > Fuselage > Prepare the fuselage

Preparing the fuselage by sanding and cutting openings for various components.

Pre-Paint > Fuselage > Undercarriage > Assemble main wheels

Assembling the main wheels, tires, and fitting the brake discs.

Pre-Paint > Fuselage > Undercarriage > Assemble main gear

Assembling the main undercarriage legs, axles, and brake components.

Pre-Paint > Fuselage > Firewall forward > Fit firewall

Installing the stainless steel firewall plate and insulation sheet onto the fuselage.

Pre-Paint > Fuselage > Fit windscreen

Preparing and fitting the Perspex windscreen to the fuselage, avoiding damage.

Pre-Paint > Fuselage > Fit control cables and lines

Routing control cables and lines from the empennage to the cockpit for later connection.

Pre-Paint > Fuselage > Empennage > Fit vertical tail fin

Fitting the vertical tail fin to the fuselage using epoxy and glass fibre reinforcement.

Pre-Paint > Fuselage > Fit cowling

Sizing, fitting, and preparing the top and bottom cowls for aerodynamic fit.

Pre-Paint > Fuselage > Pre-fit doors

Sizing and pre-fitting the aircraft doors and door jambs for proper alignment.

Pre-Paint > Fuselage > Fit windows

Preparing and fitting the aircraft windows into the fuselage frame.

Pre-Paint > Fuselage > Wheel alignment

Checking and adjusting the alignment of the main wheels for correct tracking.

Pre-Paint > Fuselage > Pre-fit wheel spats

Pre-fitting the wheel spats to the main and nose wheels for aerodynamic contour.

Pre-Paint > Wings > General

Overview of the wing assembly process and recommended sequence of tasks.

Pre-Paint > Wings > Prepare wing root

Fitting fuel and breather fittings and trimming flap arm cutouts in the wing root.

Pre-Paint > Wings > Mount flaps

Positioning and glassing flap brackets onto the wing for aerodynamic fit.

Pre-Paint > Wings > Fit ailerons

Sizing, fitting, and flocking aileron pre-mould strips and attaching ailerons.

Pre-Paint > Wings > Test fit wings

Test fitting the wings and flaps to the fuselage for final alignment before painting.

Paint

Paint > General

Overview of the painting process, filler, paint types, and color restrictions.

Paint > Masking

Techniques for masking various aircraft parts, including fine line tape usage.

Paint > Surface preparation

Detailed steps for sanding, filling, and priming all surfaces for optimal paint adhesion.

Paint > Topcoat

Instructions for applying the final topcoat, ventilation, and unmasking the aircraft.

Post-Paint

Post-Paint > Fuselage > Fit panel mounted throttle

Fitting the panel-mounted throttle linkage to the instrument panel housing.

Post-Paint > Fuselage > Assemble instrument panel

Installing instruments, wiring, and connectors onto the instrument panel.

Post-Paint > Fuselage > Electrical wiring diagrams

Diagrams illustrating the aircraft's electrical system wiring connections.

Post-Paint > Fuselage > Interior > Fit upholstery 1

Installing the initial stage of interior upholstery panels and covers.

Post-Paint > Fuselage > Interior > Fit console controls

Fitting the control stick, trim, and brake systems to the aircraft console.

Post-Paint > Fuselage > Fit rudder, elevator and elevator trim

Attaching the rudder, elevator, and trim assembly to the empennage.

Post-Paint > Fuselage > Fit doors

Refitting the painted aircraft doors and associated seals and hardware.

Post-Paint > Fuselage > Firewall forward > Final assembly

Completing fitting work in the engine bay, including muffler and ducts.

Post-Paint > Wings > Install aileron cables

Routing and connecting aileron cables through the wings for control.

Post-Paint > Wings > Prepare wings for fitting

Preparing wings by fitting fuel gauges, lines, and vent tubes before fuselage attachment.

Post-Paint > Wings > Connect wing tanks

Connecting fuel lines and earth wires from wing tanks to the aircraft's fuel system.

Post-Paint > Wings > Fit flaps

Fitting the wing flaps and adjusting their deflection for flight.

Post-Paint > Wings > Fit fairings

Fitting final trim fairings including wing root, strut, and gear fairings for aerodynamics.

Testing

Testing > General

Overview of pre-flight checks, preparation, and final assembly steps before flight.

Testing > Weight and balance

Calculating empty weight and center of gravity for aircraft loading and trim.

Testing > Rigging check

Final check of control surface deflections and adjustments for correct rigging.

Testing > Calibrate fuel gauges

Calibrating fuel gauges and marking a fuel dipstick for accurate fuel level readings.

Testing > Registration markings

Fitting compliant registration markings to the aircraft as per aviation authority requirements.

Testing > Final inspection checklist

Comprehensive checklist covering all aircraft systems and components before the first flight.

Testing > Flight testing

Procedures for conducting safe test flights, including sequences, checks, and performance analysis.

Testing > Forms

Forms for recording aircraft details, weight and balance, and flight test data.

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