Pipistrel Sinus User 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
Table of Contents
What do you need?......................................................................................................................................4
Preparing the Fuselage .............................................................................................................................. 5
Preparing the undercarriage.....................................................................................................................10
Fitting the undercarriage to the aircraft...................................................................................................18
Firewall 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
Fitting 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
Fitting the throttle assembly and the flap handle ................................................................................... 34
Fitting the ballistic chute (part 1) ............................................................................................................. 37
Fitting the ballistic chute (part 2) ............................................................................................................. 43
Fitting the lower fuel system .................................................................................................................... 49
Fitting 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
Fitting the rudder cables .......................................................................................................................... 69
Mounting the upper flaperon pushrod bracket.......................................................................................70
Mounting the electrical panel ................................................................................................................... 71
Fitting the rudder assembly ..................................................................................................................... 72
Horizontal stabilizer preparation..............................................................................................................81
Preparing the elevator / rudder ................................................................................................................ 83
Fitting the horizontal stabilizer ................................................................................................................ 88
Installation of the sliding elevator trim knob .......................................................................................... 93
Fitting the trim system .............................................................................................................................. 95
The Control System .................................................................................................................................. 98
Mounting the control system..................................................................................................................102
Nose wheel cable preparation ................................................................................................................ 107
Finishing the rudder cables ................................................................................................................... 109
Fitting the rudder .................................................................................................................................... 110
Fitting the brake lines ............................................................................................................................. 111
Mounting the fuel lines in the cabin ...................................................................................................... 117
Fitting the windscreen ............................................................................................................................ 118
Installation of the strobes ....................................................................................................................... 123
Fitting the engine (part 1) ....................................................................................................................... 126
Fitting the engine (part 2) ....................................................................................................................... 167
Fitting the dashboard ............................................................................................................................. 175
Fitting the front cowls ............................................................................................................................. 178
Fitting the cowling around the exhaust and final cowl touch ups ...................................................... 187
Propeller setup ........................................................................................................................................ 191
Fitting the nose wheel ............................................................................................................................ 196
Wing preparation ..................................................................................................................................... 197
Assembling the airbrakes........................................................................................................................215
Mounting the wings ................................................................................................................................ 223
Fitting the Wheel Spats ........................................................................................................................... 229
Fitting the nose wheel spat .................................................................................................................... 233
Fitting the luggage rack and headsets...................................................................................................234
Mounting the Autopilot System..............................................................................................................237
Automatic nose wheel and rudder centering systems ........................................................................ 245
http://www.pipistrel.si © Pipistrel Release March 2009 © Page 2 of 267

Pipistrel Sinus Specifications

General

Manufacturer	Pipistrel
Seats	2
Rate of climb	5.5 m/s (1, 080 ft/min)
Ballistic parachute rescue system	Optional
Engine	Rotax 912
Type	Motor glider