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Jabiru J400 Builder Log - December 2005
12/31/2005 4:30pm-10:34pm
1) retried the cowl fit... after many fine adjustments with a sander,
the cowl seems to sit ok against the fuselage... the oil cooler
brackets will defenitely have to me moved... the instructions say
to fit the cooler first but it doesn't seem to work well as the
cowl really determins where the oil cooler should sit...afterall
you probably shouldn't have large gaps at the cowl join with the
fuselage
2) drilled and attached all camlocks (3 on top) and countersunk
tinnerman washers with stainless steel screws to the bottom (3 each
side on bottom)... cowl sits nicely
3) removed top cowl and tried the oil cooler at the bottom... looks
like i will have to move the brackets pretty much all the way to
the back of the oil block to have a nice fit with the bottom duct...
the pictures in the manual doesn't see to really work well with
this new cowl/oil cooler... very misleading
12/30/2005 4:10pm-10:47pm
1) tried the cowl in place over the engine... doesn't seem that
bad of a fit as it seemed at first... the top edge may need some
sanding and then it may sit nice and flush...
2) removed the air ram ducts and epoxied the 1mm rubber strips at
the edge as instructed
3) drilled and riveted the oil cooler brackets into place... of
course the manual doesn't quite match up so i had to estimate where
the brackets go...
4) held the oil cooler on the brackets with clamps and tried the
cowl on... hmmm... not a perfect fit...in fact unless i reverse
the cooler so that the hoses are at the rear it doesn't really seem
to fit quite right...might need more tweaking... looks like it's
going to be a pain in the ass to get it right ;)
12/29/05 5:31pm-9:34pm
1) bought the loctite 262 and some hex sockets so I can now install
the prop flange extension
2) removed the original prop flange and trial fitted the new extension
flange... cleaned out the old loctite off of the cap screws as instructed
3) made a 90 mm hole in the cowl for the prop flange
4) trial fitted the cowl over the engine... might need some adjusting
to fit well at the joints
5) installed the oil overflow bottle as instructed and riveted...
since there really aren't much instructions i used the photos mostly
for guidance... attached the fuel pump vent tubing...attached the
air box vent to the carby as instructed... installed the oil overflow
tube aligned to vent overboard with bracket
6) trimmed air ram fiberglass joins from a previous day's work
12/19/2005 8:11pm-12:06am
1) haven't gotten much done on the plane... the holiday season has
kept me busy at work which is a bummer..
2) fitted the cylinder cooling ducts as instructed... drilled the
holes for tappet cap screws... then wired the gull wings between
cylinders as instructed with spring...wasn't sure which spring to
use so i used the smaller of the two...once done with that, i wired
the spring to cylinder 3 and 4 as instructed and riveted the elbow
into the cooling ducts
3) 5 minute epoxied the slits on the cowls and joined with AF303
as instructed
12/11/2005 4:47pm-6:27pm
1) installed the solenoid and the regulator as instructed... the
regulator was mounted slighty towards the center and higher on the
firewall... don't like that the regulator is so close to the solenoid
in the directions... the regulator would be in the way of the solenoid
when removing or connecting cables
12/10/2005 3:44pm-11:54pm
1) fitted the air box mixer to the firewall.. installed the angled
flange that goes to the carb...used 5 minute epoxy and trimed the
inside of the box as instructed
2) then siliconed and riveted the air box to the firewall
3) installed the cobra head to the carb and scat tubing to the air
box...the cobra head isn't a perfect fit on the carb and so it cracked...i
guess it's not unexpected since the cobra is inflexible... it was
hard inserting the scat hose to the cobra too since the scat has
steel wire inside which doesn't flex on the larger cobra.... i think
it's good though... so we'll see
12/8/2005 7:20-11:03pm
1) i came up with the idea of making a clamp using 4 nuts 4 washers
2 threaded rods and 2 steel flat bars...this should clear the tight
areas too... since this is made the next step is to use it to compress
the engine mount... took about 15 mins to make this clamp with air
tools
2) so the clamp with 2 flat bars flopped...the steel wasn't strong
enough so it bent...there's a pic of it... so i had to bring out
the big guns... i cut 4 inch steel L forms and used those instead...
the L worked like a charm..in fact it works real well since u can
put the L's upside down relative to each other so that the clamp
has no chance of sliding off
3) all bolts were tightened to 8ftlbs... also..note that one of
the diagrams was depicted wrong with both top and bottom have the
male rubbers inserted first... i put the female first on the top
as instructed...i think it makes more sense that way anyway...
4) one thing i notices is that the tail is so much taller that it
was before...i didn't quite remember it being this much taller on
the demo.. but i could be wrong
12/7/2005 7:40-11:57pm
1) so the engine was brought into the hangar yesterday...didn't
really log the time or such but i did open the crate and look through
it...
2) a bit nippy at the hangar... 50F with the heater in the tent...not
too bad considering it's 5F out there due to the winter storm...
it'll warm up now that the flood lights are on
3) a friend and i mounted the engine on the engine mount with 2
sawhorses and a 2x6 across holding the front edge... didn't quite
have the right rubber compressors to compress the rubbers together
and get enough thread to tighten bolt and unfortunately all the
shops are closed at this time so I just secured the engine into
place and closed shop for tonight...oh well.. but at least i won't
need help tomorrow
12/2/2005 7:15pm-10:12pm
1) checked the flocked backseat and looks fine...ready to glass
the strips onto the backseat
2) sanded the backseat joints for glassing
3) 2 layers of AF303 were glassed to the backseat with 4.4 oz of
epoxy (3.3/1.1)... current temperature is 65F
4) drilled 1/4 inch holes into seat pan and filled the seat with
Great Stuff Big Gap expanding foam
5) drilled anchor points for rudder anchor at the fin
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