Construction Manuals .
Jabiru Construction Guide.
WeCanAllFly.JabiruAircraft.
Jabiru
Technical guides and installation procedures
Regulator instructions
Cold start device installation
Information for maintenance personnel
- Summary of significant engine modifications
- Cylinder head modification procedure for CHT probe installation
- Generation 4 engine ram-air duct installation
Strobe system troubleshooting
Standard wiring practices
Exhaust tailpipe mounting in the muffler body for non-Jabiru airframes
Throttle control cable kit
Airframe Construction Manual
In these manuals, you will find all the necessary instructions to build your own Jabiru, step by step, operation by operation. Each task is designed as a standalone module, with the goal of it being completed before moving on to the next.
This approach offers several advantages: it allows for easy tracking of construction progress, serves as a comprehensive checklist to prevent any omissions, and in many cases, certain operations depend directly on the completion of a previous step. By following the order indicated in the table of contents, you avoid these types of difficulties.
The table of contents of this manual also constitutes the construction sequence.
The construction manual is written and updated continuously, and the information on this page is regularly refreshed. In all cases, the version of each task or manual corresponds to the date in the footer. The most recent date corresponds to the current version. If you have downloaded a task and wish to check if an update has been published, simply consult the footer date.
Below you will find 6 model-specific construction manuals. These are relatively large PDF files (approximately 25 MB), optimized for fast online viewing. Each manual features an interactive table of contents: click on a title to go directly to the relevant task, in accordance with standard PDF navigation functions.
If you are looking for a specific task only and do not wish to view or download the full model files, you will also find all individual construction manual tasks below, listed in the correct assembly order. These PDF files are lighter, generally between 4 and 8 pages. Simply click on the desired task to open or download it.
Model identification in individual files: J100 refers to J160 and J170, J2400 refers to J230, J250, J430, and J450. J2430 refers to J230 and J430, J2450 refers to J250 and J450, etc. JALL refers to all "J" series aircraft.
Regardless of the module you wish to consult, we recommend starting by reading the General Introduction before proceeding with individual tasks. It contains important information and must be read carefully before and during the entire construction process.
Construction Manuals by Model
- Jabiru J160 Construction Manual – March 2015
- Jabiru J170 Construction Manual – March 2015 (see individual sections below for updates)
- Jabiru J230 Construction Manual – April 2014 (see individual sections below for updates)
- Jabiru J430 Construction Manual – April 2010 (see individual sections below for updates)
- Jabiru J250 Construction Manual – April 2010
- Jabiru J450 Construction Manual – April 2010
Construction sequence for kit aircraft
- Preface JALL – July 2021
- Table of Contents JALL (placeholder)
- General Introduction JALL – Nov. 2021
Pre-painting → Fuselage
- Under-fuselage penetrations_J2400 – Oct. 2022
- Ventral fin and trim horn assembly_JALL – July 2021
- Prepare the fuselage_J100 – July 2017
- Prepare the fuselage_J2400 – Nov. 2021
Pre-painting → Fuselage → Landing Gear
- Landing Gear_Assemble main wheels_JALL – Oct. 2021
- Landing Gear_Assemble main gear and brakes_JALL – Sept. 2022
- Landing Gear_Mount main gear_JALL – Oct. 2021
Pre-painting → Fuselage → Engine Compartment
- Mount the firewall_JALL – Nov. 2021
- Firewall equipment_J100
- Firewall equipment_J170_J2400 – Oct. 2022
- Fuel pump fittings_JALL – Nov. 2021
- Assemble and mount the nose gear_J100
- Assemble and mount the nose gear_J2400 – Nov. 2021
- Mount the windshield_JALL – April 2014
- Mount the engine and its mount_J100
- Mount the engine and its mount_J2400 – July 2021
- Install cables and controls_J100
- Install cables and controls_J2400 – Nov. 2021
- Mount the engine cowling J100 – Sept. 2025
- Mount the engine cowling J2400 – Sept. 2025
Pre-painting → Empennage
- Mount the vertical fin J100
- Mount the NACA0012 vertical fin J2400 – Nov. 2021
- Mount the elevator J160 – July 2017
- Mount the elevator_J170_2400 – Nov. 2021
- Mount the horizontal stabilizer_J100 – April 2019
- Mount the horizontal stabilizer J170_2400 – Nov. 2021
- Mount the rudder J100 – July 2017
- Mount the rudder J2400 – July 2017
Pre-painting → Engine
- Mount the dynamic air cooling ducts J2400 – Nov. 2021
- Mount the dynamic air cooling ducts J100
- Mount the oil cooler J100
- Mount the oil cooler J2400 – Nov. 2021
- Mount the flap drive shaft supports JALL
Pre-painting → Interior
- Console – Handbrake pre-assembly JALL
- Console – Trim control pre-assembly JALL
- Console – Control stick assembly JALL
- Mount the rudder pedal mounting blocks JALL
- Mount the aileron cable supports J100
- Mount the aileron cable supports J2400
- Fuel system J100
- Fuel system J2400 – June 2023
- Mount the seat belt anchors J100
- Mount the seat belt anchors J200 – Oct. 2022
- Mount the seat belt anchors J400
- Mount the rear seat J400
- Pre-fit the doors J100
- Pre-fit the doors J2400
- Mount the door gutters J2400
- Mount the windows JALL
- Wheel alignment JALL
- Pre-fit the wheel fairings JALL
Pre-painting → Wings
- General JALL
- Mount the fuel tank filler neck J100 2430 – August 2024
- Mount the fuel tank filler neck J2450
- Prepare the wing root J160
- Prepare the wing root J170
- Prepare the wing root J2430 – August 2024
- Prepare the wing root J2450
- Cut the aileron cable inspection opening JALL – August 2024
- Mount the quick drains J160
- Mount the quick drains J170 J2430
- Mount the quick drains J2450
- Mount the flaps J100
- Mount the flaps J2430
- Mount the flaps J2450
- Mount the wing tips J160
- Mount the wing tips J170 J2430
- Mount the wing tips J2450
- Mount the Z-spar ailerons J170 2400 – Sept. 2022
- Mount the C-profile ailerons J160 2400
- Mount the ailerons J170
- Mount the Pitot tube on the strut JALL
- Mount the vibration damper on the strut J170 2400
- Leading edge light installation JALL
- Wing test fitting JALL
Painting
Post-painting → Fuselage
- General JALL
- Mount the panel throttle control JALL – Nov. 2021
- Assemble the instrument panel JALL
- Electrical wiring diagrams JALL
- Mount the upholstery JALL
- Install the electrical wiring JALL
Post-painting → Interior
- Mount the console controls J160
- Mount the console controls J170 2400
- Mount the rudder pedals J100
- Mount the rudder pedals J160
- Mount the rudder pedals J170
- Mount the rudder pedals J2400
- Mount the flap drive motor J100
- Mount the flap drive motor J2400 – Nov. 2021
- Mount the instrument panel housing JALL
- Mount the instrument panel JALL
- Mount the upholstery J100
- Mount the upholstery J200
- Mount the upholstery J400
Post-painting → Empennage
- Mount the rudder and elevator J160
- Mount the rudder and elevator J170 2400
- Mount the doors J100
- Mount the doors J2400
Post-painting → Engine Compartment
- Engine control wiring J100
- Engine control wiring J2400
- Mount the composite propeller and spinner JALL
- Mount the wooden propeller and spinner JALL
- Connect the cabin heater JALL
- Mount the wheel fairings JALL
Post-painting → Wings
- Install the aileron cables J160
- Install the aileron cables J2430
- Install the aileron cables J2450
- Mount the stall warning J100
- Mount the stall warning J2400
- Prepare the wings for mounting J160
- Prepare the wings for mounting J170
- Prepare the wings for mounting J2430
- Prepare the wings for mounting J2450
- Mount the wings JALL
- Connect the ailerons JALL
- Connect the wing tanks J100
- Connect the wing tanks J2400
- Mount the flaps J100
- Mount the flaps J2400
- Mount the fairings J100
- Mount the fairings J2400
Testing
- General JALL
- Weight and balance J100
- Weight and balance J2400
- Rigging check JALL
- Fuel gauge calibration JALL
- Application of registration markings JALL
- Final inspection checklist J160
- Final inspection checklist J170 2400
- Flight testing JALL
- Flight test forms JALL
- VHF interference troubleshooting JALL
Information
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