The Manual -
This page contains the links that make up the manual for all of the steps required to build the Super2. The manual is divided into Chapters and most chapters have different sections. This organization allow you to locate the drawings associated with each task. The entries in blue have been completed and are active links, the entries in black are under construction.
Chapter 1 - Introduction
- Introduction
- General Considerations
- FAA Licensing
- Tools
- Composite Techniques
- Poor Man's Vacuum Bagging
Chapter 2 - Fabricating the Tail
Section 1 - Horizonal Stabilizer
- Required Material List
- Raw Stock Preperation
- Building the Ribs
- Building the Horizontal and Elevator Spars
- Spar Assembly
- Leading Edge
- Assembly
- Post Curing the Assembly
- Sheeting
- Glassing
Section 2 - Vertical Stabalizer
- Fabricating the individual parts
- Building the Vertical and Rudder Spars
- Assembling taahe Vertical Stabalizer
- Installing the Comm Antenna
- Glassing
- Elevator Pulley
Chapter 3 - Fuselage
Section 1- Forward Fuselage
- Overview
- Side Panel Fabrication
- Bottom Panel Fabrication
- Frame Assembly
- Forward Fuse Assembly
- Fabricating the Radiused Section
- Final Trim
Section 2 - Rear Fuselage
- Introduction
- Cutting the Panels
- Bonding the Panels
- Glassing the Inside
- Glassing the Outside
- Folding the Rear Fuselage to Shape
- Trimming
Section 3 - Joining the Halves
- Joining Fuselage Halves
- Installing the Firewall
- Installing the Longerons
- Installing the Seatback
- Bulkheads
Section 4 - Fuselage Features
- Forward Deck
- Engine Mount and Nose Gear Reinforcements
- Rudder Pedal Assembly
- Rudder Cable Tail Exits
- Tail Tie Down
- Fuselage Mounted Antennas
- Wire ties and Static Ports
- Seats
- Control Tunnel
- Elevator Bellcrank
- Control Stick
- Instrument Panel
Chapter 4 - Installing theTail
Section 1 - Bonding Tail to the Fuselage
- Installing Rear Access Panel
- Preparing Fuselage for Horizontal Stab
- Bonding Horizontal Stab in Place
- Bonding Vertical Stabilizer in Place
Section 2 - Elevator
- Building the Parts
- Installing nutplates
- Building the Elevator Control Weldment
- Assembling the Frame
- Foam Core
- Carbon Fiber Skins
- Leading edge radius
- Trim Tab
Section 3 - Rudder
- Assembling the Rudder
- Control Horn
- Foaming
- Glassing
- Balancing
Chapter 5 - Gullwing Canopy
Section 1- Canopy Outer Skin
- Overview
- Wooden Canopy Support Frame
- Defining Door and Windsheild Locations
- Poor Man's Vacuum Bagging Techniques
- Facricationg Carbon Fiber Canopy Frame Skins
- Trimming Frame Skins to Size
- Bonding Canopy Frame Skins
Section 2 - Canopy Foam
- Fabricating and Installing Canopy Hinges
- Foam Core Installation
- Inner Carbon Fiber Skin
- Installing Door Latches and locks
- Bonding Door bottom skins
Section 3 - Finishing Canopy
- Fabricating Bulb Seal Flange
- Fabricating Plexiglas Flange
- Installing Canopy to Fuselage
- Installing Plexiglass
Chapter 6 - Turtle Deck
- Building the Frame
- Fuselage Flange
- Foam Sheet- outside laminate
- Forming the Turtle Deck - inside laminate
- Bulkheads
- Installing the Trutle Deck
Chapter 7 - Wing
Section 1 - Spars
Section 2 - Ribs
Section 3 - Wing Assembly and bottom Skin
- Wing Overview
- Wing Assembly
- Main Gear Legs
- Skinning Wing bottom and Glassing Bays
- Shaping the Foam Wing Skin
- Glassing Wing Bottom
Section 4 - Wing Internals
- Parts Required and Wing Prep
- Flanges
- Access Panels
- Fuel Cell Components
- Idler and Bellcrank Assemblies
- Aileron Control Tubes
- Wiring and Hydraulics
- Flap Hinges
- Gear Leg Mounting
- Tie Down
Section 5 - Wing Top Skin
Chapter 8 - Wing to Fuselage
Chapter 9 - Engine
Section 1 - Corvair Modifications
Chapter 10 - Firewall forward
Section 1 - Fuel system
Section 2 - Oil System
Section 3 - Electrical
Chapter 11 - Electrical
