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 - 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
Chapter 2 - Section 3 - Vertical Stabalizer
- Fabricating the individual parts
- Building the Vertical and Rudder Spars
- Assembling taahe Vertical Stabalizer
- Installing the Comm Antenna
- Glassing
Chapter 3 - Fuselage Boat
Chapter 3 - Section 1- Forward Fuselage
- Overview
- Side Panel Fabrication
- Bottom Panel Fabrication
- Frame Assembly
- Forward Fuse Assembly
- Fabricating the Radiused Section
- Final Trim
Chapter 3 - Section 2 - Rear Fuselage
- Introduction
- Cutting the Panels
- Bonding the Panels
- Glassing the Inside
- Glassing the Outside
- Folding the Rear Fuselage to Shape
- Trimming
Chapter 3 - Section 3 - Joining the Halves
- Joining Fuselage Halves
- Installing the Firewall
- Installing the Longerons
- Installing the Seatback
- Bulkheads
Chapter 3 - 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
- Seats
- Control Tunnel
- Instrument Panel
Chapter 4 - Section 1 - Assembling Horizontal Stab and Fuselage
- Installing Rear Access Panel
- Preparing Fuselage for Horizontal Stab
- Bonding Horizontal Stab in Place
- Bonding Vertical Stabilizer in Place
Chapter 4 - Section 2 - Elevator
- Building the Parts
- Installing nutplates
- Building the Elevator Control Weldment
- Assembling the Frame
- Foam Core
- Carbon Fiber Skins
- Leading edge radius
- Glassing
Chapter 4 - Section 3 - Rudder
- Assembling the Rudder
- Control Horn
- Foaming
- Glassing
Chapter 5 - Gullwing Canopy
- 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
- Fabricating Canopy Hinges
- Installing Canopy Hinges
- Foam Core Technique -Windsheild Bow
- Installing Foam Core in roof and Rear Pillar Bows
- Closeout skin on Windsheild bow
- Closeout skin on Roof and Rear Pillar Bows
- Bonding Door bottom skins
- Installing Door bottom removable foam core
- Skinning Door bottom
- Fabricating Bulb Seal Flange
- Fabricating Plexiglas Flange
- Installing Door Latches and locks
- Installing Canopy to Fuselage
- Installing Plexiglass
Chapter 6 - Turtle Deck
Chapter 7 - Wing Overview
