General Information:

STEP:

Install the throttle guide Plate (R1) on the case(C3).

STEP:

Attach with Qty 3, M4 x 10mm countersunk screws.

STEP:

Install the Nema sliding plate R3 on the stepper motor. Secure with Qty 4, M3 x 6mm Countersunk Screws.

STEP:

Place the R2 spur gear 8T onto the end of the shaft. This should be a tight friction fit. If the unit is too loose, shrink the component slightly and reprint.

STEP:

Install Qty 2, M4 x 30mm screws into the holding lugs of item R4

STEP:

Place the motor assy on the case as shown, Ideally the stepper motor connection should face down.

STEP:

Place the Drive clamp R4 over the top and secure with Qty 4, M4 x 10mm countersunk screws from the backside.

STEP:

Install the long arm microswitch with a roller into position. Place an m3 x 14mm screw through the upper hole. Ensure the unit is free to rotate.

STEP:

Insert an M3 x 20mm countersunk screw through the banana slot into the lower hole of the microswitch.
Secure with an M3 locknut. Adjust the microswitch arm so that the roller protrudes into the cutout orrifce.

STEP:

Install Qty2, M2 x 8mm screws into the Hall sensor and sliding plate R6

STEP:

Install an M4 x 25mm Bolt into the adjustment lug as shown.

STEP:

Install the spur gear R5 onto the pot shaft. This should be a tight friction fit. There is a hole for an M3 grub screw if required.

STEP:

Place the Hall Assy on the flat side of C3

STEP:

Secure with Qty 3, M4 x 10mm Countersunk Screws

STEP:

Install the Nema 17 stepper motor onto the sliding plate R9. Secure with Qty 4, M3 x 6mm screws.

STEP:

Instal the tension bolt M4 x 20mm into the adjustment lug.

STEP:

Install spur gear R8 onto the shaft. This should be a very tight friction fit.

STEP:

Place the drive assy into the case C3

STEP:

Secure with Qty 4, M4 x 10mm countersunk screws.

STEP:

Place the hall sensor with the supplied mounting plate over the support lugs. Secure with Qty 2, M3 x 6mm dome head screws.

STEP:

Place the Spur gear R11 onto the hall sensor shaft. It should be a tight fit, there is an orifice for an additional M3 grub screw if required.

STEP:

Place the Flaps detent bracket (R12) into position and secure with Qty 5, M4 x 12mm countersunk screws

STEP:

Insert Qty 2, 6002 bearings into the flaps stem (R17). Ensure the bearings are flush with the inboard surface.

STEP:

Insert the Flaps handle R13 on flaps stem R13. Secure with an M3 x 16mm countersunk screw. You can print the upper stem (R13) and use it as a template for the aluminium bar.

STEP:

Insert the Flaps Caddy R15 on the upper stem R13. Insert the lower stem R16 into the caddy and secure it with an M4 x 16mm countersunk screw. The screw should protrude out the other side. This is used for the location of the lever. You will need an M4 tap to create threads in the aluminium bar of the lower stem R16. This will enable the screw to tighten against the aluminium bar.

STEP:

The shows how the assembly should look from the backside and how the screw needs to protrude out.

STEP:

Place the flaps lever assy into the flaps stem assy. Use an M4 x 10mm dome head screw to secure the expansion spring (approx. 5mm x 38mm) into position at the lower end.

STEP:

Secure the other end of the spring with an M4 x 10mm dome head screw.

STEP:

Place another expansion spring (approx. 5x38mm over the protruding screw ends.

STEP:

Place the flaps lever into position. At this point, you NEED to connect the hall sensor to a computer via an interface card such as a Leo Bodnar. Set the handle to the mid position and then ensure the Sensor is mid position. Secure in place. You do not want to build the whole unit to have to take it apart to align the sensors!

STEP:

Insert Qty 2 on/off toggle switches into the stab trim cutout position. Secure with the supplied lock nuts.

STEP:

The lock nuts and thread protrusion of the toggle switches on the outside need to be adjusted to suit your needs when the decal is placed into position.

STEP:

Place 12v Led strip (warm white) into the recess and connect the necessary wires. Feed the cables through the cut out into the internal body space.

STEP:

Place the decal into position and secure with Qty 4, M3 x 6mm Dome head screws.

STEP:

Place 12v Led warm white strip lighting into the flaps decal recess. Connect the wires and feed them through the hole into the internal body space.

STEP:

Place the flaps decal on and secure with Qty2, M4 x 6mm dome head screws.

STEP:

Insert the 16mm push button into position (after connecting the cables). This should be a tight friction fit. addition hot glue may be required.

STEP:

Using Qty2, M4 x 10mm Screws, secure R20 to the case. Ensure they are flush, or below the surface.

STEP:

Build the No2 start lever the same way as No1 (steps 83 to 90)

STEP:

Place the No2 start lever into position.

STEP:

Build the no2 throttle like No1. (Steps 1 to 42)

STEP:

Place the No2 throttle over the start lever

STEP:

Insert an M8 x 80mm bolt through the unit. At this point, you NEED to connect the hall sensor to a computer via an interface card such as a Leo Bodnar. Set the handle to the mid position and then ensure the Sensor is mid position. Secure in place. You do not want to build the whole unit to have to take it apart to align the sensors!

STEP:

Secure with an M8 washer and locknut. Do not overtighten.

STEP:

Place the RHS assembly onto the LHS assembly

STEP:

Secure the two parts together with Qty 6, M4 x 25mm countersunk screws.

STEP:

Secure the reverse lock with Qty 2, M4 x 12mm countersunk Screws
(Thanks to Ido for the missed step)

STEP:

Place 12v led strip into the recess of R24

STEP:

Place the decal R25 into position and secure it with Qty 2, M4 x 8mm dome head screws.

STEP:

Place the flaps case assembly into position and secure with Qty 4, M4 x 10mm Countersunk Screws.

STEP:

Place the Fuel Cutout Decal (Tw29) into Position and secure with Qty 2, M4 x 8mm Countersunk Screws.

STEP:

Place TW30 & 31 together. Secure to the centre section with Qty 3, M4 x 16mm Countersunk Screws.

STEP:

Repeat for the other sections(TW30 to TW37) and secure with M4 x 16mm countersunk screws.

STEP:

The strips should look like this when finished.