Kit Builder Manuals

The Builder’s Assistance
Manual is available in Adobe PDF format in 5 parts.

Download all five to get the entire manual.

This legacy build manual was written in 2007.  MANY things have changed in the kits since then including the changes made when we started making the Model B four place kits with different wings. This manual is not intended to be followed 100% when building the kit.  There are other resources available to builders much more up to date and applicable to current production kits.  We leave this manual available as a reference for builders and also for interested pilots to get a general idea how the kits go together.

Part One – BHManual-Fuselage1-25Rev1.pdf

download size: 1,362kb

Chapter Page
Project Overview 3
Getting Started – What’s needed? 4
Engines and Props -Specs, do’s and dont’s 5
The Building Sequence 7
Landing Gear Installation 9
Tailwheel Installation and choices 12
Installing the Tail and Trim System 13
The Control Stick System 17
Rudder Pedal Assembly 19
Flap Control System 21
Floor Boards 23

Part Two –BHManual-fuselage26-45Rev2.pdf

download size: 1,696kb
Chapter Page
Seats 26
Installing the Stringers 28
Control Cables 30

The Fuel System

 

THE BEARHAWK  FUEL SYSTEM  AS SHOWN  IN THE  BEARHAWK BOOK IS

DESIGNED FOR USE WITHOUT  A  FUEL PUMP.

IF A FUEL PUMP IS USED  EXTRA CARE  IN FLYING  IS REQUIRED SO THAT NEITHER
MAIN TANKS BECOME UNPORTED,  AS A FUEL PUMP WOULD RATHER SUCK  AIR 
THAN FUEL.

IF ONE TANK IS VERY LOW AND THE OTHER IS NOT VERY LOW SET THE FUEL SELECTOR
ON THE FULLEST TANK AND FLY THE PLANE  SO AS NOT TO UNPORT THAT TANK.

A HEADER TANK (3 GAL) COULD BE USED TO SOLVE THIS PROBLEM,
BUT FUEL IN THE COCKPIT CAN BE A SAFETY ISSUE.  ( VENT
THE HEADER TANK TO BOTH MAIN TANKS)

31
Brake System 34
Cabin Air Vents 37
Installing the Firewall 38
The Boot Cowl 40

Part Three- BHManual-Fuselage46-79Rev1.pdf

download size: 1,514kb
Chapter Page
Instrument Panel 46
Engine Cowling and Nosebowl 49
Doors 55
Windshield Installation 58
Interior Thoughts and Variations 62
Fabric Covering the Fuselage 64
Installing the Engine 66
          Appendices
Appendix A – Hardware List by Application
Appendix B – Hardware List Totaled by Types
Appendix C – Random Covering Thoughts

Part Four – BHManual-Wing1-28Rev0.pdf

download size: 1,315kb
Chapter Page
Getting started 1
Flap actuating system 7
Aileron actuating system 9
Tip and root ribs 11
Hanging the wings 12
Setting Dihedral and making the struts 19
Installing Flaps and Ailerons 24

Part Five – BHManual-Wing29-54Rev0.pdf

download size: 1,393kb
Chapter Page
Installing gas tanks 29
Tank Bay stiffeners 31
Aux tank installation 33
Plumbing the main tanks 35
Plumbing the aux tanks 38
Tank covers and nut plates 40
Wiring 43
Pitot system 44
Inspection panels and nut plates 46
Riveting the wing skin 48
Installing Wing tips 50
Trailing edges 52
Control cables 53
Root fairings 54

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