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
| 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 IF ONE TANK IS VERY LOW AND THE OTHER IS NOT VERY LOW SET THE FUEL SELECTOR A HEADER TANK (3 GAL) COULD BE USED TO SOLVE THIS PROBLEM, |
31 |
| Brake System | 34 |
| Cabin Air Vents | 37 |
| Installing the Firewall | 38 |
| The Boot Cowl | 40 |
Part Three- BHManual-Fuselage46-79Rev1.pdf
| 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
| 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
| 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 |
