Build Manuals

We realize that building your own aircraft can be a daunting task. We are committed to helping you complete your aircraft in a timely and safe manner. Our legacy building manuals are listed here for the time being. New manuals are under construction and will be a step by step guide to assembling these amazing aircraft. These new manuals will be released in increments as they are completed. Additional resources are available at the bottom of this page.

Build Manuals

Five

Intro

Fuselage Pre-Assembly

Final Assembly

Four

Intro

Fuselage Pre - Assembly

Final Assembly

Companion

Intro

Fuselage Pre - Assembly

Final Assembly

Patrol

Intro

Fuselage Pre-Assembly

Final Assembly

LSA

Intro

Fuselage Prep-Assembly

Wing Build

Final Assembly

*Under development

View electronically or print on 11.5x17 paper

Legacy Manuals

Part 1 - Fuselage

  • 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

Fuselage

Part 2 - Fuselage

  • Seats - 26

  • Installing the Stringers - 28

  • Control Cables - 30

  • The Fuel System - 31

  • Brake System - 34

  • Cabin Air Vents - 37

  • Installing the Firewall - 38

  • The Boot Cowl - 40

Part 3 - Fuselage

  • 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

  • Appendix A – Hardware List by

  • ApplicationAppendix B – Hardware List

    Totaled by Types

  • Appendix C – Random Covering Thoughts

Wings

Part 4 - Wings

  • 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 5 - Wings

  • 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

Additional Builders Resources

Bearhawk Four Resources

Bearhawk Companion Resources

Bearhawk Five Resources

Bearhawk Patrol Resources

Bearhawk LSA Resources

Additional Documents

Download Ready Tools

Wings

Fuselage