In our last blog entry we had just completed the wings and attached them temporarily to the airframe prior to covering. The next step was to install the engine. The Nynja can use a variety of powerplants including the Rotax 912, Rotax 912S, Rotax 582, Jabiru 2200, BMW R100 and even the Simonini Victor inverted engine! However, it’s widely accepted the Rotax 912 and 912S are the best match to the airframe. We have decided to go with the Rotax 912S, 100hp variant with a Kiev prop. To date we have just installed the main engine block, many of the accessories will come over the next few weeks including the starter, oil tank and hoses. The engine on the Nynja is mounted a little further forward on the Nynja than the Skyranger classic allowing a little more access to the back of the engine when the firewall is installed.

With that job complete it was time to cover the wings. Before covering the wings we used ACF50 to protect the structure from corrosion. We’ve gone for the Xlam skins which last longer and have improved resistance to UV light. There are some parts of the leading edge that have bolt heads slightly protruding. These are covered with tape to prevent vibration from abrading the anodising. The same is done to the U brackets on the wing tip. Once complete the wings are ready to be covered. We removed the wings from the airframe and placed them on the ground. The wing can collapse in a scissor like fashion and the wing skin goes over the structure much like a sock. The wing is then expanded back out into its original shape and hey presto! The fabric can then be stretched into place if needed. The wing battens are then inserted to give the wing its aerodynamic shape.

Both wings were then re-attached to the fuselage as described in our previous blog entry. The aileron cables were then re-attached and the flaps connected to the flap lever in the cockpit between the two seat. The next job will be to wire up the throttles, install the windscreen, add the floor pan and start working on the firewall forward. We’ve ordered the avionics but we’ll keep that exciting story until a future blog! In the meantime, enjoy some of the photos below.

The Rotax 912S being craned into position.

It’s important to tape up any protrusions along the leading edge to prevent vibration which could wear off the anodising causing stains on the fabric.

It’s a relatively quick job to get the skins on. The main frame collapses in a scissor like fashion, the fabric slides over the then it’s opened up again. Batons are then inserted to give the wing it’s aerodynamic shape.

We have the left wing covered and attached before lunch!

Mark and Steve manoeuvring the right wing following covering.

It’s a two-man job to re-attach the wing.

It’s looking like a complete aircraft now but as they say in aircraft building 80% done, 80% to go!

Once in position the aileron control cables can be reattached.

The flap control rod was then connected which is linked to a flap lever in the centre of the cockpit between the two seats.

The engine is in position but many of the accessories are still to be added.