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FEATURED BUILD Kit Building *** BEFORE YOU BUILD *** This is the section where we are presenting a complete Challenger II Short Wing Build - In Progress Challenger Aircraft Kits - Options and Accessories Other Options & Accessories Instruments Recommended Tools AN Bolts and Designations *** THE ACTUAL BUILD *** Preamble, Building of a Challenger Preparation & Building Area Arrival & Unpacking Of Your Kit Inboard Wing Construction Outboard Wing Construction Placement Of The Wing Ribs Hoerner Wing Tip Construction Tail Section Hinge Fitting Aileron Completion & Hinge Fitting High Side Rail Fabrication Fuel Tank Holder & Placement Fiberglass Nose Cone Fabrication & Placement Top Door Assembly Installation of Flaperon Assembly Former Plate Construction Shoulder Belts Installation Instrument Panel Design & Layout Temporary Installation Of Landing Gear Installing A Capacitance Tube Fuel Gauge Total Plane Wiring for A Digital Panel Total Plane Wiring for An Analog Panel Motor Mount Assembly & Engine Mounting Pre-Fit Tail Section Pre-Fitting Your Wings Covering The Wings - AFS Covering The Wings - Poly Securing & Riveting The Wing Ribs - AFS Securing & Riveting The Wing Ribs - Poly Covering The Tail - AFS & Poly Preparation For Covering The Fuselage Covering The Fuselage - AFS Method Covering The Fuselage - Poly Fiber Method Fuse Box & Power To Instrument Panel Installing Wing Tip Strobe Lights Adjusting Aileron & Rudder Turnbuckles and Cables Painting Your Fiberglass Sections Painting Fuselage, Wings & Tail Sections - AFS Method Painting Fuselage, Wings & Tail Sections - Poly Fiber Method Installing Factory & Custom Throttle Quadrants Intercom/Radio System Engine Firewall Wiring & Connectors Carburetor Install, Connection and Calibration *** ADDITIONAL BUILDING TIPS *** FAA REQUIRED Decals & Placards Final Step - Building Debris Removing a Rivet Engine Related Articles Challenger Synchronous Belt Report Carburetor Ice Rotax 2 Stroke Carburetor Sockets Carb Synchronization Controlling Throttle Creep CHT Sensor Location (Revised 1-14-04) Coolant Mix and Overheating - Lg. Engines Do-it-Yourself $5 Prop Balancer - Ralph Shultz Engine Test Run, Unloaded Energy, Power, and Torque Exhaust Gas Temperature Exhaust and Intake Tuning Fuel Storage Fuel Delivery System Basics - Andy Humphrey Fuel Systems Keeping Your Two-Stroke Engine Flying NGK Spark Plug Chart Olive Jar Test for Alcohol Priming, Choking, and Enriching Props 101 Protect your Engines Vibration Mount Installing the QCU Prop Drive Redrive - Bearing Replacement Remove The Drive Pulley On The PSRU Retorqueing Of The 503's Head Nuts Resistance Values for Ducatti Ignition The $1.55 Manometer - Fine Tuning the Carbs Torque Spec.'s - Rotax Engines Tuned Pipes Two Stroke Engine Oils Upright Mounted Engine Wood Prop Repair & Balancing Modifications Bulletproofing the 503 - Jim Showker Covering the Tail Section Detachable Rear Control Stick Fabric Plates Front Gap Cover Foil Fuel Pressure Monitoring System - Richard Provenzano Fuel Tank Front Brace Mikuni Fuel Pump Mount Nose Gear Brace Mod Pitot Tube Pitot Tube - Other Styles and Locations Rear Seat Battery Mount Rudder Pedal Mod Spark Plug Cap Securing Tail Cross Tube Support Modification Tail Feathers Tail Wheel Modification Wheel Pant Mounting Electrical System, Communications & Gauges - ARTICLES Barometric Pressure and Altimeter Settings Build Your Own Comm Antenna Calibrating your Air Speed Indicator Flying without an ASI LED Warning Circuit for EIS Miracle Air Whip Antenna Review Pressure, Barometers, & Barometric Pressure Rotax 503 Charging System The 10/10 Special Antenna Other Challenger Build Articles Building a Breathing System For Painting Aerothane Fabricating An Engine Stand Gross Weight Silicone Sealants: Not For Use On Aircraft! Two Ways To Make A Refueling Station Visual CG Calculator - Ralph Shultz Weighing A Plane Using Bathroom Scales Wing Stands For Painting Helpful Articles & Tips - ARTICLES Challenger Building Web Page Links Checklists: Pre-Flight, Before-Landing & Securing Cleaning Your Challenger Correcting Turning Tendencies A Dream Machine Fuselage Edging & Seat Cushion Getting Started in Ultralight & Sport Plane Flying Is This Used Challenger A Good Buy Helpful Tips Corner Landing Gear Mixing Fuel Opinions Quietly Fade The Safety Thing Newsletters from the International Challenger Owners Association - ARTICLES 4th Quarter, 1993 Issue 4th Quarter, 1994 Issue - A Little Bit of History 3rd Quarter, 1994 Issue - A Spirit Violated Site Pages Private Airfields By State - Listings How to find a Challenger Dealer - Article Engines Rotax - Factory Site Hirth - Main US Importer & Sales Site FAA Regulations Glossary of Terms & Abbreviations Helpful Tips Hangar Talk First Flight Articles First Flight of N142JL I Love This Challenger II What It Is To Fly - Ralph Shultz Forced Landing's Charlie Radford Dave Goulet Doc Green George Hurt Jim Hamilton Jim Hayward - #1 Jim Hayward - #2 Jim Hayward - #3 Jim Hayward - #4 John Davis - #1 John Davis - #2 John Shadel General Interest Articles 2nd First Solo in My Challenger II - Terry C. Savage Practice Makes Perfect Noteworthy Incidents Battered By Turbulence BRS Save Number ? He Now Flies A Harley Just Fly the Plane Thunderstorms Hiding In The Murky Haze WE ARE DOWN... THANK GOD!! Rotor Current Long Flights - Cross Country OSHKOSH BY ULTRALIGHT A Trip to the Challenger Factory Fly-in The Great Cross Country 2002 The Happy Builder Initial Flight, Don't Trim Anything Something Special Angel Hair Me an 5JW - 3,000' to Heaven Quad City's 20th Anniversary Flight to Quad Cities' 20th Anniversary Celebration Manuals Parts & Accessories Piloting & Navigation ARTICLES - Beginner to Advanced Piloting Basic Flying Instruments Book of William Question - Air Foil's Learning To Use Your Rudder Getting Lined Up on Final Ground Reference, Part 1 Ground Reference, Part 2 Night Flight In A Challenger Stalls 101 Stalls 201 Tailwind Takeoffs & Landings Take Off & Landing Pattern Traffic Pattern, Description Flying the Traffic Pattern Navigation Compass Directions Cross Country Planning and Flying - Part One Cross Country Planning and Flying - Part Two Short Piloting Tips 10 Ways To Help Prevent Runway Incursions Pilots, Certificates and Ratings Shutting Engine Off While Gliding Soaring, Emergency Procedures The Risks Of Flying Low Thermals, Etc. The Yaw String Controls Controls 101 Controls 201 - Part I Controls 202 - Part II The Bookshelf * New Arrivals * Featured Links SALES PAGE - Challenger Accy. Dealers & Private Party Sales EAA FAA FlyChallenger Discussion Group NOTAM's Challenger Photo Gallery Quad City USUA Site Map This Web Page About Us Short Bio.'s of the Challenger BTT web site Advisory Committee Members Downloads Helpful MS Excel Charts, Small Conversions Program, Palm OS Database - Freeware & GPS Program, Fuel Mix Chart, Wiring Schematics and all FREE! Will be adding to this page as other downloads become available.

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