THEFun by Airborne
OWNER andSERVICE MANUALPO Box 7042, REDHEAD, NSW 2290 AUSTRALIA
E-mail fly@airborne.com.au
www.airborne.com.au
Phone (02) 4944 9199 Int +61 2 4944 9199
Fax (02) 4944 9395 Int +61 2 4944 9395

AirBorne WindSports- Fun MANUAL – Rev 1

TABLE OF CONTENTSTABLE OF CONTENTS ................................................................................................................3
Section 1
DESIGN FEATURES .............................................................................................4
Section 2
SPECIFICATIONS .................................................................................................5
Section 3
OPERATING LIMITATIONS ..................................................................................6
Section 4
WARRANTY STATEMENT....................................................................................7
Section 5
ASSEMBLY PROCEDURE ...................................................................................8
Section 6
PRE-FLIGHT INSPECTION.................................................................................10
Hang Glider Daily Inspection ........................................................................................................................ 10

Section 7
Section 8

BREAK DOWN PROCEDURE............................................................................11
ASSEMBLY FROM SHIPPING LENGTH............................................................12

Section 9

FLIGHT TECHNIQUE ..........................................................................................13

Section 10

TUNING ................................................................................................................14

Section 11

PERIODIC INSPECTIONS and MAINTENANCE ...............................................17

Section 12
Section 13
Section 14

TRANSPORTATION AND STORAGE ................................................................19
MAINTENANCE RECORD ..................................................................................20
HANG GLIDER COMPLIANCE SCHEDULES ...................................................21

Section 15

ASSEMBLY DRAWINGS ....................................................................................25

Breakdown For Shipping........................................................................................................................... 12
Take Off..Don’t forget to hook in............................................................................................................... 13
Turns......................................................................................................................................................... 13
Stalls ......................................................................................................................................................... 13
Spins ......................................................................................................................................................... 13
Thermalling ............................................................................................................................................... 13
Landing ..................................................................................................................................................... 13
Pitch Trim.................................................................................................................................................. 14
Pitch Stability System................................................................................................................................ 14
Bridle Checking Specifications.................................................................................................................. 15
Roll/Yaw Trim............................................................................................................................................ 16

Maintenance Schedule ................................................................................................................................. 17
Log Book................................................................................................................................................... 17
Notes on Periodic Inspections ...................................................................................................................... 18
Airframe Tubing ........................................................................................................................................ 18
Bolts .......................................................................................................................................................... 18
Sails .......................................................................................................................................................... 18
Inspection after Hard Landing................................................................................................................... 18
Defect Reports .......................................................................................................................................... 18

Fun 160 ........................................................................................................................................................ 21
Fun 190 ........................................................................................................................................................ 22
Fun 220 ........................................................................................................................................................ 23
A4-4644 Fun X-Bar Hinge Assembly........................................................................................................ 25
A4-4654 Fun X-Bar To L/E Assembly....................................................................................................... 27
A4-4653 Fun Nose Junction Assembly..................................................................................................... 29
A4-4655 Fun Keel Assembly .................................................................................................................... 31
A4-7237 HG A-Frame Faired Corner Unit Assembly................................................................................ 33
A4-4651 HG A-Frame Round Down Tube Corner Assembly ................................................................... 35

Issue Date: 1 July 2003

Page 3

AirBorne WindSports- Fun MANUAL

Section 1

DESIGN FEATURESThe Fun is the latest hang glider from AirBorne Windsports, and is the result of continued testing andrefinement by AirBorne’s research and development team.
The philosophy behind the development of the Fun was to design a glider which was light weight, strong and
set up quickly. The glider also needed to be easy to fly , take off and land.
We believe that we have succeeded in all aspects of our design parameters.
Landing is one of the best features of the Fun. The Fun is statically balanced with the control bar top well
rearward whilst still allowing the glider to be assemble flat on the ground. Moving the top of the control bar
back improves the static balance and also improves the flair authority.
Imported 7075-T6 Aluminium is used in the airframe construction of the Fun. The battens are also made from7075-T6 aluminium which require almost no maintenance. The overall result is a very strong glider withminimum weight.
Pitch stability has been achieved using a split reflex bridle system to minimise drag and washout rods
constructed from carbon fibre. The carbon washout rod is extremely strong and light weight.
The Fun maintains all the fast set-up features which have become a trade mark of AirBorne hang gliders. It
can, as with all AirBorne gliders, be assembled flat or on the control frame.
AirBorne’s quality assurance program, which is unique to the industry, ensures that every glider is built inaccordance with the standard it was designed to. This gives even the most experienced pilot a sense of
security when flying an AirBorne glider.
We hope that you have hours of great flying with your new glider. Fly high and safely.

Rick Duncan, Russell Duncan, Shane Duncan, Rob Hibberd and Paul Mollison

AirBorne WindSports

Issue Date: 1 October 2001

Page 4

AirBorne WindSports- Fun MANUAL – Rev 1

Section 2

SPECIFICATIONSFUN 160METRICSAIL AREA
WING SPAN

IMPERIAL

FUN 190METRIC

IMPERIAL

14.9 sqmeter

160 sq ft

17.7 sqmeter

190 sq ft

9.07 m29.8 feet

10.1 m33.1 feet

FUN 220METRIC

IMPERIAL

20.5 sq

220 sq ft

meter
10.8 m35.3 feet

ASPECT RATIO

5.5

5.8

5.7

NOSE ANGLE

118 degrees

118 degrees

118 degrees

DOUBLE SURFACE %

30%

30 %

30 %

BATTENS

13

15

15

GLIDER WEIGHT

19 kg

ASSEMBLY TIME

42 pound

23 kg

6 min

51 pound

28 kg

6 min

62 pound
6 min

PACK UP LENGTH

5.31
meter

17.4 feet

5.9 0
meter

19.5 feet

6.34 meter

20.8 feet

SHORT PACK LENGTH

3.60
meter

11.8 feet

4.10
meter

13.4 feet

4.60 meter

15.0 feet

RECOMMENDED
PILOT HOOK IN
WEIGHT RANGE(Includes Equipment)

50-75 kg

110-198
pounds70-120 kg

154-265
pounds85-160 kg

187-353
poundsVNE (Velocity Never to
Exceed)80 km/h

50 mph

80 km/h

50 mph

65 km/h

40 mphVA ( Maximum rough air
manoeuvring speed)

69 km/h

43 mph69 km/h

43 mph

65 km/h

40 mphNote The stall speed for of the Fun at maximum recommended wing loading is 25 mph (40 km/h) or less. The
maximum, or steady state speed is at least 35 mph (56 km/h) for a prone pilot with correctly adjusted
harness.

Conversions: * 0.4536 kg/pound * 25.4 mm/inch * 1.609 km/mile•

Va = Test speed x 0.707 * Vne = Test Speed x 0.816

Issue Date: 1 July 2003

Page 5

AirBorne WindSports- Fun MANUAL

Section 3

OPERATING LIMITATIONSWARNING
Hang Gliding is a high risk sport. The safe operation of this hang glider ultimately rests
with you, the pilot. We believe that in order to fly safely you must maturely practice thesport of hang gliding. You should never fly this hang glider beyond the placarded limits.
The velocity never to exceed (VNE) for your glider is given in Section 2, as is the
maximum speed for manoeuvres or flying in rough air (VA). The indicated airspeeds
given are for calibrated instruments mounted on, or near, the base bar of the control
frame. During your initial flights on the glider it is recommended that you fly with anairspeed indicator until you are able to recognise the control feel that produces theairspeeds shown.
Flight operations should be limited to non-aerobatic manoeuvres where the pitch angle
does not exceed 30 degrees up or down to the horizon and where the bank angle does
not exceed 60 degrees.
Aggressive stalls and spins should not be attempted. Operations outside therecommended flight envelope, such as aerobatic manoeuvres or erratic pilot technique
may ultimately produce equipment failure.
Your glider was designed for foot launched soaring and should not be flown by morethan one person at a time. It should not be flown backwards or inverted.
The setting up and breaking down of a hang glider, transportation on cars and flying
itself, will have an effect over time on its structural integrity. The glider will require
maintenance as outlined in the maintenance section of this manual. Like any aircraftsafety depends on a combination of careful maintenance and your ability to fly
intelligently and conservatively.
The owner and operator must understand that due to inherent risks involved in flying ahang glider, no warranty of any kind is made or implied against accidents, bodily injury
and death, other than those which cannot by law be excluded.
We hope that your new glider will provide you with many hours of safe flying.

AIRBORNE.

Issue Date: 1 October 2001

Page 6

AirBorne WindSports- Fun MANUAL – Rev 1

Section 4

WARRANTY STATEMENT

This warranty extends to new Hang Gliders and/or accessories and equipment manufactured by AIRBORNE
WINDSPORTS PTY LTD (“Airborne”) and shall not embrace any other accessories or equipment in the sale.
AIRBORNE warrants to the customer the hang glider and/or accessories manufactured or supplied by
AIRBORNE to be free from defect in material and workmanship under normal use and service and ofmerchantable quality and fit the purpose for which they are ordinarily used. This Warranty will apply for aperiod of ninety (90) days from the date of dispatch of the hang glider not withstanding the number of hours
flown but subject to the hang glider remaining the property of the customer. This warranty does not exclude
any rights implied in favour of any customer by any applicable Federal and State legislation.
AIRBORNE will make good any parts required because of defective material or workmanship as set out in
the Warranty.

THE WARRANTY WILL NOT APPLY TO:
•
•
•
•
•
•

•
•

Any mechanical adjustments, parts, replacements, repairs or other servicing that in the judgement of
AIRBORNE are made or should be made as maintenance.
Any defect caused by any alteration or modification not approved by AIRBORNE.
Any defect caused by the fitment of parts that are not made or approved by AIRBORNE.
Any defect caused by misuse, accidents, negligence or failure to carry out proper maintenanceservice.
Damage caused by continued operation of the hang glider after it is known to be defective.
Any defect or consequential loss, damage or injury caused by overloading.
Loss of use of the hang glider, loss of time, inconvenience, damages for personal injuries, loss ofproperty or other consequential damages.
Failure due to wear and tear, accident, fire, incorrect or incomplete rigging and/or assembly,
exposure to the elements, operation outside the placarded limitations and repairs attempted or madeother than by AIRBORNE or its authorised agent.

AIRBORNE will replace, free of charge, any original part that is determined by AIRBORNE to be defective
under the terms of this Warranty and reserves the right to pay monetary compensation or make good thedefect in any manner it deems appropriate.
he customer is responsible for transporting the hang glider or parts to and from AIRBORNE or its authorised
agent when making claims under this Warranty. The hang glider or parts are at the customer’s risk whilst intransit to and from AIRBORNE or its authorised agent.
NOTE: Warranty service is available to the customer from AIRBORNE WINDSPORTS PTY LIMITED or
authorised agent.

AIRBORNE WINDSPORTS

Issue Date: 1 July 2003

Page 7

AirBorne WindSports- Fun MANUAL

Section 5

ASSEMBLY PROCEDURE

The wing can be assembled in two positions, either lying flat or standing on the control frame.
Assembling the Fun on the control frame is the most popular method of assembly in light winds. This method
is preferable as the sail is less prone to being soiled or damaged during assembly. In higher winds it ispreferable to lay the glider flat for assembly with the nose into the wind until ready to launch.
Our suggested sequence is as follows:•

UNZIP THE BAG. Lay the wing down with zip up and the nose facing approximately 120 degrees
from the wind direction. The nose should be facing into the wind when assembling flat. Unzip the bag
and un clip centre ties.

•

ASSEMBLE CONTROL FRAME. Spread the control bar down tubes and attach base bar to knuckle.
The pip pin is then inserted with the cover firmly secured. Check that all the rigging wires are outside
the control frame.

•

STAND GLIDER UP. Rotate the control frame to the vertical position and rotate the wing 180
degrees so that it is sitting on the base bar. If assembling flat ensure that control bar is central andthe wires are not tangled.

•

REMOVE BAG. Remove the glider bag and un clip remaining ties.

•

SPREAD LEADING EDGES. Carefully spread both leading edges out half way then spread leadingedges to their approximate flying position.

IT IS ESSENTIAL THAT THE KEEL AND THE LEADING EDGES ARE KEPT IN THE SAME PLANE ORDAMAGE WILL RESULT.

•RAISE KING POST. Raise the kingpost and attach the reflex bridles.

•

Issue Date: 1 October 2001

INSERT MAINSAIL BATTENS. Remove the battens fromthe bag. The red battens are for the left side and the green
for the right. Insert the battens from the centre to the tip
with gentle pressure, until the batten meets resistance.
Shake the sail at the trailing edge whilst maintaining gentle
pressure on the batten to allow the batten to be inserted
over the cross bar. DO NOT FORCE THE BATTENS!
Locate batten in to sail pocket. It is advised not to insert
the last cambered tip batten and tip strut until the
crossbars are tensioned.

Page 8AirBorne WindSports- Fun MANUAL – Rev 1•

TENSION CROSS BARS. The crossbars are now tensioned bypulling the webbing loop until the shackle is positioned on the Quick
Clip. Ensure that the catch is positively locked. When tensioning
the glider lying flat the keel can be raised slightly allowing the side
flying wires to become looser.

•

ATTACH REAR TOP WIRE. The rear top wire should now be
attached to the rear Quick Clip block.

•

INSERT TIP STRUTS. Insert the tip battens and locate tip struts on
to leading edge fitting.
•

ATTACH FRONT FLYING WIRES. The ringon the front flying wires can now be inserted
in to the Quick Clip Block. Ensure that thecatch is positively locked. If the glider has
been assembled flat it should now be lifted on
to the control frame. Be aware of the tip
battens! Make sure you have a firm grip on
the keel when raising the nose from the flat
position in strong winds.

•

INSERT NOSE BATTEN. Insert the nose batten tail end first and locate it on the fitting on the front of
the keel. A visual check of the nose junction is advisable at this point.

•

PREFLIGHT INSPECTION. You are now ready for the wing pre-flight inspection as outlined in thenext section. It is imperative that you carry out this inspection every time you rig and before you fly.

Issue Date: 1 July 2003

Page 9

AirBorne WindSports- Fun MANUAL

Section 6

PRE-FLIGHT INSPECTION

A thorough pre-flight inspection is mandatory for any aircraft, and the best technique is a circular walk aroundthe wing. The nose area is the ideal place to start your pre-flight check, followed by each assembly point.
Keep in mind the three most critical set up areas:•••

The nose quick clip
Control bar base tube connecters.
The cross bar tension quick clip.

Starting at the nose we suggest the following checklist (ensuring all bolts and fasteners have the appropriate
thread protruding beyond the nut).
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•

Check the nose plate assembly ensuring that the king post wire is not kinked. Sight along both
leading edges checking for similar curves.
Walk towards the tip feeling for dents in the leading edge.
Check cross bar/leading edge junction through the zipper access.
Check sail tip webbing is undamaged and is located properly on the fitting. Ensure velcro is in place.
Crouch down and lift tip to eye level to inspect the tip strut and dive stick are properly located and thatthe rear leading edge is undamaged.
Walk towards the keel checking all battens are secured and correctly loaded.
Check all reflex bridle attachments are in order.
Check that the cross bar retaining shackle and rear top wire are secured on the quick clip.
Check the rear top rigging and that the reflex bridle carabina is properly closed.
Check king post base.
Repeat the above steps for the other side wing in reverse order.
Check all lower rigging is correctly routed and free from damage. The most likely area for damage on
wires is around the swage and thimble area.
Check Control Bar corners are correctly assembled with pip pin and cover in place.
Ensure hang loop is positioned correctly, secure and in good order.
Check control bar top assembly and ensure that the down tubes are straight.
Check cross bar hinge and retaining strap. Ensure cross bar ball and socket is properly located andcover is not caught in the joint.
Clip your harness into the main and back up hang loops and perform a “hang check”. Make sure thatyour harness is the correct distance from the base bar, your leg loops are secure and your carabina
is locked.

Hang Glider Daily Inspection
Inspection of the following items after every assembly of the glider is required:
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•

Check for bends, dents, scratches in all tubes;
Check wire ends for bolt and/or other fastener security;
Check wires for twisted or jammed thimbles;
Check wires are free of kinks, frays, abrasions, broken strands etc;
Nose plate connections;Tips secure;
Battens secure;A-frame connections at the top and base on both sides;
Rear keel connections;
Cross-bar tension wire;
Cross-bar (free floating);
King post connections;
Reflex Bridles - attached and tension correct;
Sail condition;
Harness straps and webbing secure, height adjustment correct;
Emergency parachute secure, attached and operating handle accessible.

Issue Date: 1 October 2001

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AirBorne WindSports- Fun MANUAL – Rev 1

Section 7

BREAK DOWN PROCEDURE

To break down your Fun, just reverse the set-up procedure steps as described. Included here are a few
guidelines to follow which will save you time and prevent potential wear areas on your sail.
It is possible to leave the nose batten in during daily operations!
•Remove tip struts and two tip battens.

•

Let off the sail tension and pull each wing in slightly. Pull out all main sail battens.

•

Disconnect reflex bridle and attach rear quick clip padding.

•

Fold both wings in symmetrically, bringing both leading edges back at the same time. Disconnect
carbon washout rods.

•

Roll the sail up from the last reflex bridles. Roll the reflex bridles into the sail. This will avoid tanglingof the bridles during the set up procedure. One tie should be wrapped around the keel and leadingedge to hold them together whilst the other side wing is rolled.

•

Place padding over the end of the keel.

•

Place glider bag in position.

•

Roll glider over, undo control bar pip pin. Fold base bar rearward. Attach base bar padding arounddown tube base. Place padding over the end of the base bar. Undo the two center ties and fold thecontrol bar down between the leading edge pockets. Secure the center ties and zip up bag.

For de-rigging flat. Undo nose wires and pull wing forward. Follow steps as above.
If resistance is encountered during any phase of set up or break down procedure stop andinvestigate.

Issue Date: 1 July 2003

Page 11

AirBorne WindSports- Fun MANUAL

Section 8

ASSEMBLY FROM SHIPPING LENGTH

If your Glider was delivered to you in the short pack form the following procedure should be used.
•
•
•
•

•

•

Unzip bag and remove ties. Remove all padding from the tube ends.
Assemble the control frame. Rotate the glider on to the control bar, lying flat on the ground.
Spread both leading edges approximately ½ metre. Remove the tip bags which have been used asprotection on the rear of the front leading edges.
Check rear leading edge bungs for R (right) and L (left). Insert rear leading edges in the appropriate
side of the front leading edge with the slot on the rear leading edge facing horizontally. Push on theleading edge and rotate slightly to ensure it is located correctly. It should be impossible to rotate theleading edge if correctly installed.
You are now ready to tension the sail. Prior to tensioning ensure the wash out rods are through thesail hole. There are two webbing loops on the tip of the sail. The inside loop is for the sail tension andthe outward loop is used to apply tension to locate the primary sail tension loop. Place one hand on
the rear of the leading edge and the other through the tensioning loop. Pull sail firmly until the inside
loop is located on the end of the leading edge fitting. Ensure the webbing is centrally located. Secure
velcro tabs on the inside of the leading edge. Repeat for the other leading edge.
Your glider can now be fully assembled as outlined in the Set Up Procedure.

Breakdown For Shipping
Reverse the procedure above ensuring that all possible wear points are padded.
Be sure to remove the nose batten from the sail and place in batten bag. Be careful when folding the sail toavoid damage.
When you have finished packing the glider, place the front of the glider bag over the rear of the short packed
glider. Zip up bag carefully and place the rest of the bag inside the package. The bag is installed back tofront because it is tapered and the glider is bulkier at the rear when short packed.

Issue Date: 1 October 2001

Page 12AirBorne WindSports- Fun MANUAL – Rev 1

Section 9

FLIGHT TECHNIQUE

Take Off..Don’t forget to hook in...
The Fun has a slightly tail heavy static balance and is very easy to launch. Hold the nose in a slightly elevatedposition with the wings level, run hard keeping the nose at the same angle.
It is important that the pilot accelerates smoothly during the launch run. A rapid acceleration willcause the nose to rise sharply with the risk of stall on launch.

Turns
The Fun can be easily directed into a turn even at slow speeds, however for a fast roll rate and easier
handling, it is best to pull on a little extra flying speed.
The Fun will maintain a turn until the turn is removed by pilot input. Allow yourself plenty of margin for safety.
Don’t fly too slowly when scratching close to the hill.

StallsWhen practising stalls make sure you have sufficient altitude. Push out slowly (approx 1 mph per sec. speed
reduction), the glider will tend to mush without dropping a wing. The sink rate will increase in this mush mode
more than two fold.
If you push out faster the nose will pitch higher, this is followed by a gentle pitch down until the glider regains
flying speed and recovers from the stall.
Never stall the glider with the nose pitched up too high. This is a dangerous manoeuvre and can result in a
tail slide and severe tumble. As a guideline, the angle at which the glider stalls is about the same as the angle
it will recover.
If you push out too much in a turn the glider will turn tighter unless you are flying very slow, in which case you
may tip stall. So keep on a little extra speed in turns until you get used to the glider.

Spins
The Fun will resist spinning. If you do stall a wing in a turn and enter the initial stages of a spin, move yourweight forward and to the high side of the rotation and the glider will recover.

Thermalling
The optimum speed for thermalling is a little above stall speed, it may be necessary to fly faster than this inrough conditions to maintain good control. Depending on the nature and area of the thermal a bank angle ofbetween 10 and 50 degrees can be used.

Landing
Landing is easy in the Fun.
Your final approach should be a straight glide into the wind faster than trim speed, approx 25 mph (40 km/h).
Reduce air speed slowly keeping wings level.
When the glider reaches trim speed a full flare is required. Flare aggressively holding the uprights out and up.
It is important that the pilot does not swing the legs forward whilst flaring. This results in the pilot’s
centre of gravity moving forward which will cause the nose to drop.
In strong wind it is possible to fly the glider onto the ground slowing up gradually. Be careful not to push out
too hard in windy conditions.

Issue Date: 1 July 2003

Page 13

AirBorne WindSports- Fun MANUAL

Section 10

TUNINGYour Fun was test flown and delivered to you in good trim. If, however, any adjustments are made to yourglider, we recommend that they be recorded in your maintenance log at the rear of this manual.
If you feel that the glider requires adjustment to trim in the roll or pitch axis you should check that the problem
is not caused by something asymmetrical in the frame or battens. In order of priority, check the following:
•
•
•
•
•

Ensure that the wires, including reflex bridles, are correctly routed;
Check the battens against the profile;
Check that the keel is straight;
Check that the sail is correctly mounted on the leading edges.
Check leading edges are straight and the rear leading edges are located correctly;

Pitch Trim
Standard position of the hang loop is outline in the compliance schedule at the rear of this manual.
To make the glider trim faster move the hang loop forward 10-15 mm. To make the glider trim slower movethe hang loop rearward 10-15 mm. The velcro tensioner should be firm to secure the loop.
A heavier pilot may make the glider trim slower than a lighter pilot. The heavier pilot causes an increase in
twist through extra leading edge flex. The hang loop should be moved forward if this is the case.

Pitch Stability System
Stability in the pitch axis is provided by reflex in the root section. Alterations to the lengths of rigging, airframeor adjustments to the airfoil can have adverse effects on pitch stability.
Reflex bridles provide pitch stability at low angles of attack. Correct attachment and adjustment of the reflex
bridles is essential for maximum stability.
A string line can be used to check the reflex bridles are correct. The line should be firmly stretched between
the reflex bridle attachment eyelet on corresponding battens on the right and left side of the glider. Check themeasurement from the string line to the top of the keel. The glider should be standing on the control
frame. It is important to support the keel off the ground from the rear flying wire attachment point
otherwise the keel will flex and the measurements will be incorrect.
String tension and measurement technique will cause variations of +/- 10 mm. This tolerance should beconsidered when checking against the chart below.

Issue Date: 1 October 2001

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AirBorne WindSports- Fun MANUAL – Rev 1
Bridle Checking Specifications
REAR OF GLIDERREFLEX LINE
ATTACHMENTREAR OF KEEL

4545.TCW

Fun 160

Fun 190

Fun 220

BattenNumberAbove Keel
MetricAbove Keel
Imperial

Above Keel
MetricAbove Keel
Imperial

Above Keel
MetricAbove Keel
Imperial

1

245 mm

9.7 “

225 mm

8.9 “

245 mm

9.6 ”

2315 mm

12.4 “350 mm13.8 “325 mm12.8 “

3

385 mm15.2 “

465 mm18.3 “

385 mm15.2 “

4

N/A

N/A

430 mm16.9 “

425 mm16.7 “Issue Date: 1 July 2003

Page 15

AirBorne WindSports- Fun MANUAL
Roll/Yaw Trim
Through time and use it is possible that you glider may become “unbalanced”. The glider may turn one way orroll into a bank easier in one direction than the other. It is possible that the cloth may stretch asymmetrically if
the pilot, over an extended period of time, consistently thermals in one direction. Hard landings or high “G”
loads may also cause abnormal cloth stretch.
There are a couple of methods, which can be used to remedy a turn in your glider. It is important that you
check the points at the beginning of this section before attempting the following adjustments.
•

TIP PLUG ADJUSTMENT. The tip plug can be rotated to increase or decrease lift on either wing. To
remove a persistent turn the fast wing should have the tip fitting rotated upward to decrease the lift onthat side. To remedy a right hand turn, for example, rotate the left-hand tip fitting anti-clockwise ifviewed from the rear of the leading edge. The tip fitting should be rotated a maximum of 5 mm fromthe standard position. The right side can be rotated anti-clockwise if the turn persists.
The rivet retaining the tip fitting should be drilled out. The fitting should be drilled when adjustment ismade and a new rivet installed.
Ensure that the sail velcro is secure after sail is re tensioned.

•

DIFFERENTIAL BUNGIE TENSIONING. The tension can be increased on the tip strut and tip
battens to remove a turn. The increase in tension flattens out the sail, which causes more lift. Thisshould be attempted on the slow wing. To remedy a right hand turn, for example, the tension should
be increased by re tying the knot in the bungie closer to the sail.

NB If the glider turns to the right we refer to the right wing as the slow wing.

Issue Date: 1 October 2001

Page 16

AirBorne WindSports- Fun MANUAL – Rev 1

Section 11

PERIODIC INSPECTIONS and MAINTENANCE

Maintenance Schedule
1 - Clean and service, 2 - Check as directed, 3 - Check for security, cracks, wear and faulty operation, 4 Remove, inspect and replace ifnecessary, 5 Recommend replacement or overhaul.
MAINTENANCE REQUIREMENT

Maintenance Period
Period >Daily

Flying Days >1Monthly Three
Six
Months Monthly

Every
Year

Every 2 Every 4
Years Years

10

30

50

100

200

400

Wing Fabric deterioration and tears

2

2

2

2

4

5

Wing Fabric Stitching

2

2

2

2

2

Wing Fabric attachment points

3

3

3

3

3

3

Batten Elastics

3

3

3

3

4

4

Check Battens against template supplied

2

2

2

2

2

2

3

3

4

4

5

5

2

2

2

4

4

4

2

4

4

4

Wing wires and attachment fittings

2

Check leading edges, keel & A Frame for straightness, dents andcorrosion
Remove leading edges, cross bar, keel & A Frame structural members
and check for fatigue cracks radiating from drilled holes.
Check reflex bridle for kinks

2

2

2

2

2

2

2

Check Inspection Zips

2

2

2

2

2

2

All bolts, nuts, washers & safety pins. At least one thread showing
outside each nut.

2

2

2

2

2

2

Check hang straps and karabiners for wear or damage

2

2

2

4

5

5

Check Saddles and fittings for cracks

2

2

2

4

4

5

Check Security of King Post Base.

2

2

2

2

2

2

2

Check Bottom Down Tube fitting and security of grub screws

2

2

2

2

2

2

2

It is recommended that:(a) those items marked 1,2 and 3 be performed by the owner of the glider;(b) those items marked 4 be performed by the owner in conjunction with another pilot; and(c) those items marked with a 5 should be performed by Airborne or an accredited Airborne service
agent.

Log Book
When maintenance is performed always check appropriate square and make an entry in the maintenance log
at the rear of this manual.

Issue Date: 1 July 2003

Page 17

AirBorne WindSports- Fun MANUAL

Notes on Periodic Inspections
Airframe Tubing•••

INSTALLATION & REMOVAL. When removing tubing do not bend or force tubes. When installing
do not distort tubing from its original shape.
INSPECTION. Inspect tubing for cracks, damage from abrasion, elongated holes or distortion in tube
surface. Never attempt to repair tubing, always replace with new part. Inspect tubing for corrosion in
and out. If corrosion is present the component should be replaced.
REPLACEMENT. Aluminium tube comes in many different sizes and grades. It is important that thecorrect replacement parts are used.

Bolts
•
•

INSTALLATION & REMOVAL. After tightening, all bolts should have at least one and a half to two
threads showing. All self-locking nuts should not be installed more than two times. Be sure not toover-torque bolts when installing.
INSPECTION. Check bolts for worn shanks, bad threads or corrosion.

Sails
CONTINUED EXPOSURE TO SUN DRAMATICALLY SHORTENS THE LIFE OF SAILS••INSPECTION. Check for tears in the sailcloth or any loose or unravelled seams. Check all inspection
zippers to see if they function smoothly and close completely. Inspect tip webbing for damage.
REPAIR. The sail may be repaired with appropriate sail tape or a sewn on patch. Airborne or an
authorised agent should be consulted about sail repairs. Keep the sail clean of oil and dirt bywashing the sail with soap and water. Keep the sail covered when not in use.

Inspection after Hard Landing
It is necessary to do a detailed inspection following any unusual stressing of the Hang Glider this fullinspection should include all details listed for six monthly maintenance.
The inspection should be noted in the logbook, and any replacement to be recorded.

Defect Reports
Details of any defect which develops in service and which, if kept uncorrected, would compromise thecontinued safe operation of the hang glider should be reported to Airborne as soon as practicable.

Issue Date: 1 October 2001

Page 18

AirBorne WindSports- Fun MANUAL – Rev 1

Section 12

TRANSPORTATION AND STORAGE

Avoid damage to your glider by using well-padded racks.
We recommend that you support the glider in at least 3 places to spread the load.
Flat straps should be used for tie downs to avoid damage to leading edge mylar.
Store the glider in a dry room off the ground. Air the glider out regularly to avoid mildew, and never store wet.

SAFE FLYINGTEAM AIRBORNE

Issue Date: 1 July 2003

Page 19

AirBorne WindSports- Fun MANUAL

Section 13

Date

Issue Date: 1 October 2001

MAINTENANCE RECORD

Details of Repairs or Maintenance

Carried out by.

Page 20

AirBorne WindSports- Fun MANUAL – Rev 1

Section 14

HANG GLIDER COMPLIANCE SCHEDULES

Fun 160
GLIDER MODEL: Fun 160
MANUFACTURED BY: AIRBORNE WINDSPORTS Pty Ltd
NOTE: These specifications are intended only as a guideline for determining whether a given glider is acertified model and whether it is in the certified configuration.
Be aware, however, that no set of specifications, however detailed, can guarantee the ability to determine
whether a glider is the same model, or is in the same configuration as was certified, or has those
performance, stability, and structural characteristics required by the certification standards. An owner’s
manual is required to be delivered with each HGMA certified glider, and it is required that it contain additional
airworthiness information.

MetricImperial

19.0 kg

42 lbs

Nose Plate anchor hole to crossbar plate attachment hole

3130 mm123.23”

Nose Plate anchor hole to rear sail attachment point

5235 mm206.10”Outside diameter at nose

50 mm

1.97”

Outside diameter at cross bar

52 mm

2.05”

Outside diameter at rear sail attachment point

50 mm

1.97”

Overall pin to pin length from leading edge attachment point to hingebolt at glider centre line

2755 mm

108.46”Largest outside diameter

62 mm

2.44”

1270 mm50.00”

1475 mm
1525 mm58.07”
60.04”

Chord length at 3 ft outboard of centre line

2100 mm82.68”

Chord length at 3 ft inboard of tip

1225 mm48.23”

Span (extreme tip to tip)

9075 mm

357.28”Weight of glider with all essential parts and without cover bags and non essential
parts.
Leading Edge Dimensions

Crossbar Dimensions

Keel dimensions 1
The cross bar centre load bearing pin
The pilot hang loop

Fwd
Rear

Sail Dimensions

Location of Information Placard

Cross Bar

Location of Test Fly Sticker

Front Keel

Recommended Pilot Hook in Weight Range

50-75 kg
NoviceMinimum Recommended Pilot Proficiency

110-198 lbs
NoviceNB: Conversions * 0.4536 kg/pound * 25.4 mm/inch

1

least and greatest allowable distances, whether variable through tuning or through in-flight variable geometry, from the line
joining the leading edge nose bolts to:

Issue Date: 1 July 2003

Page 21

AirBorne WindSports- Fun MANUAL

Fun 190
GLIDER MODEL: Fun 190
MANUFACTURED BY: AIRBORNE WINDSPORTS Pty Ltd
NOTE: These specifications are intended only as a guideline for determining whether a given glider is acertified model and whether it is in the certified configuration.
Be aware, however, that no set of specifications, however detailed, can guarantee the ability to determine
whether a glider is the same model, or is in the same configuration as was certified, or has those
performance, stability, and structural characteristics required by the certification standards. An owner’s
manual is required to be delivered with each HGMA certified glider, and it is required that it contain additional
airworthiness information.

MetricImperial

23.0 kg

51 lbs

Nose Plate anchor hole to crossbar plate attachment hole3530 mm

138.98”

Nose Plate anchor hole to rear sail attachment point

5810 mm

228.74”

Outside diameter at nose

50 mm

1.97”

Outside diameter at cross bar

52 mm

2.05”

Outside diameter at rear sail attachment point

50 mm

1.97”

Overall pin to pin length from leading edge attachment point to hingebolt at glider centre line

3100 mm122.05”Largest outside diameter

62 mm

2.44”

1455 mm

57.28”

1600 mm
1650 mm62.00”
64.96”

Chord length at 3 ft outboard of centre line

2280 mm

89.76”

Chord length at 3 ft inboard of tip

1225 mm48.23”

Span (extreme tip to tip)

10100 mm

397.63”Weight of glider with all essential parts and without cover bags and non essential
parts.
Leading Edge Dimensions

Crossbar Dimensions

Keel dimensions

2

The cross bar centre load bearing pin
The pilot hang loop

Fwd
Rear

Sail Dimensions

Location of Information Placard

Cross Bar

Location of Test Fly Sticker

Front Keel

Recommended Pilot Hook in Weight Range

70-120 kg

154-265 lbs

Minimum Recommended Pilot Proficiency

NoviceNoviceNB: Conversions * 0.4536 kg/pound * 25.4 mm/inch

2

least and greatest allowable distances, whether variable through tuning or through in-flight variable geometry, from the line
joining the leading edge nose bolts to:

Issue Date: 1 October 2001

Page 22

AirBorne WindSports- Fun MANUAL – Rev 1

Fun 220
GLIDER MODEL: Fun 220
MANUFACTURED BY: AIRBORNE WINDSPORTS Pty Ltd
NOTE: These specifications are intended only as a guideline for determining whether a given glider is acertified model and whether it is in the certified configuration.
Be aware, however, that no set of specifications, however detailed, can guarantee the ability to determine
whether a glider is the same model, or is in the same configuration as was certified, or has those
performance, stability, and structural characteristics required by the certification standards. An owner’s
manual is required to be delivered with each HGMA certified glider, and it is required that it contain additional
airworthiness information.

MetricWeight of glider with all essential parts and without cover bags and non essential
parts.

Imperial

28.0 kg

62.0 lbs

Nose Plate anchor hole to crossbar plate attachment hole3730 mm

146.85”

Nose Plate anchor hole to rear sail attachment point

6240 mm245.70”Outside diameter at nose

50 mm

1.97”

Outside diameter at cross bar

52 mm

2.05”

Outside diameter at rear sail attachment point

50 mm

1.97”

Overall pin to pin length from leading edge attachment point to hingebolt at glider centre line

3280 mm129.13”Largest outside diameter

62 mm

2.44”

1480 mm

58.27”

1650 mm1700 mm65.18”
66.99”

Chord length at 3 ft outboard of centre line

2400 mm

94.49”

Chord length at 3 ft inboard of tip

1225 mm

Span (extreme tip to tip)

10800 mm48.22”
425.10”

Leading Edge Dimensions

Crossbar Dimensions

Keel dimensions

3

The cross bar centre load bearing pin
The pilot hang loop

Fwd
Rear

Sail Dimensions

Location of Information Placard

Cross Bar

Location of Test Fly Sticker

Front Keel

Recommended Pilot Hook in Weight Range

85-160 kg

187-353 lbs

Minimum Recommended Pilot Proficiency

NoviceNoviceNB: Conversions * 0.4536 kg/pound * 25.4 mm/inch

3

least and greatest allowable distances, whether variable through tuning or through in-flight variable geometry, from the line
joining the leading edge nose bolts to:

Issue Date: 1 July 2003

Page 23

AirBorne WindSports- Fun MANUALFun X/Bar Hinge Pull Back Assembly
Fun X/Bar Hinge Pull Back Assembly
Dwg No A4-4644 20/09/2001
Id Part No

Details1103360103361

PULL BACK WIRE 1515 F190
PULL BACK WIRE 1670 F220

FUN160

FUN190

FUN2202

12103502

PULL BACK WIRE 1435 F160

22101900

PULL BACK COVER NEOPRENE

1

1

1

3

101192

CABLE TIE (SHORT) 98MM

1

1

1

4

102018WASHER SS 1/4 X 3/4"

2

2

2

5

101055

NYLON WASHER M 6 XOD

2

2

2

6

101333AN4-13A

1

1

1

7

100035

AN4 NUT HALF NYLOC

1

1

1

8

101765

PULL BACK STRAP HANDLE 305

1

1

1

9

102021SHACKLE PULL BACK

1

1

1

10

103373

X/BAR F190

2

1103374

X/BAR F220

103530

X/BAR F160

211102449X/BAR BALL SKT TYPE 2

1

1

1

12

102409X/BAR BALL TYPE 2

1

1

1

13

100629AN3-30A BOLT

2

2

2

14

100011

AN4-30A

2

2

2

15

102424

NYLON WASHER 1/4" OBA THICK

4

4

4

16

100042

AN4 WASHER

2

2

2

17

100034AN4 NUT FULL NYLOC

2

2

2

18

103286

X/BAR STRAP TANG 280

1

1

1

19

100049AN3 WASHER

4

4

4

20

100051AN3 NUT FULL NYLOC

2

2

2

22

100015AN5-15A

1

1

1

23

100804

X/BAR BOLT COVER - NO SLOT

1

1

1

24

100595

NYLON WASHER M 8 STD

2

3

3

25

100604

CAP WASHER BASE CLIP 5/16

1

1

1

26

100603

CAP WASHER COVER BLACK M8

1

1

1

27

100037AN5 NUT HALF NYLOC

1

1

1

Issue Date: 1 October 2001

1

2
1

Page 24

AirBorne WindSports- Fun MANUAL – Rev 1

Section 15

ASSEMBLY DRAWINGS

A4-4644 Fun X-Bar Hinge Assembly

ALL PARTS ASSEMBLED TO MAKE AIRFRAME

9

8

5

6

5

4

7

4
1

3

2

26

17

22

16

13

25

13

19

24
15

24
23
27

REAR VIEW

15

10
19
Xbar Strap 18
20

TOP VIEW
12

14
Rev

AMENDMENTS

11

Date

AIRBORNE WINDSPORTS
ALL DIMENSIONS IN MILLIMETRES

Issue Date: 1 July 2003

Drawn By

Scale

Date

Rick

1:2.5

03/11/98

FUN X/BARHINGE ASSEMBLY

PTY
LTD

A4-4644

Page 25

AirBorne WindSports- Fun MANUALFun X/Bar to L/edge Junction
Fun X/Bar to L/edge Junction
Dwg No A4-4654 20/09/2001
Id

Part No

Details1103373

X/BAR F190

103374

X/BAR F220

103530

X/BAR F160

103370L/EDGE FRONT F190

103513

L/EDGE FRONT F220

103514

L/EDGE FRONT F160

1

3102006

X/BAR MOUNT CHANNEL

2

2

2

4

102271SADDLE TO SUIT 45MM TUBE

4

4

4

5

100080SADDLE TO SUIT 60MM TUBE

2

2

2

6

100965AN5-41A

103668AN4-42A

2

2100034AN4 NUT FULL NYLOC

6

6100037AN5 NUT HALF NYLOC

103406TOP SIDE WIRE HG 3305 F190

103509TOP SIDE WIRE HG 2935 F160

103526TOP SIDE WIRE HG 3510 F220

103398SIDE BOTT WIRE HGT 2860 1/8"

2

7
8

9

FUN160

FUN190

FUN220

1
1
1
1
1

2

6
1
1
1
2

2
2

103500SIDE BOTT WIRE HGT 2480

2

10100820

NYLON WASHER M 8 XOD

2

2

11

100009AN4-26A

4

4

4

12

103289VELCRO 50MM LOOP/BLACK ADHESIVE

0.24

0.24

0.3

13

100042

AN4 WASHER

4

4

4

14

100549AN4-22A

2

15100035

AN4 NUT HALF NYLOC

2

Issue Date: 1 October 2001

Page 26

AirBorne WindSports- Fun MANUAL – Rev 1
A4-4654 Fun X-Bar To L/E Assembly

6

7

7

13

13

TOP VIEW

81

4(RIGHT HAND SIDE)MOUNT CHANNEL ON OTHER SIDE
OF L/EDGE FOR LHS

8FRONT
LEADING
EDGE

15
5
10
2

FRONT
LEADING
EDGE
39SIDE VIEW

REAR L/EDGE LOCATORBOLT FOR 220 ONLY
14
11

120

30

7
12

12

PTY
LTD

ALL DIMENSIONS IN MILLIMETRES
Drawn byScale
Date
20/11/98
RICK
HALF SIZE

Issue Date: 1 July 2003

Page 27

AirBorne WindSports- Fun MANUAL

Fun Nose Junction Assembly
Fun Nose Junction Assembly
Dwg No A4-4653 20/09/2001
Id Part No

Details

FUN160

FUN190

FUN2201

100009AN4-26A

3

3

3

2

100042

AN4 WASHER

3100034AN4 NUT FULL NYLOC

3

3

1

4

102460NOSE PLATE HANG GLIDER 3MM

2

2

2

5

102271SADDLE TO SUIT 45MM TUBE

46106152QUICK CLIP ASM 75MM

1

1

1

7

103368KEEL TUBE ASSEM FUN 190

103604KEEL TUBE ASSEM FUN 160

103609KEEL TUBE ASSEM FUN 220

103370L/EDGE FRONT F190

103513

L/EDGE FRONT F220

103514

L/EDGE FRONT F160

2

8

2

1
1
1
2
2

9

101055

NYLON WASHER M 6 XOD

10

10

10

10

100915

NUT NYLOC M 8

1

1

1

11

100043AN5 WASHER

1

1

1

12

100035

AN4 NUT HALF NYLOC

13100595

NYLON WASHER M 8 STD

15103408TOP FRNT WIRE HGWR 3870 F190

103409TOP FRNT WIRE HGWR 4090 F220

103506TOP FRNT WIRE HGWR 3505 F160

Issue Date: 1 October 2001

2
2
1
1
1

Page 28

AirBorne WindSports- Fun MANUAL – Rev 1
A4-4653 Fun Nose Junction Assembly

15
1

10

12

10

11

9
4
9

9

7

13

5
8

Saddles on
Fun 160 only
94
9SAIL TANG
220 ONLY

7

9

2

13

220 ONLY
H NUT 220
F NUT 160 / 190

1

6

1

SIDE VIEWFRONT VIEW

Rev

AMENDMENTS

Date

AIRBORNE WINDSPORTS

Issue Date: 1 July 2003

Drawn By

Scale

Date

Rick

1:2.5

14/10/98

FUN NOSE
JUNCTION ASSEMBLY

PTY
LTD

A4-4653

Page 29

AirBorne WindSports- Fun MANUAL

Fun A Frame Top Assembly
Fun A Frame Top Assembly
Dwg No A4-4655 20/09/2001
Id

Part No Details

1100310SHOCK CORD 4MM

0.9

2102379ENDCAP FOR 42MM TUBE LUG WITH HOLE

1103628ENDCAP TO SUIT 50X.9MM TUBE

103278QUICK CLIP ASM 65MM

3

FUN160

FUN190

FUN220

FUN_160 FUN_190 FUN_220
1.05

1.2

1

1

1

106152QUICK CLIP ASM 75MM

1

1

4

101765

PULL BACK STRAP HANDLE 305

1

1

1

5
6
7
8

100042100915100043102271

AN4 WASHER
NUT NYLOC M 8
AN5 WASHERSADDLE TO SUIT 45MM TUBE

2
4
3

2
4
3

1
2
4
3

10
11

103362
100009100587A FRAME SS TOP BRACKET FUN TYPE 1
AN4-26A
AN4-24A

1

1
1

1
1

12

AN3-23A BOLT
AN3-21A BOLT
AN4 NUT FULL NYLOC

1

1

13

100558101184100034

1
1

1

1

14
15
16

100051103358102332AN3 NUT FULL NYLOC
BOLT M8 A/FRAME TOP HG 53MMWASHER SS 5/16 X 3/4"

1
1
2

1
1
2

1
1
2

18
19
20

103365100967103404

K/POST BRACKET SS TYPE 2
AN4-15A
K/POST HG 1200 TYPE 2 - NO SLEEVE

1

1

1

21

103610103948100035

K/POST HG 1100 TYPE 2
K/POST HG 1290 TYPE 2 - WITH SLEEVE
AN4 NUT HALF NYLOC

104083
104084103999

D/TUBE TOP KNUCKLE 28X1.6 HG TYPE 2
D/TUBE TOP KNUCKLE 28X2 HG TYPE 2
D/TUBE TOP KNUCKLE FAIRED HG TYPE 2

1104083

D/TUBE TOP KNUCKLE 28X1.6 HG TYPE 2

1

24
26

104084102015102020

D/TUBE TOP KNUCKLE 28X2 HG TYPE 2
SPRING CLIP 1 PIN TYPE 1
NEOPRENE D/TUBE CVR

2
1

1

1

27
28
29

106047106138100602

K/POST HEAD PLUG
K/POST HEAD COVER
CAP WASHER COV WHITE 5/16

1
1
2

1
1
2

1
1
2

30
31

100604103368103604

CAP WASHER BASE CLIP 5/16
KEEL TUBE ASSEM FUN 190
KEEL TUBE ASSEM FUN 160

2

2
1

2

103609104611KEEL TUBE ASSEM FUN 220
KEEL TUBE ASSEM FUN 220 TYPE 2

22
23

32

Issue Date: 1 October 2001

1

1

1
1

1

1
1

1

1
1
1
2
1
2

2

1
1
1

Page 30

AirBorne WindSports- Fun MANUAL – Rev 1
A4-4655 Fun Keel Assembly
FRONT TO REAR WIREABOVE SIDE WIRES11

TOP SIDE WIRES

11

12

CONSTRUCTION DETAILSFOR FUN 220, FROM #42 ON. (09/01)
FRAME TOP MOVED 100mm FORWARD
D/TUBE TOP KNUCKLE MODIFIED

18

TOP VIEWFRONT TO REAR WIRE

33

8

28
FRONT TO REAR WIRETOP SIDE WIRES
8

31
13

10

27
20

14
GRANNY KNOT

13

5

20

1

FRONT TO REAR WIRE

26

11

29
30

19

21

4

12

3
18

18
16

15

16

32

7

8

6

10

8
24

22

2

24

7

8

SAIL TANG

23 -Type 2 used on 220 FUN

10BOTTOM REAR
WIRES

31

7
6

14

13

VIEW FROM FRONT OF GLIDERSIDE VIEW
Rev

AMENDMENTS

1

FRAME TOP MOVED (FUN 220)

Issue Date: 1 July 2003

AIRBORNE WINDSPORTS

Date

Drawn By

Scale

Date

Mollo

QUARTER SIZE

13/10/98

FUN KEELASSEMBLY

PTY
LTD

A4-4655

Page 31AirBorne WindSports- Fun MANUALHG AFrame Faired Corner Unit Assembly Type 2

HG AFrame Faired Corner Unit Assembly Type 2
Dwg No A4-7237 20/09/2001
Id

Part No

Details

1103957

D/TUBE A/FOIL SILVER 1700 SLEEVED

FUN2202

2103988

D/TUBE BTM KNUCKLE FRD LHS 1/4" HOL

1

3

103989

D/TUBE BTM KNUCKLE FRD RHS 1/4" HOL

1

4101713

C/BAR KNUCKLE HG TYPE 226101745

BOLT M6 D/TUBE BOTTOM KNUCKLE

2

9100950LOCKING RING 12MM RF1142

13104001

CLEVIS PIN 1/4"X 1 1/16"

2

14101055

NYLON WASHER M 6 XOD

416103393

FRNT FLYING WIRES HG 2225 NO THYMBL

1

17101449REAR FLYING WIRE HGNT 2075

1103949REAR SINGLE FLYING WIRE F2202

18106172SKT BUTTON SCREW M5 X 10419100055WASHER SS 3/16 X 7/16" 304 FLAT

4

20106171A FRAME LOCK SHAFT 20MM

2

21

100035

AN4 NUT HALF NYLOC

1

22100042

AN4 WASHER

1

23102737

SPEED BAR TYPE 2 1400 W/OUT CLEAT

1103525

C/BAR STRAIGHT 28X2 INC GRIPS 1640

1

24101333AN4-13A

1

25106050PIP PIN 33 WITH CAP

1Issue Date: 1 October 2001

Page 32

AirBorne WindSports- Fun MANUAL – Rev 1
A4-7237 HG A-Frame Faired Corner Unit Assembly
ALL PARTS ASSEMBLED TO MAKE WING
LEFT HAND SIDE KNUCKLERIGHT HAND SIDE KNUCKLE
1

13

13

8

NOTE:
CLEVIS PIN AND RING USEDONLY ON TANDEM GLIDER

9

17

17

9

16

16
19

20

3

19

18

18
6

2

6
V.G PULLEYOPENING
31 PULLEYBEARINGS

5
4

14

14

NOTE: TYPE AB FAIRED CORNERUNITS HAVE AIRBORNE ON CASTING

7
4

14

25

KEEL

NOTE:
MATERIAL LIST ITEM 32
CLIMAX STREAMLINE OPTION

30

27

28

ASSEMBLY DETAIL
1. THE WIRES ARE FITTED INTO THE FAIRED KNUCKLES FIRST WITH THE LOCKING SHAFT,
2 WASHERS & 2 SCREWS HOLDING THEM IN PLACE (NOTE : USE LOCTITE 262)
2. THERE IS A LEFT & RIGHT HAND SIDE KNUCKLE AND WHEN
3. THEN THE V.G ROPE MUST BE INSERT THROUGH THE RIGHT DOWNTUBE.
4. THE KNUCKLES CAN BE FITTED TO THEIR DOWNTUBES,NOTE: GUIDE THE V.G ROPE THROUGH THE V.G PULLEY OPENING
5. FIT THE A-FRAME CORNER KNUCKLES & SIDE WIRES TO THE FAIRED KNUCKLES.
6. THE SOCKET SCREW HOLDS THESE COMPONENTS IN PLACE.
REMEMBER TO INSERT THE V.G ROLLER IN TO THE PULLEY. (NOTE : USE LOCTITE 262).

Issue Date: 1 July 2003

21

24

22
BASE BAR
CLEAT TO REAR

29

23

26
CLIMAX ONLYPTY

ALL DIMENSIONS IN MILLIMETRESUNLESS STATED OTHERWISE

Drawn by

Scale

Date

JADY

HALF SIZE

28-5-91

AirBorne WindSports LTD
HG A-FRAME FAIRED CORNER
UNIT ASSEMBLY TYPE AB

A4-7237

Page 33

AirBorne WindSports- Fun MANUALHG SA Frame Corner Unit Assembly Round TypeHG SA Frame Corner Unit Assembly Round TypeDwg No A4-4651 20/09/2001
Id Part No

Details1

103401

D/TUBE ROUND TYPE 2 28X2 1645

103524

D/TUBE ROUND TYPE 2 28X1.6 1480

103391

D/TUBE BTM KNUCKLE FOR 28X2 TUBE

2

FUN160

FUN190222103629

D/TUBE BTM KNUCKLE FOR 28X1.6 TUBE

2

4101713

C/BAR KNUCKLE HG TYPE 2

2

2

6

100547

AN4-12A2

2

13102015SPRING CLIP 1 PIN TYPE 1

2

2

14

100624

MYLAR WASHER

4

4

16

103392FRNT FLYING WIRES HG 2160 NO THIMBL

103487FRNT FLYING WIRES HG 1945 NO THIMBL

103399REAR FLYING WIRE HG 2025 NO THIMBLE

103492

REAR FLYING WIRE HG 2115 NO THIMBLE

1

18106172SKT BUTTON SCREW M5 X 10

4

4

20

103403A FRAME LOCK SHAFT 24.5MM

2

2

21

100035

AN4 NUT HALF NYLOC

3

3

22

100042

AN4 WASHER

1

1

23

102210C/BAR STRAIGHT 28X1.6 INC GRIPS 134

1

1

24

101333AN4-13A

1

1

25106050PIP PIN 33 WITH CAP

1

1

17

Issue Date: 1 October 2001

1
1
1

Page 34

AirBorne WindSports- Fun MANUAL – Rev 1
A4-4651 HG A-Frame Round Down Tube Corner Assembly
ALL PARTS ASSEMBLED TO MAKE WING
LEFT HAND SIDE KNUCKLERIGHT HAND SIDE KNUCKLE
1

13

13

17
2

17

2

16

16

20
18

20
18

21

21

6

6

5

14

14

4

4

14

25

21

24

22
ASSEMBLY DETAIL
1. THE WIRES ARE FITTED INTO THE FAIRED KNUCKLES FIRST WITH THE LOCKING SHAFT,
2 WASHERS & 2 SCREWS HOLDING THEM IN PLACE (NOTE : USE LOCTITE 262)
2. THERE IS A LEFT & RIGHT HAND SIDE KNUCKLE AND WHEN
3. THEN THE V.G ROPE MUST BE INSERT THROUGH THE RIGHT DOWNTUBE.
4. THE KNUCKLES CAN BE FITTED TO THEIR DOWNTUBES, NOTEGUIDE THE V.G ROPE THROUGH THE V.G PULLEY OPENING
5. FIT THE A-FRAME CORNER KNUCKLES & SIDE WIRES TO THE FAIRED KNUCKLES.
6. THE SOCKET SCREW HOLDS THESE COMPONENTS IN PLACE.
REMEMBER TO INSERT THE V.G ROLLER IN TO THE PULLEY. (NOTE : USE LOCTITE 262

Issue Date: 1 July 2003

23
ALL DIMENSIONS IN MILLIMETRESPTY

AirBorne WindSports LTD

Drawn by

Scale

Date

MOLLO

HALF SIZE

12/11/98

HG A-FRAME ROUND D/TUBE
CORNER ASSEMBLY

A4-4651

Page 35