Flying Pengu uin RC FPRC ZERO Specificationss Wing Span 42.75 (1085 mm) Fuselage length 30.5 ( 775 mm) Empty Weight 9.5 10 oz. (150 160g) Estimated Flying Weight 20 255 oz. (320 400g) Wing Area: 151 sq. Inch (975 sq. cm) Transmitter: 4 or 5 channel with flaps Brampton, Ontarioo Canada www.flyingpenguinrc.com flyingpenguin@live.ca
CONTENTS Introduction.... 1 Electronics & hardware... 2 Building Materials... 2 Tools.. 2 Assembly instructions 1. Power Core Base Assembly.. 2 2. Rear Fuselage Frame... 7 3. Complete Fuselage Frame....... 8 4. Hardware installation... 11 5. Fuselage Cover.. 13 6. Front Access Cover..... 19 7. Canopy Cover..... 21 8. Wings... 25 9. Rudder / Tail Wing.. 33 10. Wing Reinforcement.. 35 11. Fit Rudder / Tail Wing... 36 12. Air Scoop / Rear panels. 36 13. Landing Gear Option...... 38 14. Final Connections.. 39 Parts Index.. 40 INTRODUCTION 1. Your FPRC Zero should not be considered a toy, but rather a sophisticated, working model that functions very much like a full size airplane. Although the FPRC ZERO is a light weight model, just the same as any R/C plane, it should still be flown with care. Even while gliding at slow speeds, the FPRC ZERO could possibly cause injury to yourself or spectators and damage property. Ultimately, it is the modeller s responsibility to select a suitable, safe flying area. 2. You must assemble the FPRC ZERO according to the instructions. Do not alter or modify the model, as doing so may result in an unsafe or unflyable model. 3. Be patient. You must take the time to build straight, true and strong. 4. You must use an R/C radio system that is in excellent condition. 5. You must correctly install all R/C and other components so that the model operates correctly on the ground and in the air. 6. You must check the operation of the model before every flight to insure that all equipment is operating and that the model has remained structurally sound. Be sure to check connections often and replace them if they show signs of wear or fatigue. 7. If you are not already an experienced R/C pilot, you should fly the model only with the help of a competent, experienced R/C pilot. NOTE: We, as the model designer, provide you with top quality plans and detailed instructions, but ultimately the quality of your finished model depends on how you build it; therefore, we cannot in any way guarantee the performance of your completed model, and no representations are expressed or implied as to the performance or safety of your completed model. Remember: Take your time and follow the instructions to end up with a well built model That is straight and true. If you have not flown this type of model before, we recommend that you get the assistance of an experienced pilot in your R/C club for your first flights. If you re not a member of an R/C club, your local hobby shop has information about clubs in your area whose membership Includes experienced pilots. 1 P age
ADDITIONAL REQUIRED ITEMS ASSEMBLY INSTRUCTIONS Electronics and Hardware Motor: 1200kv / 250w brushless electric ESC: 25 amp brushless speed controller Battery: 2200 mah 3S 11.1V Lipo Pack Servos: (4x) 9 10 gram digital micro servos Propeller: 8x6E or 9x6E Control Horns (x4) Push Rods: 1mm piano wire. (2x 16 & 2x 3.5 ) 1. POWER CORE BASE ASSEMBLY Parts required: 1 5 Building Materials 1. Start with power core base (1) flat on table. Four (4x) sheets foam board / foam core board 3/16 x 20 x 30 (5 x 510 x 760mm) One (1x) sheet poster board 1/8 hobby plywood Two (2x) wood dowels. 1/8 diameter, 5 long. Popsicle Sticks Velcro or rare earth magnets 3/16 dia. or square carbon tube (optional) Tools 2. Apply a thin layer of white school glue or multi purpose craft glue to shaded surface as shown above. X Acto knife & replacement blades Utility knife & replacement blades Metal ruler or straight edge Hot glue gun or CA Adhesive Pen or pencil Drill and small wood bits Clear Packing Tape Small Screwdrivers 3. Fold top surface over. Appling even pressure, hold down until dry. 2 P age
4. Repeat steps 2 and 3 for bottom surface. 6. Apply a thin layer of white school glue or multi purpose craft glue to shaded surface as shown above. Combine parts (2A), as the two parts are identical all edges will align. 7. Repeat steps 5 and 6 for (2B). 5. Next we can combine parts (2A 2A) and (2B 2B). First, use a pen or pencil to mark the center on the edge as shown above. This will help us to align the fuselage cover later. 3 P age
8. Repeat steps 5 and 6 for (4A 5A) and (4B 5B). Apply glue to frame section (5) first then combine with (4). 11. Place a bead of glue in the space as shown above. Fold the side so that it rest on top of the Adjacent surface. 9. Frame sections (5) are slightly smaller than frame sections (4) so align the parts with the square opening and bottom edge. 10. Prepare part (3). Remove foam between 50% cut lines leaving paper on opposite side. A small flat top screwdriver is good for this. 12. Repeat step 11 for the other side. 4 P age
13. Next we can combine parts (1 5) 16. Apply glue to front edge and bottom edges of part (3) as shown above. 14. Place a bead of glue along the top/front edge of the power core base (1). 17. Attach part (3) to top of power core base (1) and to back of frame section (2A) as shown above. Align the inside walls of part (3) with the square opening in front of frame section (2A). 15. Attach frame section (2A) to power core base (1). Align with front edge and center. Make sure frame section (2A) is 90 to power core base (1), hold until dry. 5 P age
19. Apply glue to bottom edge of frame section (2B). Attach to bottom of power core base (1) as shown above. Align with front edge and center. Make sure frame section (2B) is 90 to power core base (1), hold until dry. 18. Apply glue to bottom of frame sections (4A/5A) and to the back edges of part (3) as shown above. Attach frame section (4A/5A) to top of power core base (1) with frame section (5A) facing back. Align with square opening in part (3) and sides of power core base (1). 20. Apply glue to bottom edge of frame section (4B/5B). Attach to bottom of power core base (1) with frame section (5B) facing back as shown above. View from the side and align with frame section (4A/5A) on top. Make sure frame section (4B/5B) is 90 to power core base (1), hold until dry. 6 P age
2. REAR FUSELAGE FRAME Parts required: 6 10 21. Apply a thin layer of white school glue or multi purpose craft glue to one side of frame section (6). Combine parts (6), as the two parts are identical all edges will align 23. Apply a small amount of glue over the tab slot in side frame (7) as shown above. Insert frame section (6) with center line facing the front. 22. Use a ruler and pen or pencil to create a center line on one side of frame section (6). This side will face the front of the frame. 24. Repeat step 23 for frame section (8). 7 P age
above. Insert frame support (9) between frame sections (6) and (8). 25. Apply a small amount of glue in tab slots in frame sections (6) and (8) and to back edge of side frame (7) as shown above. Insert second side frame (7) into frame section (6) and (8). 27. Repeat steps 26 for frame support (10) on the bottom of frame between frame sections (6) and (8) as shown above. Parts required: power core base assembly (1 5), rear fuselage frame (6 10) and parts 11 14. ` 3. COMPLETE FUSELAGE FRAME 26. Apply a small amount of glue on the top center of frame sections (6) and (8) as shown 28. Apply glue to each side of the slot in the back of the power core base (1) about the width of the side frame (7) as shown above. 8 P age
29. Insert ends of side frames (7) into slot at the back of the power core base (1). Make sure the power core base and rear frame top/bottom is oriented correctly. 31. Frame section (11) should rest on top of side frame (7) and beside back of power core base (1) and aligned with edge of side frame (7). Tip: A foam block can be used to steady the frame for the rest of the build process. 30. Apply glue to the bottom edge of frame section (11) and to back edge of power core base (1) above side frames (7) as shown above. 32. Place a bead of glue along the edges of servo plate (12) and across frame section (6) as shown above. Center servo plate (12) with frame section (6). 9 P age
33. Place a bead of glue along the bottom and one side edge of frame support (13) and side frame (11) as shown above. Insert the frame support (13) between frame section (11) & (6). 35. Prepare bottom frame supports (14). Fold part over at the 50% cut as shown above. Apply glue to inside of frame support (14) as shown above. Place flat on table and apply a little down pressure until dry, repeat for second frame support (14). 34. Repeat step 33 for second frame support (13) to opposite side as shown above. 36. Test fit battery before moving to next step. Enlarge battery opening if necessary and use a pencil to trace the sides of the battery on bottom of power core base (1) for reference. 10 P age
5. HARDWARE INSTALLATION 37. Place a bead of glue along the top of frame support (14) and on the side of frame section (5B) as shown above. Insert frame support (14) between frame sections (5B) and (6). 39. Place a small bead of glue of one side of servo and attach second servo facing opposite direction as shown above. 38. Repeat step 37 for second frame support (14) on opposite side. 40. Place servo wires through opening in servo plate (12). Apply a small amount of glue to the bottom of the servo tabs on each side of servos. 11 P age
41. Insert servos into servo plate (12) as shown above. 44. Glue the reinforcement plates to the top and bottom of the power core base (1) as shown above. 42. Glue two straws between small holes in frame sections (6) and (8) as shown above. These will help guide the control rod to the servos later in the build. 43. Use 1/8 hobby plywood or old plastic gift cards to create reinforcement plates for the power core locking holes. 45. Test fit battery and mark location of rear of battery on bottom of power core base (1). 12 P age
5. FUSELAGE COVER Partss required 15 19 47. Prepare the fuselage cover parts (15 19). Lay the parts flat on a piece of foam. (A flat couch cushion works best) and using a rolling pin roll across the part to create a natural curve in the foam as shown above and below. 46. Glue Velcro strips to power core base (1) and to underside of square opening in frame section (5B) as shown above. This will create a battery harness to hold the battery in place during flight. 13 Pag e
49. Dry fit fuselage cover (15) and mark the ends at the bottom center and trim if required. 48. All fuselage cover parts should now have a natural curve as shown above. This will make fitting over the fuselage frame much easier. 50. Trim each edge to create a snug fit. 14 P age
51. Apply a small bead of glue on the center/top of frame sections (2A) and (4A) as shown above. 54. Complete the side by applying glue to the bottom side edges of frame sections (2B) and (4B) as shown above. Hold the fuselage cover (15) in place and hold until dry. 52. Center the fuselage cover (15) between frame sections (2A) and (4A) and align with front as shown above. Make sure the longer side of fuselage cover (15) faces the back. 55. Now move to the opposite side and repeat the process. Start with the top, applying glue to the frame sections and along power core base. Fold over and hold until dry. 53. To glue the frame cover (15) to the frame start with one side. Apply glue to the top edges of frame section (2A) and (4A) and along the side edge of the power core base (1) as shown above. Hold the fuselage cover (15) in place and hold until dry. 56. Finish the bottom area. Apply glue to the side frames and fuselage section (15) edge as shown above. Fold over and hold until dry. 15 P age
Finished Front Fuselage Cover (15) 59. Finish the bottom area. Apply glue to the side edge of frame section (5B) as shown above. Fold over and hold until dry. 57. Next we can attach the center fuselage cover (16). Using the previous process; dry fit first, trim (if required), center and glue to top of frame sections. 60. Repeat steps 58 59 to finish the front half of fuselage cover (16). 58. Start with one side and glue the front half of the fuselage cover first. Apply glue to edge of frame section (5A) and along the side frame as shown above. Fold over and hold until dry. 61. Next, apply glue to the side of frame section (6) and along the side frame as shown above. Fold over and hold until dry. 16 P age
62. Finish the side by applying glue to the side edge of frame section (6) as shown above. Fold over and hold until dry. This will help to strengthen the area where we will install a wood dowel for securing the wing. 63. Repeat steps 61 62 to finish the back half of fuselage cover (16). 65. Repeat the process for rear fuselage cover (18). Dry fit first, trim (if required), center and glue to top of frame. 64. Apply glue to one side of support part (17) and insert inside fuselage as shown above. Center with fuselage cover (16) and repeat for the other side. 66. Do one side at a time. Front half first, starting with top area. 17 P age
67. Glue the bottom area of the front half first. 70. Sand the outer edge of the nose fuselage cover (19) to a bevel shape. 68. Place a small bead of glue on one edge of the bottom / back of fuselage cover (18). Hold together until dry. Wipe access glue away with a piece of scrap foam. The bevel shape will allow the cover to fit flush to the front edge when curved. 69. Apply a bead of glue along the back edge of the side frame as shown above. Hold the fuselage cover to the frame until dry. Repeat for the other side. 71. Start at the top applying a small amount of glue to the front edge and use the process we used for the other fuselage covers. Work your way around about an inch each time. 18 P age
6. FRONT ACCESS COVER Parts required 20 22 Completed front fuselage Completed rear fuselage 72. Draw a center line on the sides of cover frame (21) and on the bottom of cover (22). Measure 3/4 or 19mm from the front edge and make a mark as shown above. Roll the cover (22) as we did for the fuselage covers to create a natural curve. Completed side and bottom view of fuselage. 19 P age
75. Apply glue to the top edges of the cover frame as shown above. 73. Place a bead of glue along the center line we drew earlier. Center and attach cover frame (20) as shown above. 76. Align the cover (22) to the 3/4 mark we made earlier and center with frame. Fold over sides and hold until dry. 74. Apply glue to the side edge of cover frame (20) and attach the second cover frame (21) as shown above. Lay flat on table and use a ruler to make sure the cover frames are aligned. 77. Glue a piece of scrap foam about 1.5 x 1/4 or 38mm x 7mm across the front edge of the cover frame as shown above. Use another piece of scrap foam to measure the gap between the cover and the scrap piece. Remove the measuring scrap foam. 20 P age
78. Insert the front access cover into the first opening front first locking the scrap piece of foam under the fuselage cover. Rotate the back down to lock in the cover. Rare earth magnets and Velcro can also be used to secure the front access cover. Parts required 23 27 7. CANOPY COVER 79. Use a small flat screwdriver to remove the foam between 50% cuts canopy frame (24) as shown above. 80. Apply a small bead of glue in the slot as shown above. 21 Pag e
81. Fold side over top as shown above, hold until dry. 84. Place a bead of glue along each side of tab of canopy frame (23) as shown above. Insert into slot in canopy frame base (24). Make sure the front faces the side with the tab. 82. Repeat step 81 for other side. Apply glue to tab as shown above. 83. Fold tab over as shown above, hold until dry. 85. Apply glue to the bottom edge of canopy frame (26A) and insert in first slot in canopy frame (23) as shown above. 22 P age
86. Repeat step 85 with canopy frame (26B) in center slot and (26C) in the last slot as shown above. 88. Place a bead of glue on the side edge of canopy frame (26C) as shown above. Fold canopy cover (27A) over and hold until dry. Do this for both sides. 87. Apply a small bead of glue to the top edge of canopy frame (23) as shown above. Center and attach canopy cover (27A), hold until dry. 89. Repeat the process for canopy covers (27B). Center and glue to top, then glue sides. 23 P age
90. Repeat the process for canopy covers (27C). Center and glue to top, then glue sides 93. Repeat this process for each tab. The front canopy cover (27D) will start to take shape. 91. Fold tabs back on canopy cover (27D) as shown above. 92. Apply glue to the tab and stick to the back of the adjacent side as shown above. 94. Repeat the process we used for the other canopy covers. First, center and glue to frame. Then glue sides. 24 P age
Completed canopy cover The canopy cover willl fit the same way as the front access cover. Insert front first and rotate back down to lock in canopy cover. Rare earth magnets and Velcro can also be used to securee the front access cover. 95. Mark the location of the center line and remove paper lines on the edges of the wing covers (28) as shown above. 8. WINGS Parts required 28 31 96. Remove the paper between the magenta liness and use a Popsicle stick to create a light crease across the center of the wing cover (28). 25 Pag e
99. Measure 1 from the inside edge of the bottom wing cover (28) and use a pen or pencil to draw a parallel line to edge as shown above. 97. With the wing cover (28) on the edge of your table, create a beveled edge on the aileron as shown above. 98. Use the rolling technique we used on the fuselage covers to create a natural curve to the center area where the paper was removed. 100. Place a bead of glue along the back flat area of the bottom edge of wing section (29A) as shown above. Align the wing section (29A) with the line we drew in the previous step and to the back edge as shown above. Hold until dry. 26 P age
103. Align the wing section (29C) with the back edge and keep parallel to the first wing section (29A) as shown above. 101. Place a bead of glue along the bottom edge and side edge (wider side) of wing section (29B) as shown above. Align the part with the thickest area of wing section (29A), about 1/2 or 1 cm from the paper line as shown above. 102. Place a bead of glue along the flat area of the bottom edge of wing section (29C) and on the edge of wing section (29B) as shown above. 104. Repeat the process for (29D 29G) as shown above. Align wing sections with back edge and keep parallel. 27 P age
Tip. Use a small piece of masking tape to hold the servo connector or wire near the servo opening for easy retrieval later. Tip. Before moving to the next step it is a good idea to place tape on the outside of the wing cover along the leading edge. This will prevent tearing during the folding process and also strengthen the wing. Now is also a good time to apply tape to the ailerons for extra reinforcement as well. 105. Install the servo wires or extension wires. Make a small cut in the top of wing sections (29A & 29C) as shown above. Slide the servo wires into the cuts. Tip. Small elastics will keep the wires neatly tucked away while you build. 106. Slowly and gently preform a test fold of the wing. 28 P age
107. If you are happy with the bend in the foam and the alignment place a bead of glue under the front edges of each wing section as shown above. 110. Fold wing cover (28) over and hold until dry. Spread your fingers to cover as much area as possible and remember to hold the front area as well as the back so that the top of the wingg cover (28) has contact with all the wing sections inside. 108. Fold until dry. the wing cover (28) over and hold 109. Place a bead of glue across the top edges of the wing sections as shown above. If using hot glue, make sure the glue is hot and be sure to move quickly beforee the glue starts to dry. 111. Apply a bead of glue along the bottom edgee of the wing where the top and bottom meet as shown above. Wipe any excess glue awayy with a piecee of scrap foam and hold until dry. 29 Pag e
112. Place a little glue inside the wing tip and lightly squeeze together until dry. 114. With a piece of sand paper flat on the table, make 2 or 3 passes on the inside edge of the wing half as shown above. This will remove a small amount of foam on the edge improving the fit of the two halves. 115. Repeat steps 94 113 for the other wing half. 113. You can now sand the edge for a smoother look. 30 P age
116. Place a piece of tape (we used clear duct tape on this build) along the inside / bottom of one wing half. 119. With one wing half flat on the table, gently lift the other wing half until the center edges meet. Hold in this position until dry. 117. With the wings upside down, hold the tape back and align the edges. Fold the tape to join the two wing halves. 120. Place a piece of tape along the top / back edge where the wings meet for extra reinforcement. 118. Turn the wing over so you are looking at the top. Place a bead of glue along the edge of one of the wing halves as shown above. 121. Place a piece of tape along the top / center edge where the wings join. We won t tape the front / top area as we are about the trim this area for our battery in the next steps. 31 P age
123. Cut the shape from the top area of the wing as shown above. 122. Measure 3 (75mm) from the front where the wing halves meet as shown above. Place your battery on this mark and use a pen or pencil to trace the sides of the battery. 124. Glue a small piece of scrap foam about 2 x 3 (50 x 75mm) to reinforce the battery opening as shown above. 32 P age
9. RUDDER / TAIL WING Parts required 32 34 125. Remove the servo wire or plug from the servo opening. Plug in your servo as shown above. 127. Prepare the rudder and tail wing. Create a beveled edge on the control surfaces as we did for the ailerons and add tape to reinforce the hinge area as shown above. 128. Glue a Popsicle stick to the bottom of the elevator control surface as shown above to reinforce the elevator. (Optional) 126. Place a small amount of glue on the underside of each servo tab and insert the servo. 33 P age
129. Another option to reinforce the elevator is to use a small piece of square carbon tube. Center the carbon tube and use a pen or pencil to trace on the paper. 131. Place a bead of glue along the top edge of the tail wing (32), insert rudder 90 to tail wing as shown above. Hold until dry. 130. Place a bead of glue in the slot and insert the carbon tube. Press the tube in firmly and wipe any excess glue away with a piece of scrap foam. 34 P age
133. Apply glue to the bottom of the front of wingg reinforcement (38) as shown above. 132. Apply glue to one side of resting plate (34) and attach to bottom of tail wing as shown above. Hold until dry. Place the assembly to the side for now, we will install the rudder / tail wing assembly last to ensure it is parallel to the wings. 134. Attach wing reinforcement (38) to bottom of fuselage, hold until dry. (Elastic bands can help hold the part in place.) Apply glue to the rest of the wing reinforcement (38) and fold into fuselage as shown above. 10. WING REINFORCEMENT Parts required: 38 39 135. Repeat stepss 142 and 143 for the back wingg reinforcement. 35 Pag e
11. FIT RUDDER / TAIL WING 12. AIR SCOOP / REAR PANELS Partss required 35 37 136. Install wood dowels through wing reinforcement and attach wing as shown above. The air scoop is a attractive option. 137. Apply glue to the back area of the fuselage where the rudder / tail wing will sit, the back of frame section (8) and to the front/bottom edge of rudder (32) as shown above. 139. Use the rolling techniquee to create a curve in the air scoop bottom (36). 138. Attach rudder / tail wing assembly and before the glue dries, adjust so the tail wing is level with the wing when viewed from the back or front. 36 Pag e
140. Place a small bead of glue along the front top of air scoop bottom (36) as shown above. 143. Repeat for the other air scoop side (37). 141. Hold the air scoop side (35) on top and hold until dry. 144. Apply glue to the top edges of the air scoop as shown above. Center and hold to bottom / front of fuselage. Hold until dry. 142. Now place glue along the back edge as shown above. Hold until dry to finish the side. 37 P age
145. Before installing the rear panels (37) use a pen or pencil to mark the location on the side of the fuselage of the control rod hole in the frame section (8) as shown above. 147. Make a small notch in the rear panel (37) for the control rod as shown above. 13. LANDING GEAR (OPTION) 148. Apply glue to the bottom of the landing gear plate as shown above. 146. Use the rolling technique to create a natural curve to the rear panels (37). Test fit first and trim edge if necessary. Place a bead of glue around the edges as shown above and fit rear panel (37) in place. 149. Fit the landing gear plate into the landing gear opening on the bottom of the wing as shown above. Hold firmly until dry. Wipe excess glue away with a piece of scrap foam. 38 P age
150. Repeat for the other side and insert your landing gear. 152. Install Power Core and plug in servos and ESC to receiver. For complete landing gear build instructions visit flyingpenguinrc.ca 14. FINAL CONNECTIONS 153. Insert locking pegs to secure power core and Install battery and lock with Velcro 151. Install control horns as per manufacturer s instructions and connect control rods. 154. Use strong elastics to secure wing to fuselage. 39 P age
Parts Index A 40 P age
Parts Index B 41 P age
Parts Index C 42 P age
Parts Index D 43 P age
Parts Index E 44 P age