High performance 90mm fiberglass jet Assembly manual For intermediate and advanced fliers only! Specs Wingspan: 1255mm Fuselage length: 1250mm Flying weight: 2600-3000g Wing area: 22.6 dm² Wing loading: 125g/dm²
Included in the box: Fuselage Main wings x2 Winglets x2 Horizontal stab x2 Canopy 90mm EDF unit EDF fuselage door Battery tray Tricycle landing gear with wheels Servo bay covers Pushrods (x8) and associated hardware CF rod x2 (main wing and horizontal stab attachment) Additional hardware (screws, bolts, blocks etc.) Equipment required (not included): 6 channel radio and receiver Suitable motor and speed controller Servo extension wires 5g servos x3 (high quality metal gears), 9g servo x1, 17g servos x4 Epoxy (5 and 30min) and CA glue Velcro Drill or dremel, 1.5mm, 2mm, 2.5mm and 12mm bits Small screwdrivers and Allen (hex) keys Craft knife Sandpaper
Step 1: Main wing servo instillation Locate the two main wings and cut away the covering film as below. Remove the covering film from the four main wing servo bay covers to accommodate the servo horns.
Take your four 17g servos and attach them to the underside of each of these. (Tip, centre your servos at this point to save unnecessary complications later on!) To do this, first screw two small wooden blocks to each servo. Position as shown below. Drill 1mm or 1.5mm pilot holes to prevent the screws from splitting the wood. Then, glue these in position to the underside of the servo bay covers. Use 5minute epoxy or strong CA. Attach the servos to their extension wires (appx. 50cm) and feed them through the wing through to the exit provided as shown.
Secure with a woodscrew in each corner. Again drill pilot holes to prevent the wood from splitting. Repeat for all four servos. Note the orientation of the servo door with respect to the wing. Keep the orientation of the flap servo the same, as below Step 2: Control surface attachment The aircraft is supplied with the control surfaces in position, however they are not glued in place. To attach them securely, first remove the surface and hinges from the plane. Use a small drop of CA glue to secure each hinge to the surface, making sure appx. half of each hinge remains exposed. Next, drop a small drop of CA on the tip of each hinge and slide it into place. Repeat for all surfaces.
Step 3: Control horns and clevises Start with the ailerons. Arrange the control horns in position and drill 2mm holes to bolt these on. Drill fully through the surface and attach on the other side using the plastic pieces provided. Next take a main wing pushrod and install in the usual manner. Hint: to determine which pushrods go where, arrange them in size as follows. Nose gear Rudder Flaps & ailerons Elevators
Next do the flaps. Instead of bolting the flap horns in position, use two 2mm woodscrews (provided) to attach them. Don t drill pilot holes and use a drop of CA on each of the screws to secure. Put a drop of CA here before tightening. Step 4: Rudder servo, pushrod, horn and clevis instillation The procedure for rudder setup is almost identical to that completed above. The only difference to note is that a 9g servo is instead required and that the servo bay cover should be glued, not screwed in place. Feed the servo extension wire through the body of the plane to the nose. Step 5: Main wing attachment In preparation for gluing the main wings in place, drill a hole in the following location, through which the servo wires will pass.
25mm behind the hole for the CF re-enforcement spar Take a look at where the servo wires exit the main wings if still unsure where to drill. Next, roughen the surface you just drilled through using sandpaper to ensure a good bond between the main wings and the fuselage. Now, take a look at the following image.
Note the two CF locator pins to keep the incidence of the wing as designed. To install these, first test fit them in each of the holes in both the fuselage and wings. This is necessary as during painting and transport these holes can effectively shrink. If they are too small, drill out to the diameter required. Next, glue these to the fuselage (or to the main wings, the choice is yours) using 5 minute epoxy or strong CA. Wait for this glue to dry and apply 30 minute epoxy between the main wings and fuselage. Apply glue and tape or clamp both surfaces and support using blocks if necessary. It is recommended that you glue both wings at the same time. Step 6: Horizontal stab attachment Repeat the same procedure as above for the horizontal stabs. Note that a symmetrical airfoil is used for these so there is no left wing or right wing as such, either orientation is correct. Step 7: Elevator servo instillation For the elevators, begin by taking two high quality 5g micro servos. Screw these side by side as shown. Drill pilot holes in the wooden blocks (provided) and make sure that the combined width of the servos does not exceed 24mm.
Centre both servos and attach horns and clevises. Insert into the rear of the plane as shown below. Make sure that the servos fit as deep as possible in this slot, but still move freely without the clevises rubbing against the fiberglass. Try to visualize where the thrust tube will eventually reside and make sure that there will be enough clearance between the clevis and the tube. Alternatively, flip the pushrods and use the Z bend in the servos and attach the clevises to the control horns.
Step 8: Elevator pushrod and horn instillation Cut a slot in the fuselage as shown. (If you do not have access to a dremel, drill a series of 3mm holes and cut out with a craft knife). Connect the pushrods to the servos and through these slots. Finally, attach the horns to the elevator surfaces. Position these so that the pushrods move freely throughout the full range of servo travel.
Step 9: EDF instillation First assemble your EDF, motor and fan. Test for excessive vibrations. Also, make sure that your motor is orientated such that the motor wires are as shown below. 90 Now, look back at the image above. Note that the fan protrudes from the EDF duct. Now examine the fuselage where the EDF will sit. Note that this piece will interfere with the placement of the EDF.
The fiberglass in this location must be cut away to allow the fan to rotate freely.
Keep test fitting the EDF and checking to see if the fan can rotate freely. Secure the two sides together with strong tape. Feed the ESC and wires through the body at this point also. Next, drill pilot holes and secure the EDF in position with large wood screws. Note that the correct position for the EDF is as shown below. If the two surfaces pointed out below are not flush with one another, you may not have removed enough fiberglass above. Surface 1 (EDF) Surface 2 (Wooden mount)
Finally, attach motor wires to the ESC and test the direction of rotation. Step 9: EDF shroud (thrust tube) Cut out the following template from the sheet of fiberglass supplied. The notch for the motor wires is located appx. halfway along the 310mm side. Also note that the sheet you are provided with may look square, but have one side longer than 310mm and the other side shorter. 290mm 30x20mm 250mm 310mm Roll this up and place it in the fuselage. Pass the motor wires through the notch. Secure the
tube to the EDF with strong tape. If the template was measured correctly, the shroud should reach almost to the rear of the fuselage as shown below. Secure with tape. Step 10: Fuselage cover Secure with clear tape as shown below.
Step 11: Battery tray and nose gear servo instillation Take the battery tray and another micro servo and install as shown below. Make sure you glue the battery tray in place with good, 30minute (or longer) epoxy, as there will be surprisingly large forges on these joints in flight. It is also recommended that you trim the battery tray slightly as shown below to maximize the gluing area. Trim edges on this side into a curve to follow the curve of the fuselage
Step 12: Nose gear Take the remaining block of wood provided in your kit and glue in place with epoxy as shown below. Here Next, flip the plane over and drill a 2.5mm hole as shown. Aim for the centre of the block you just glued. Use the image below for guidance Aim appx. 5mm in front of this line
Keep the hole as vertical and as true as possible. Next, take the nose gear strut and slide on a collar. Slide the assembly into the hole you just drilled. If the hole is too small drill out slightly, but make sure that the strut is not loose in the hole.
Flip the plane over and install the following parts as shown. Note the clevis. Install the pushrod and a servo horn at this stage. Arrange the pushrod so that it passes through the small gap between the battery tray and the wooden structure beneath and the Z bend attaches to the servo horn.
Finish off this step by installing a wheel, followed by a collar to secure. Step 13: Main gear Arrange the following parts as shown. Apply glue as indicated. Epoxy here
Secure with the following plastic part and two large woodscrews. Finish off by installing a wheel and collar in the same manner as the nose gear. Step 14: Winglets Drill a hole in the tip of each wing corresponding to the location of the hole in the winglet. Insert a CF pin into these holes and glue in place with epoxy.
Step 15: Finishing touches and CG Finish off electronics instillation. Position the battery on the tray using Velcro and Velcro straps as shown. CG: The ideal CG is 35mm in front of the main landing gear. For the first flights, make sure that the CG is in this location! Enjoy! Take pictures and videos of your scale looking, high performance ProDesign fighter! Attention! This is not an aircraft for beginners! Pre-flight adjustment and trimming must be done before flying. Check that all linkages, nuts, servo horns, linkage nuts and screws are tightened. Make sure thread locks are applied where necessary. Ensure the flying field is spacious and safe to fly. Bench test the electronic equipment on load for 5 minutes. Check the temperature of the ESC, BEC and battery. This is to ensure the power system and the BEC are reliable and compatible. All EDFs should be run in to test for vibrations and loose shafts. Balance if necessary. Check all electronic equipment. Range check the radio equipment. Test all control surface are moving in their assigned directions. Check battery voltage before use, even the batteries are recently charged.
After the first flight, it is prudent to check the CG for all subsequent flights.