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3D Hobby Shop YAK55, Assembly Manual, Page: 2 / 46

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3D Hobby Shop YAK55 Assembly Manual Download Page 2

Suitable for 55/60cc gas engines

 or 12s Electric Power

2

Summary of Contents for YAK55

Page 1: ...91 Yak55 Assembly Manual ...

Page 2: ...Suitable for 55 60cc gas engines or 12s Electric Power 2 ...

Page 3: ...s follow these important guidelines ALWAYS protect your eyes when working with adhesives knives or tools especially power tools Safety glasses are the best way to protect your eyes ALWAYS protect your body especially your hands and fingers when using adhesives knives or tools especially power tools Do not cut toward exposed skin with hobby knives Do not place hobby knives on tables or benches wher...

Page 4: ...ylon geared servos on this airplane THIS AIRCRAFT IS NOT A TOY IT IS A HIGH PERFORMANCE AEROBATIC AIRCRAFT AND IMPROPER SETUP AND OR USE COULD RESULT IN INJURY OR DEATH Assembly Instructions Unpacking Unpack your airplane and examine the components Check for damage of any kind If you find any damage contact 3DHobbyShop and report the damage Shippers are not always kind to our planes but we do our ...

Page 5: ...g material will shrink as you apply the heat and this will remove the wrinkles BE CAREFUL Too much heat applied too quickly can damage the covering either by causing it to pull away from the wood at seams and corners or even by melting it Wrinkles do not affect flight performance Covering Materials Your Yak is covered with genuine OraCover material If you need to repair larger sections matching co...

Page 6: ...vos servo horns wing screws belly vents wing locating pins servo arms etc Work slowly and carefully to make sure you cut the openings YOU need for your build If you use a soldering iron it tends to melt the edge of the covering sealing it to the wood If you use a knife we recommend following up with a covering iron to seal the edges around the openings you ve just made 6 ...

Page 7: ...retained with a steel wire hinge axle inserted from the top of the rudder This wire is taped inside your kit box To attach the rudder slide the wire down through the hinges as shown This feature can make transporting your Yak much easier if you have a small vehicle Trim this wire flush with the bottom of the rudder 7 ...

Page 8: ...ontrol horns on this airframe Take your time and clean up any extra epoxy with alcohol as needed Once you open the slots up use the square plates and a sharpie marker or pencil to trace the area where you need to cut the square Dry fit the control horns fully into the surface to make sure the slots are clear before mixing epoxy 8 ...

Page 9: ...s for the fiberglass plates Dry fit the control horns through the rudder before mixing epoxy While glue is curing put the 4 40 ball link and screw in its place to align the control horns properly NOTE The rudder in these photos has a different type of hinge than your Yak 9 ...

Page 10: ...t The use of thread locking compound or lock washers is always recommended on all surface control hardware to prevent loosening in flight The Photos below illustrate elevator servo mounting and hardware installation Do not forget to use some type of lock on all your servo wire to extension plugs Center the servos and slide your servo arms onto the servo output splines Rotate the servos and arms as...

Page 11: ...ost servo arms If your arms are different for instance very thick aluminum obtain the correct length screws TIP We have found that it is possible to assemble ball links and pushrods quickly using a cordless variable speed drill to turn the metal threaded pushrod in the proper direction while holding the plastic ball joint gently with pliers Use a slow speed so you do not melt or damage the plastic...

Page 12: ...ight We prefer a slice of glow fuel tubing behind the washer to prevent these screws from backing out during flight Thread locking compound is also suitable but it will be more difficult to remove than if using a rubber backed or fuel tube backed washer The Yak includes a fiberglass tube installed into the fuselage to assist in cleanly routing your elevator servo extensions into the rear of the fu...

Page 13: ...apply thin CA glue to the wood at each screw It is OK if the CA is still wet when you re install the screw as this tends to prevent loosening in flight You can also glue the end of the wire into the fuse for added security using epoxy or gorilla glue Use wood screws and the same CA technique to put the rudder spring T on the bottom of your rudder as shown Install the tail wheel springs slightly st...

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Page 15: ...nuts as shown The gear IS DIRECTIONAL and has been designed to sweep slightly forward Pay attention to your gear installation to make sure you have not installed it backwards Use a wrench or locking pliers to hold the nuts inside the fuselage as you tighten the screws from outside 15 ...

Page 16: ...fs They are different right to left Try them on each side to determine which is which They are attached to the landing gear using 4 40 screws and washers NOTE Thread the screws into the gear without the cuffs once to be certain you can easily do this Slide the cuffs on and probe with a sharp point to locate the holes then tighten the screws We prefer to put some silicone caulk on and around these ...

Page 17: ...ith a very hard corrosion resistant layer and it is difficult for the set screws to clamp to this layer A few seconds with a Dremel tool or a file will break through this layer and allow the set screws to grab Loctite is also recommended for these screws Install the wheel and axle into the wheel pant Bolt the axle pant wheel unit onto the main landing gear with the locking nut as shown 17 ...

Page 18: ...Install the wheel pants screws as shown Use loctite 18 ...

Page 19: ...ull pull setup the holes you use in your double sided servo arm on the servo should be of approximately equal width from right to left as the mounting holes you use on the rudder control horn Center the rudder servo Install the rudder servo as shown and finish cable installation inside the fuselage as shown in the photos below Make sure to have the brass connectors threaded adequately into the pla...

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Page 21: ...ngths of the pull pull cable to get good tension just snug with no sag and no play in the rudder banjo string tight pull pull wires will not make your plane fly better but they will wear out your servo Below are some photos of Pull Pull wire installation 21 ...

Page 22: ...le mufflers of tuned pipes All these products are slightly different sizes and so installing them will require some custom fitting on your part The tunnel has a front access cover and a rear access cover If you wish to install a canister or tuned pipe mufflers remove the covering over the access cover areas as shown 22 ...

Page 23: ...remove the covering over these cooling outlets as desired NOTE Canister and Pipe mufflers come in a variety of sizes and shapes Installing one is always a semi custom project We have provided some generic outlets 3 in the front tunnel cover and one in the rear tunnel cover for the exhaust outlet dump pipes You may be able to use these outlets to route your exhaust outside or you may need to provid...

Page 24: ...We have provided several canister pipe mounts that fit into the exhaust tunnel as shown Our preferred canister muffler for 50 60CC engines is the MTW TD 75K 24 ...

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Page 26: ...ak has right thrust built in We do not recommend altering the thrust angle on the airframe as the right thrust chosen has been carefully selected to provide straight tracking in precision flight without requiring too much rudder compensation during slow flight The correct distance between the firewall mounting surface and the prop mounting surface on the front of the engine is 6 and inches Tape th...

Page 27: ...e on the template as a test before cutting your firewall In particular the DA60 requires cutting a relief for the carburetor bolts and choke plate This cut should be tested on you template and then transferred to the firewall Below is an example of a firewall marked in pencil for a DA60 installation prior to the holes being drilled and cut 27 ...

Page 28: ...In the above photo a hole saw is being used to create the largest opening for the DA 60 installation 28 ...

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Page 30: ...in the photo Using high quality mounting hardware attach your motor to the firewall Use locking compound or nylock nuts on ALL mounting fasteners You want the bolts to be tight but not crushing the wooden firewall Above is one typical layout for throttle servo and choke linkage for a DA60 For a DA 50 or DLE or similar engine the choke typically runs forward in the cowl and is accessed from the fro...

Page 31: ... it from vibrating around in flight and cutting itself by rubbing on the cowl Pay attention to carefully securing all wiring for a neat and trouble free ignition installation It is never good to rub through your wiring or cut the ignition lead on your cowl as either of these can lead to an unexpected loss of engine power Notice that the ignition power wire is also carefully secured and that the co...

Page 32: ...quality throttle servo A full size servo such as a Hitec 7955 is recommended for durability and proper centering It is important to use a good quality servo that centers well to establish a consistent and reliable idle When setting up a throttle servo as in the right hand photo notice that the servo arm is centered when the throttle is at its middle position Choose a servo arm with a length simila...

Page 33: ... airframe Assemble the fuel tank as shown using small nylon zip ties as hose clamps to retain the flexible fuel tubing onto the rigid metal tubing Place a piece of foam rubber under the tank to isolate the tank from vibration and install the long nylon ties or flexible Velcro straps through the slots in the tray as shown We recommend using a fuel filter in the filling line coming from your fuel ta...

Page 34: ...The fuel feed line runs from the tank to a Y connector and fuel dot and then to the carburetor Run the vent line as shown to prevent fuel loss during aerobatics 34 ...

Page 35: ...ice of glow fuel tubing behind the washers will prevent the screws from loosening during flight without requiring the use of thread locking compound on these screws The easiest way to cut a cowl for gasoline engine installations is to use cardstock to make a cutting template for marking the cowl In the photos below you see that we have taped a piece of cardstock to the bottom of the plane and we h...

Page 36: ... airframe and engine you can enlarge the holes slightly to allow for vibration during flight Note the evolution of the spark plug hole in the photos below in the center and on the right from providing just enough opening for the tip of the plug to include room for the cap and wire We have started with only a small hole for the tip of the plug enlarging the hole for the plug wire as required Make s...

Page 37: ...all servo plugs to prevent accidental disconnection during flight Install the servo with the servo head toward the front of the airplane and attach the pushrod as you did for the elevator Set the length of your turnbuckle rods so that the servo arm alignment is parallel to the hinge line when the aileron is centered to provide equal positive and negative throw Notice that the ball link on the aile...

Page 38: ...the first several times you install them Go slowly and patiently to prevent damage the first several times The wing tubes typically loosen up with use so don t panic if it is tight when the plane is new Don t forget to use clips or other methods to prevent aileron wires from coming unplugged in flight and to properly restrain aileron wires so they will not be damaged from chafing with airframe vib...

Page 39: ...act the SFG during flight Also included are some angled SFG wingtips where the SFG is canted inward at the front and out at the rear as shown in the lower photo This setup is recommended for precision flight Our test pilots have flown the Yak in every possible combination and we suggest you try them all for yourself to see which setup you prefer SFG s and wingtips attach using 3mm socket head cap ...

Page 40: ...n and then epoxy to strengthen the front canopy hatch mounting dowel pins These pins take high stresses and abuse from vibration Inspect them frequently Radio Installation Notes We have provided locations for two full size switches or servo plug sized charge jacks on each side of the fuselage as well as a 6mm hole for a Smart Fly flag style safety switch if desired We also mount our fuel filler or...

Page 41: ...ht Take your time when installing your components and properly secure all wiring and protect your wiring from pinch points or chafing with airframe vibration The use of redundant power sources and soft switches or parallel switches in your power system is advised to avoid failures As with any gasoline powered airframe the use of a transmitter operated ignition kill is very important for safety Opt...

Page 42: ...ons to push more airflow over the battery packs To mount your electric motor create a mounting template for your particular motor mount on paper Match up the center of your template with the thrust line center on the firewall and mark your hole locations Be sure to use blue Loctite on all of your fasteners When assembling your motor mount the correct distance from the firewall to the back of your ...

Page 43: ...e access plate on the top of the engine mounting box open and we recommend making another hole the same size in the bottom of the motor box or battery tray allowing more air to enter the fuselage You will need an air exit near the rear of the fuselage Make this by removing some of the covering on the bottom of the fuselage behind the wing We typically remove one or two squares but you can remove m...

Page 44: ...own in the photo above is a 3 diameter unit High power electric setups can benefit from forced cooling particularly after landing from a hard flight We have had good success carrying onboard cooling fans on our large electric aircraft but whether you use a portable cooling fan or an onboard one it will benefit your power system and reduce the cooldown time between flights 44 ...

Page 45: ...urfaces can allow for very fast pitch and roll rates The massive ailerons can be overwhelming at first if you simply max out the throws We advise you to start your flights on low rates Throws High Rate Ailerons 40 degrees Elevator 45 degrees Rudder Maximum throw available without interference High rate controls typically use 50 75 exponential Throws Mid Rate optional Ailerons 25 degrees Elevators ...

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