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AeroWorks 75cc YAK-54 ARF-QB, Assembly Manual

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AeroWorks 75cc YAK-54 ARF-QB Assembly Manual Download Page 2

 

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TABLE OF CONTENTS 

 
 

 

 Page 

 
Aeroworks Contact Information …………………………………………………………...........    3 
 
Introduction ……………………………………………………………………………………….   4 

 

 
Kit Contents………………………………………………………………………………………    5 

 

 

Items Needed To Complete ………………………………………………………………………    7 

 

 
Tightening and Re-shrinking the Covering / Check all Seams and overlaps for good seal…     8 

 

  
Wing Assembly………………………………………………………………….…………………   9

 

 

Stab and Elevator Assembly……………………………………………………………………  15 
 
Rudder and Tail wheel Assembly ……………………………………………………………….  19 
 
Main Landing Gear / Wheel pants Assembly ……..……………………………………………  34 
 
Engine, Throttle, Mufflers, Pipe, Canister, Tank, and Cowl Installation…………………….  40 
 
Radio Installation ……………………………………………………………………………….  85 

 

 
Preflight Preparation ……………………………………………………………………………  90

 

 

Summary of Contents for 75cc YAK-54 ARF-QB

Page 1: ...1 75cc YAK 54 ARF QB Quick Build ASSEMBLY MANUAL AEROWORKS 401 Laredo St Unit D Aurora CO 80011 www aero works net...

Page 2: ...ening and Re shrinking the Covering Check all Seams and overlaps for good seal 8 Wing Assembly 9 Stab and Elevator Assembly 15 Rudder and Tail wheel Assembly 19 Main Landing Gear Wheel pants Assembly...

Page 3: ...orkmanship at the date of purchase This warranty does not cover any component parts damaged by use or modification In no case shall Aeroworks liability exceed the original cost of the purchased kit Fu...

Page 4: ...ft IMPORTANT Please read through this manual carefully before starting the assembly of your new 75cc YAK 54 ARF QB Inventory and inspect all parts and hardware for any im perfections or damage Please...

Page 5: ...led on the fuselage by 4 4 40x16mm hex style bolts 4 6 bonded washers for the mounting of the can opy 1 Antenna Tube installed 1 Pilot holes pre drilled for tail wheel assembly Left Wing with Aileron...

Page 6: ...hrod with nuts and clevises for elevator 4 4 40 3 two end threaded pushrod with nuts and clevises for ailerons 2 4 40x250mm Threaded one end pushrod 2 4 40 Metal clevises 16 4 40 ball linkages with Lo...

Page 7: ...22 gauge min 3 x Y harness 2 x 6 2 x 12 2 x 18 2 x 36 1 Receiver PCM 1 x Receiver battery min 6 0 volt 1700ma 1 x ignition battery min 4 8 volt 1700ma 2 switches with charge jacks 22 Gauge min Tools...

Page 8: ...d rub in the covering If any bubbles occur your iron may be to hot Reduce heat and work slowly IMPORTANT Go over any and all seams and color overlaps with your iron to assure good adhesion of the cove...

Page 9: ...EMBLY 2 Layout the servos extensions and Y harness on the wing to test fit the installation and ensure servo leads are the correct size Recommended servo 160 in oz Metal geared Digital 3 Attach the 18...

Page 10: ...s with safety wire string tape or other method Ensure the con nectors will not come apart from vibration or light tension 8 Fasten the pull string from the inboard servo hole to the male connector of...

Page 11: ...end of the 18 extension and secure as before Secure the servo con nectors with safety wire string tape or other method Ensure the connectors will not come apart from vibration or light tension 11 Tuc...

Page 12: ...hat both aileron servos are mounted in bottom of wing as shown Aileron Control Linkage Installation 1 To locate the control horn use a ruler against the outboard side of the servo case to project a li...

Page 13: ...on lock nut IMPORTANT The ball link for the inboard control horn goes in the bottom hole of the horn The ball link for the outboard horn goes in the middle hole of the horn This gives the correct offs...

Page 14: ...so go to the next step 8 Align the left and right sides of the control horns to the mounting holes and mount using six wood screws as shown Note Use thin CA to lock screws in place 9 Repeat above step...

Page 15: ...nd two 36 servo exten sions as shown below STAB AND ELEVATOR ASSEMBLY 2 Gather the elevator control linkage parts as shown below There are 2 pushrods 4 ball link assemblies 2 left and 2 right side con...

Page 16: ...s shown The ball link goes be tween the left and right sides of the control horn sides and is secured with a nylon lock nut 2 To locate the control horn use a ruler against the outboard side of the se...

Page 17: ...r hinge line Attach front ball link to servo arm Adjust the length of the pushrod so that the leading edge of the control horns are aligned with the bot tom leading edge of the elevator Center the con...

Page 18: ...at center or either end point at full deflection 8 Plug the servo wire into the female end of the 36 extension and secure the servo connectors with safety wire string tape or other method Ensure the c...

Page 19: ...or light oil to the hinge joint This ensures no epoxy gets into the hinge during assembly 3 Mix epoxy in mixing cup and use a tapered stick to apply the epoxy inside the pre drilled holes in the trail...

Page 20: ...ck to apply the epoxy inside the pre drilled holes in the leading edge of the rudder Apply epoxy on to each hinge Carefully slide the rudder onto each hinge and against the trailing edge of the fin Wi...

Page 21: ...ntrol horns and 12 wood screws 2 Gather the rudder control horn parts as shown below 2 ball link assemblies and 2 left and 2 right side control horns Assemble the ball links between the control horns...

Page 22: ...ting holes may have been factory drilled for you If so go to the next step 6 Align the left and right sides of the control horns to the mounting holes and mount using six wood screws as shown Note Use...

Page 23: ...om vibration or light ten sion 3 Install the aft rudder servo with the output shaft forward 4 Pull the servo lead and Y harness up through the forward servo cutout 5 Attach the Y harness to the forwar...

Page 24: ...mounting holes Note If using a higher Torque 300oz min Digital Metal geared servo only one servo is required 8 Install rudder servos with servo screws Rudder Pull Pull Cable Installation 1 Gather the...

Page 25: ...d the front Repeat on other side 3 Pull the rudder cables from the fuse tail to the rudder servo tray 4 Insert rudder cable through the brass swage tube then through the threaded coupler hole and back...

Page 26: ...tach a metal threaded RC link to each threaded coupler Attach the RC links to the rudder servo arm and then attach the servo arm to the aft rudder servo as shown Note You will want to use a 3 to 3 1 2...

Page 27: ...rod to give adequate strength Note Rudder coupler hardware is not supplied 13 Plug the rudder servo Y harness into the rud der channel of the receiver and power up Turn on transmitter to center rudder...

Page 28: ...ere the cable hole is located This may cause burrs on the coupler that can eventually cut the rudder pull cable 17 Attach ball link to rudder control horn on both sides of the rudder Thread the rudder...

Page 29: ...through the brass swage tube as shown 20 Crimp the brass tube with a crimping tool or pliers 21 Hint If additional crimping is needed a small C Clamp may be used for additional crimping pressure 22 C...

Page 30: ...can eventually cut the rudder pull cable 25 Attach ball links to rudder control horns on both sides with 4 40 socket head bolts and ny lon safety nuts as shown 26 Adjust rudder pull pull cables to de...

Page 31: ...d 1 leaf spring 3 tail wheel mounting screws steering tiller and 2 mounting screws 2 steering springs 2 Place tail wheel steering tiller over the pre drilled holes in the bottom of the rudder Ap ply a...

Page 32: ...over the pre drilled pilot holes Place a drop of thick CA on tail wheel strut mounting screws before inserting in the pre drilled mounting holes on the bottom rear of the fuse 5 Mount the tail wheel...

Page 33: ...to the springs Slightly stretch the springs and then bend through the tail wheel tiller while holding tail wheel straight 8 Use pliers to twist spring ends closed around the tillers after desired ten...

Page 34: ...s with washers MAIN LANDING GEAR WHEEL PANTS ASSEMBLY 2 Prepare to mount the landing gear strut Gather the landing gear strut 4 mounting bolts wash ers and lock washers and blue lock tite 3 Remove the...

Page 35: ...ing gear bolts before attaching the landing gear 6 Bolt landing gear strut to fuse with 4 bolts and washers Ensure tapered edge of the gear strut is facing toward the rear 7 Use a drop of blue lock ti...

Page 36: ...tite on the wheel axle before assembly 3 Use two wrenches to screw the lock nut on the wheel axle Note Do not tighten axle securely yet 4 Align the flat sides of the axle bolt vertical and snug the l...

Page 37: ...pant in place Do not use lock tite at this time 7 Now tighten the axle nut against the landing gear strut with a small wrench while using the wheel pant slot to hold the flat sides of the axle bolt i...

Page 38: ...wheel collar in place 10 Install the wheel and outer wheel collar Use blue lock tite on the wheel collar set screw before final tightening 11 Slide the lock washer then the flat washer on the wheel p...

Page 39: ...39 13 Repeat above steps for other wheel and wheel pant...

Page 40: ...carbu retor style engine with Pitts style muffler The 3W 75i rear carburetor is shown in the follow ing steps The same steps would apply to the ZDZ70 80 engines and other rear carburetor engines of yo...

Page 41: ...4 drill to drill the engine mounting holes in the template 7 Line up the template with the firewall thrust lines and mark the location of the engine mounting holes onto the firewall 8 It is recommende...

Page 42: ...manufacturer owners manual for special instruction for removing the carbu retor Take care not to get any dirt or foreign matter into the engine 11 Insert the carburetor mount through the hole in the...

Page 43: ...engine prop hub back of spinner 7 to 7 1 4 inches from the firewall as shown 15 Securely tighten the engine to the firewall as shown We recommend using 1 4 20 bolts and lock nuts for engine mounting Y...

Page 44: ...floor to allow adjust ment of the carburetor high and low needle screws 19 3W 75i rear carburetor engine with Pitts style muffler installed Note there is no requirement to modify the engine box for mu...

Page 45: ...fler clearance 1 The following illustrations are for the 3W 75i US side mounted carburetor or similar style engines 2 Locate the laser cut engine mounting template that matches the bolt pattern for yo...

Page 46: ...s shown 4 Mark the location of the engine mounting holes on the template 5 Use a 1 4 drill to drill the engine mounting holes in the template 6 Line up the template with the firewall thrust lines and...

Page 47: ...gine mounting holes 9 Remove the engine back plate mounting screws and re install using locktite 10 Use the provided spacers to make the front of the engine prop hub back of spinner 7 to 7 1 4 inches...

Page 48: ...ecommend using 1 4 20 bolts and lock nuts for engine mounting You may also use blind nuts behind the firewall for en gine mounting if you prefer Note The use of large fender washers is rec ommended be...

Page 49: ...sing lock tite as shown 16 Securely tighten the muffler to the engine cyl inder as shown 17 3W 75iUS side carburetor engine with Pitts style muffler installed Note there is no requirement to modify th...

Page 50: ...ter assembly silicon tub ing silicon rubber nylon strap and plywood canister holding bracket with screws 2 The canister muffler installation will be illus trated first Canister muffler parts are shown...

Page 51: ...f the fuse and ensure there is one inch of space from the line just marked to the rear of the canister 5 Draw a line across the fuse belly on the mark location as shown This will be the location of th...

Page 52: ...e to the mark between the two bottom fuse string ers 8 Covering material removed from two bottom fuse bays 9 Use a razor saw to remove the front former cross brace across the canister tunnel 10 Use a...

Page 53: ...earance on all sides and at the rear 13 Locate the pre painted balsa canister tunnel rear former as shown below 14 Dry fit the canister tunnel rear former inside the rear of the canister tunnel Tilt t...

Page 54: ...he former to fit the bottom of the fuse 17 Apply thick CA glue to the top of the canister tunnel former Insert the former into the tun nel and press in place Apply CA glue to the sides and bottom to s...

Page 55: ...of the canister tunnel 2 Transfer this mark to the top of the canister tunnel Ensure the mounting holes in the top of the canister tunnel will not interfere with any equipment installed or to be inst...

Page 56: ...the canister mounting bracket on the piece of flat silicon as shown 7 Use a hobby knife to cut the flat silicon rubber to match the size of the canister mounting bracket 8 Locate the pre drilled count...

Page 57: ...l piece of medium sand paper to scuff one side of the silicon rubber to ensure a good glue bond 11 Apply thick CA glue to the scuffed side of the silicon rubber piece 12 Glue the silicon rubber piece...

Page 58: ...mounting bolts to pass through the silicon rub ber and seat against the washers inside 14 Insert the canister mounting bolts through the holes in the canister mounting bracket as shown 15 Locate the n...

Page 59: ...and insulate it from the metal canister surface 18 Prepare to slide the silicon tubing onto the ny lon tie The split end of the tubing goes oppo site the nylon tie lock a shown 19 Slide the silicon t...

Page 60: ...in the motor box first then slide under the fuel tank floor 22 Align the blind nuts with the mounting holes as shown 23 Use a drop of thick CA to TACK glue the pipe mounting doublers in place 24 Plac...

Page 61: ...the blind nuts on the opposite side Tighten the mounting bolts securely 27 After the canister strap is installed use thin CA to securely glue the pipe mounting doublers in place 28 Cinch the nylon tie...

Page 62: ...e final canister muffler in stallation Tuned Pipe Installation 1 Gather the header and tuned pipe parts as shown below 1 header Teflon coupler 2 steal clamps and tuned pipe assembly 2 Iron the bottom...

Page 63: ...ss brace to the pre installed rear tuned pipe former and from the front former to the front of the landing gear cross brace as shown 5 Use a razor saw to remove the front former cross brace across the...

Page 64: ...he location of the rear tuned pipe mounting hanger This should be approxi mately two thirds back on the pipe or as de scribed in the pipe installation instructions and as desired by the builder Mark t...

Page 65: ...g bracket 4 Align the centerline of the plywood bracket with the mounting location previously marked on the top of the pipe tunnel 5 Mark the location of the pipe bracket mount ing holes 6 Use a 1 8 b...

Page 66: ...flat silicon rubber to match the size of the pipe mounting bracket 9 Locate the pre drilled counter sunk holes in the plywood pipe mounting bracket and the two flat washers as shown below 10 Place th...

Page 67: ...er piece on top of the counter sunk holes on the plywood pipe mounting bracket This will seal the washers inside the pipe bracket mount as shown 14 After the CA glue has fully cured use a hobby knife...

Page 68: ...silicon rubber tubing as shown below 17 Use a pair of scissors to split one end of the silicon tubing in half approximately 3 4 deep as shown 18 After splitting the silicon tubing cut off one side of...

Page 69: ...ock a shown 20 Slide the silicon tubing onto the nylon tie as shown to form the pipe strap assembly 21 Locate the two plywood pipe mounting doub lers with pre installed blind nuts as shown 22 Slide th...

Page 70: ...tunnel as shown Allow the nylon tie lock to extend out of the tunnel 11 2 as shown 25 Place the canister mounting bracket over the canister mounting strap 26 Place a drop of blue locktite on each cani...

Page 71: ...CA to securely glue the pipe mounting doublers in place 29 Cinch the nylon tie around the canister tube and tighten securely Ensure that the nylon tie does not touch the metal surface of the canister...

Page 72: ...ion Cowl Installation 1 Gather the following material for making a cowl cutout template Hobby Knife Ruler Tape Felt tip pen or marker Use a large envelope or cardboard file folder for template materia...

Page 73: ...will allow for the over hang of the cowling to the front former 4 Template after marking 5 Mark a line 3 16 behind the front former on each side of the pipe tunnel 6 Align the center of the template w...

Page 74: ...nd the front former as shown 8 Tape the template in position as shown 9 Lift the template up toward the engine and trace the outline of the cylinder on the tem plate as shown 10 Remove the template an...

Page 75: ...hown 13 Slide the template aft so that the line on the template is aligned with the aft edge of the cowl Ensure the centerlines are still aligned Tape the template in place on the bottom of the cowl 1...

Page 76: ...until an exact fit is achieved and the cowl does not contact the engine cylinder head This is a typical cowl cut out with canis ter or tuned pipe installation Note It may be necessary to open the bott...

Page 77: ...choke and throttle servo mounting trays the choke and throttle servos and pushrod parts as shown be low 2 x 4 40 one end threaded rods 2 x 4 40 Ball Links 2 x 4 40 Solder couplers 2 x 4 40 Threaded Cl...

Page 78: ...r threaded coupler to unthreaded end of metal 4 40 rod 5 Completed servo pushrod shown below 6 Typical servo installation for rear carburetor engine The exact servo installation will de pend on the en...

Page 79: ...l 4 40 All thread pushrod shown below 9 Typical servo installation for rear carburetor engine The exact servo installation will de pend on the engine used Align the servo tray so there is no binding o...

Page 80: ...th set screw Take care not to strip threads by over tighten set screw Note The fuel tank supplied with your kit may differ slightly from the tank pictured be low Fuel Tank Installation 1 Gather the fu...

Page 81: ...nt line to the rear of the fuel tank as shown to prevent fuel spilling when the model s tail is lifted or flying a down line 5 Connect the fuel line to the engine carburetor intake nipple Drill a fuel...

Page 82: ...el will siphon out when fueling Ignition Installation 1 Gather the engine ignition parts as shown be low Engine ignition nylon ties and foam rubber 2 Locate the plywood ignition mounting bracket as sh...

Page 83: ...d mark the location of the nylon tie holes as shown 5 Use a 1 8 drill bit to drill the ignition mount ing holes 6 Roll the supplied foam rubber to make a 4 layer pad as shown 7 Cut off excess foam to...

Page 84: ...84 8 Mount the engine ignition module using nylon ties and the foam rubber as shown 9 Route the ignition wire to the engine as shown and secure with nylon ties as necessary...

Page 85: ...ilar for all switches RADIO INSTALLATION 2 Mount the ignition switch battery and regula tor if used first Switch location is at the dis cretion of the builder We chose to place the switches toward the...

Page 86: ...es inside fuse through the switch cutout 6 Mount switches in accordance with the switch instructions and hardware 7 Mount ignition regulator as desired 8 Mount the ignition battery as desired using th...

Page 87: ...tor switch and mounting Velcro as shown below 10 Mark location for switch using switch tem plate Use a modeling knife to cut out the switch holes 11 Remove the wood plug as shown 12 Slide switch wires...

Page 88: ...accordance with the switch instructions and hardware 14 Mount receiver regulator as desired 15 Mount the receiver battery as desired using the radio tray cutouts 16 Mount the receiver as desired using...

Page 89: ...h receiver antenna all the way into the re ceiver antenna tube aft of the rudder servo tray Note Apply baby powder to antenna wire to assist getting it into the tube 19 Attach all servos battery regul...

Page 90: ...shers on the wing mounting bolts and insert bolts through the fuse side and into the wing root blind nuts Tighten snugly but do not over tighten and crack the fuse or wing root wood 3 Gather the 4 sta...

Page 91: ...olts and rubber backed washers The rubber backed washers are to prevent the fiberglass cowl from cracking from normal engine vibra tion 7 Gather the 4 hatch mounting bolts and 4 6 small rubber backed...

Page 92: ...to allow a good bond to the surface The decals may be applied using Windex or a solu tion of 1 drop of dish detergent to a cup of water sprayed on the model to assist in proper posi tioning The water...

Page 93: ...cially when shifting the CG to ward the tail Move the battery or add small stick on weights to the nose or tail as necessary Note If additional nose weight is necessary we rec ommend moving the engine...

Page 94: ...e Use a wooden dowel pencil or pen taped to the trailing edge of the rudder to give a clearer reference point 5 Use the supplied flight control deflection me ter to measure the throws in degrees Locat...

Page 95: ...including break in and tuning completely Flight Controls Ensure all flight controls are free from binding and are centered Check that all hinges are tight and will not pull out Control linkages must b...

Page 96: ...is a list of some of the more popular aerobatic and 3D maneuvers you can try Loops and rolls Knife edge flight Stall turns Snap rolls 2 4 and 8 point rolls Slow rolls Spins upright and inverted Flat S...

Page 97: ...__________________________________________________________________________ ___________________________________________________________________________ _________________________________________________...

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