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AeroWorks YAK 54 ARF-QB, Assembly Manual

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AeroWorks YAK 54 ARF-QB Assembly Manual Download Page 51

 

51

 

Standard Muffler Installation 

 
1.  Gather the standard muffler parts as shown: 
 

 

Shown:   DA150-C (Compact muffler set)  

 Also 

fits: 

DA150 (Standard muffler set) 

 

 

 

2.  Use a drop of blue Loctite on muffler bolts be-

fore installation. 

3.  Install muffler cans using the supplied gasket or 

high temp silicon gasket material and     securely 
bolt to cylinder heads as shown. 

Greves Long Pipe Installation 

 

1.  Gather the headers and Greves pipe parts as 

shown: 

 

 

1 - 70mm drop flex header (left) 

 

1 - 70mm drop flex header (right) 

  

2 - Greves long pipes (Rear exit) 

 

2 - Teflon couplers 

  

4 - clamps  

Summary of Contents for YAK 54 ARF-QB

Page 1: ...1 150cc YAK 54 ARF QB Quick Build ASSEMBLY MANUAL AEROWORKS 401 Laredo St Unit D Aurora CO 80011 www aero works net...

Page 2: ...n Landing Gear and Wheel Pant Installation 40 Engine Installation 44 Throttle and Choke Servo Installation 46 Standard Muffler Installation 51 Greves Pipe Installation 51 Canister Muffler Installation...

Page 3: ...ip at the date of purchase This limited 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: ...mbly manual carefully before starting the as sembly of your new model Inventory and inspect all parts and hardware for any imperfec tions or damage Notify Aeroworks immediately if there are missing or...

Page 5: ...the pipe brackets 1 Top hatch cover of engine box pre installed by 4 T2 6 x 10mm PWA wood screws 1 Canopy base painted installed on the fuselage by 4 4 40 blind nuts and 4 4 40x16mm hex style bolts 1...

Page 6: ...40mm Carbon wing tube 1 16mm O D x 220mm Carbon stab tube Front 1 16mm O D x 460mm Carbon stab tube Rear 4 8 32 x 30mm Hex head bolts for wing mounting 4 8 bonded washer for wing mounting 4 4mm split...

Page 7: ...Blue 885 Small repairs 1 300x300mm True Red 866 Small repairs 1 300x300mm White 870 Small repairs 1 300x300mm Dark Yellow 889 Small repairs 1 600x300mm Transparent covering Sealing hinge gaps 11 24 6...

Page 8: ...x 18 2 x 24 2 x 36 2 x 48 2 Receivers PCM recommended 2 x Receiver battery min 6 0 volt 1700ma 1 x Ignition battery min 4 8 volt 1700ma 3 switches with charge jacks 22 Gauge min Tools Allen wrenches U...

Page 9: ...educe heat and work slowly IMPORTANT Go over any and all seams and color overlaps with your iron to assure good adhesion of the covering to the wood This is especially im portant at the leading edges...

Page 10: ...nge gaps Use covering iron to seal the clear covering snugly into the bottom of the hinge lines as shown for air tight hinge seals Note The clear covering does have a transparent protective backing Th...

Page 11: ...on Note A 6 extension will also be needed per wing when connecting aileron servos to receiver WING ASSEMBLY 2 Layout the servos extensions and Y harness on the wing to test fit the installation and en...

Page 12: ...nd of the connector to assist in drawing the servo wire through the wing without hanging up inside the wing 6 Pull both servo leads through the root end of the wing 7 Attach a Y harness to the inboard...

Page 13: ...th safety wire string tape or other method Ensure the connectors will not come apart from vibration or light tension Secure excess wire from Y harness and extensions inside the wing root rib using tap...

Page 14: ...own The ball link goes between the left and right sides of the control horn sides and is secured with a nylon lock nut IMPORTANT The ball link for the root end control horn goes in the bottom hole of...

Page 15: ...ns have been set at a slight offset to allow for maximum torque at full deflection 6 Use thick CA on each screw prior to installing to lock screws in place Note CA glues have a fast drying time Rememb...

Page 16: ...rvo arms are parallel to the aileron hinge line Ensure all servos do not fight each other at center or either end point at full deflection Take advan tage of servo programmers and match boxes availabl...

Page 17: ...te Seal ends of carbon tube with thin CA to help prevent ends from splitting 6 Remove the 4 40 ball link and lock nut from the pushrod Note Make sure lock nut against servo arm ball link is tight so p...

Page 18: ...18 8 Final pushrod assembly shown below 9 Repeat all the above steps for installing the aileron servos into the other wing panel...

Page 19: ...ne 11 Y harness one 48 and one 12 servo exten sion Note 48 and 12 servo extension will be used to connect servos to receiver during a later step You may also use one 60 extension STAB AND ELEVATOR ASS...

Page 20: ...shrods 4 4 40 ball link assemblies 2 flat washers not pic tured 2 brass spacers 2 left and 2 right side control horns and 12 wood screws per stab and elevator Note There is also a Carbon tube for rein...

Page 21: ...ball links into any of the three control horn holes However it is very important that you use the same hole for each control horn We recommend you use the middle or bottom hole to achieve desired 3D t...

Page 22: ...olders in the fuse 17 Plug the elevator servo extension into the re ceiver and turn on Ensure each servo is cen tered and the servo arm is parallel to the ele vator hinge line Adjust the length of the...

Page 23: ...ting 3 Mark cut location onto carbon tube Carbon tube should fit between 4 40 ball link lock nuts Note Make sure lock nuts are tight so pushrod length does not change 2 Wrap masking tape around carbon...

Page 24: ...e other stab 7 Slide carbon reinforcing tube over the 4 40 push rod and reassemble ball link to pushrod end 6 Remove the 4 40 ball link and lock nut from the pushrod Note Make sure lock nut against se...

Page 25: ...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 trailing edge of the fin Apply epoxy to one side...

Page 26: ...y with alcohol wetted wipes 7 Ensure there is minimal to no gap between fin and rudder Allow epoxy to fully cure Note Ensure you have full rudder deflection before epoxy fully cures Rudder Horns Servo...

Page 27: ...o obtain full rudder deflection 4 Use thick CA on each screw prior to installing to lock screws in place Note CA glues have a fast drying time Remember to work quickly 5 Align the left and right sides...

Page 28: ...servos are required This is the installation we will use If three servos are used installation process will be similar 7 Remove wood screws from the fuselage remov able radio floor 8 Remove radio floo...

Page 29: ...he connectors will not come apart from vibration or light tension Push the servo leads and Y harness back through the for ward servo cutout 11 Install the forward rudder servo with the output shaft fo...

Page 30: ...rom pulling into fuse 15 Pull the rudder cables from the fuse tail to the rudder servo tray 16 Insert rudder cable through the brass swage tube as shown 17 Thread cable through the threaded coupler ho...

Page 31: ...ck through the brass swage tube and pull tight as shown 19 Crimp the brass tube with a crimping tool or pli ers 20 Cut off excess cable as shown 21 A drop of thin CA may be applied to the swage tube t...

Page 32: ...sing the supplied brass spacers 4 40 bolts flat washers and locknuts 25 Tape the rudder balance tab to the top leading edge of the vertical fin in the neutral position as shown This ensures the rudder...

Page 33: ...ecure with lock nut at this time This will make final adjustment of cables easier shown during a later step 30 Slide brass swage onto rudder cable Next thread the rudder cable through the threaded cou...

Page 34: ...34 31 Loop the cable back through the brass swage tube as shown 32 Pull cable until tight 33 Crimp the brass tube with a crimping tool or pli ers 34 Cut off excess cable as shown...

Page 35: ...of cables is complete se cure ball links with 4 40 lock nut Rudder Servo Arm Coupler 1 Gather the rudder servo arm coupler hardware as shown below There are 4 4 40 ball links with hardware 2 4 40 all...

Page 36: ...ervo double output arms using the 4 40 ball links spacers and bolts as shown Secure bolts with lock nuts Note You will want to use a minimum of 3 to 3 1 2 servo arms 6 Install the rudder servo output...

Page 37: ...steering springs are installed 2 Gather the tail wheel parts shown below 1 carbon Tail wheel strut 3 tail wheel mounting screws 1 aluminum steering tiller 2 tiller mounting screws and 2 steering sprin...

Page 38: ...tail wheel strut over the pre drilled holes in the bottom rear of the fuse 7 Place a drop of thick CA on tail wheel strut mounting screws before inserting in the pre drilled mounting holes on the bott...

Page 39: ...s to twist spring ends closed around the tail wheel tiller Cut off excess spring wire as shown 12 Repeat for opposite side tail wheel spring Ad just length and spring tension so that tail wheel is cen...

Page 40: ...nting hardware MAIN LANDING GEAR AND WHEEL PANT INSTALLATION 2 Remove 4 40 gear cover bolt from inside fuse 3 Gear cover removed shown below Repeat for opposite side gear cover 5 Align mounting holes...

Page 41: ...he landing gear 7 Bolt landing gear strut to fuse with 4 4 40 bolts and washers Ensure tapered edge of the gear strut is facing toward the rear 8 Install the axle into the gear strut with nylon lock n...

Page 42: ...l collar in place 11 Install the wheel and outer wheel collar Use blue Loctite on the wheel collar set screw before final tightening 12 Slide the lock washer then the flat washer on the wheel pant mou...

Page 43: ...wheel and wheel pant 15 Reinstall the landing gear cover Repeat installation steps for other gear cover 16 Reinstall landing gear cover bolt with Loctite and fasten firmly 17 Final gear assembly with...

Page 44: ...inum spacers are included to set the proper stand off distance for your en gine if the DA 150 is not your engine of choice 3 Locate the laser cut engine mounting template for the DA 150 Note If other...

Page 45: ...ovided DA150 wooden spacer mounting block Install mounting bolts through engine mounting plate and spacer Note Using the provided hardwood spacer rather then using conventional standoffs provides the...

Page 46: ...end 2 x 4 40 ball links and hardware 2 x Brass spacers 2 x 4 40 threaded solder couplers 2 x 4 40 threaded quick links Note Servo mounting trays have been supplied for your convenience However we have...

Page 47: ...erfere with the standard muffler cans 4 When the final location of the throttle servo is determined use a pencil to trace the outline of the servo onto the bottom of the engine box as shown 5 Use a ro...

Page 48: ...le servo mounting screws from inside the engine box to prevent loosening from engine vibration 9 Thread a 4 40 ball link half way onto the threaded coupler as shown 10 With the servo arm centered and...

Page 49: ...like Sta Brite silver solder 13 Solder the threaded coupler to the throttle pushrod wire Note Lightly sand end of rod for best bond 14 Attach the throttle pushrod with the 4 40 ball links and secure...

Page 50: ...ip the carbon rod over the 4 40 threaded pushrod 1 A none soldering method of attaching throttle pushrod is shown in the following steps Hardware for this method is not supplied Gather 2 4 40 ball lin...

Page 51: ...ctite on muffler bolts be fore installation 3 Install muffler cans using the supplied gasket or high temp silicon gasket material and securely bolt to cylinder heads as shown Greves Long Pipe Installa...

Page 52: ...o ensure the covering is bonded to the bottom of the fuse frame around the pre cut air exit holes 4 Use a hobby knife to remove the covering from the pipe tunnel pre cut air exit holes Note There are...

Page 53: ...necessary Apply medium CA glue to sheeting and install 8 Front tunnel sheeting installed shown below 9 Dry fit the pre cut rear tunnel balsa floor sheet ing and trim as necessary Apply medium CA glue...

Page 54: ...pieces of silicon tubing into the plywood cutouts in the pipe mounting formers 12 Mount front bracket to former with 4 40 mount ing bolts flat washers and lock washers Apply blue Loctite to mounting b...

Page 55: ...elage 15 Slide rear mounting bracket into position next to fuse former 16 Mount rear bracket to former with 4 40 mount ing bolts flat washers and lock washers Apply blue Loctite to mounting bolts 17 S...

Page 56: ...for your engine application will enhance overall engine perform ance Note The Yak s fuselage has been designed for adjustable pipe lengths for optimal engine performance 20 Assemble the pipes to the h...

Page 57: ...Make final adjustments and secure Teflon cou plers with clamps 23 Position bottom tunnel hatch into place at bot tom of fuse 24 Apply blue Loctite to hatch mounting bolts 25 Assemble hatch to bottom o...

Page 58: ...Installation 1 Gather the header and canister parts as shown 1 70mm drop flex header left 1 70mm drop flex header right 2 MTW TD 110 Long canisters Rear exit 2 Teflon couplers 4 clamps 2 Gather the in...

Page 59: ...six canister tunnel pre cut hot air exit holes Note There are pre cut holes for both canister and long Greves pipe installations Take care to only cut out the required hot air exit slots 5 Covering re...

Page 60: ...eet ing and trim as necessary Apply medium CA glue to sheeting and install 9 Front tunnel sheeting installed shown below 10 Dry fit the pre cut rear tunnel balsa floor sheet ing and trim as necessary...

Page 61: ...installed canister mounting former 13 Insert first canister from front of fuse through the canister mounting former Push canister back into fuse to allow easier installation of the sec ond canister 1...

Page 62: ...with manufactures instructions 16 Use blue Loctite to secure header pipe bolts to engine Remember to always use the engine manufacturers suggested gasket for proper seal 17 Make final adjustments and...

Page 63: ...Assemble hatch to bottom of fuse 21 Final canister installation with hot air exits slots cut out 22 Dry fit both sides of the aft canister tunnel sheet ing to fit behind the former just aft of the can...

Page 64: ...n the kit are large and small ny lon ties One Wrap Velcro ties and foam rubber pads as shown 2 Gather the ignition module and mounting hard ware as shown 3 Position the ignition module inside the engi...

Page 65: ...Roll the supplied foam rubber to make a 4 layer pad as shown Make the pad slightly larger than the ignition module 6 Install the ignition module and the foam pad with a nylon tie as shown 7 Use a 1 4...

Page 66: ...connector through firewall and connect ignition timing connectors with safety wire string tape or other method Ensure the connectors will not come apart from vibration or light tension 9 Final igniti...

Page 67: ...upplied brass fuel barbs Two for the fuel tank and Two for the smoke tank Solder a brass fuel barb to the fuel line pick up tube This will keep the weight of the fuel clunk from pulling the fuel line...

Page 68: ...and bend upward Air vent tube should rest as close to the top of fuel tank as possible Without touching the top of the tank 7 Install the fuel tubing and clunk Secure the fuel tubing with nylon ties t...

Page 69: ...nk fuel tubing foam rubber fuel T fuel filler dot fuel filter and nylon ties Note The fuel T fuel filter and filler dot are not supplied but are available through Aeroworks 2 Place the fuel tank on th...

Page 70: ...f the fuel T 5 Install the fuel filter fuel filler line and carbure tor fuel line to the fuel tank Be sure to leave enough fuel line to reach the engine carburetor and the filler dot Note It is recomm...

Page 71: ...to hold the tank against the foam on the fuel tank floor Cut off excess nylon tie material after tank is firmly in stalled 10 Mark and drill the fuel line exit hole in the bot tom of the engine box No...

Page 72: ...l filler dot and drill bits as shown below Note We recommend you start with a smaller size drill bit then increase the bit size to the correct size to fit your filler dot This will help prevent the fu...

Page 73: ...ot fuel filter and engine fuel line installed 18 Route the vent line on top of the fuel tank and secure with small nylon ties as shown This will stop excess fuel from draining out the vent line during...

Page 74: ...it are large and small ny lon ties One Wrap Velcro ties and foam rubber pads as shown 2 Gather the ignition battery switch and voltage regulator as shown 3 A typical battery arrangement is shown below...

Page 75: ...the wing leading edge on the fuse to avoid conflict with the switch mounting location 5 Mark the location for ignition switch using the switch mounting plate for a template 6 Use a rotary cutting tool...

Page 76: ...nition installation shown below Secure the ignition battery with supplied one wrap Velcro ties Secure the regulator to the fuse floor using manufactures suggested instructions 11 We chose to mount the...

Page 77: ...ro ties and mount the regulators to the fuse floor using manufactures suggested instructions Note For an easier radio installation remove radio floor from fuse 14 Secure all connectors with safety wir...

Page 78: ...y into the pre installed receiver antenna guide tubes 18 Tape the receiver antenna wires to the end of the antenna guide tubes and to the radio floor as shown This will prevent the antenna wire from v...

Page 79: ...dequate cooling for the DA150 Depending on your engine s operat ing temperature you may need to allow for more exit air cooling for your engine to run at its recommended operating temperature 3 Using...

Page 80: ...stack exit holes Note Mark the template Cowl Side for easy reference when fitting to cowl 5 Using a hobby knife cut out the exhaust stack exit holes 6 Trial fit the template until the proper size and...

Page 81: ...te cooling for the DA150 Depending on your engine s operating temperature you may need to allow for more exit air cooling for your engine to run at its recommended operating temperature Always check t...

Page 82: ...s Note Paten pending interlocking cowl design 14 Finished cowl with top and bottom section aligned shown below 15 Mount top inside section of cowl using 4 4 40x20mm hex head bolts 4 6 bonded washers 1...

Page 83: ...ion with Canisters 1 If using canister mufflers use the same cowl mounting steps as for standard mufflers No other steps or required for mounting of the cowl All hot air exit holes have been pre cut f...

Page 84: ...wl when the choke control arm is fully pushed aft Cut pushrod to correct length and make a 90 bend at the end of the pushrod as shown 2 Attach the choke pushrod and ball link to the engine choke arm a...

Page 85: ...use or wing root wood 3 Gather the 4 4 40 stab mounting bolts and 4 6 small rubber backed washers 4 Slide the stab tubes in the fuse stab tube sleeves short tube front long tube rear Slide the stabs o...

Page 86: ...olts from coming loose from normal engine vibration 7 Secure center section of cowl with 4 40 x 25mm hex head bolts and 6 bonded washers 8 Secure top section of cowl with 4 40 x 20mm hex head bolts an...

Page 87: ...old down dowels This is a High vibration area and can loosen the front dowels Always check the front dowels are secure before each flying session 11 Slide the rubber backed washers on the hatch mounti...

Page 88: ...hobby knife plastic squeegee or credit card Windex or Application fluid like Rapid Tac Also a solution of 1 drop of dish detergent to a cup of water sprayed on the model will as sist in proper positio...

Page 89: ...NOT throw away any transfer tape until decal placement is complete Decals supplied with the kit may vary from the photos below Decal application steps will be similar 6 Remove backing from Clear tran...

Page 90: ...ansfer tape to top of decal 9 Peel backing from decal 10 Spray model surface with application fluid Windex or soapy water solution 11 Spray back side of decal with application fluid Windex or soapy wa...

Page 91: ...cal smooth and remove all excess application fluid Let decal set until dry enough to be able to remove transfer tape with out removing decal Do not leave until completely dry or transfer tape will be...

Page 92: ...rtable adjust the CG to suit your flying style in small steps especially when shifting the CG toward the tail Move the battery or add small stick on weights to the nose or tail as necessary Note If ad...

Page 93: ...udder throw measured in inches from the rud der boost tab 4 Use the supplied flight control deflection meter to measure the throws in degrees It is recom mended you level the model as shown 5 Elevator...

Page 94: ...der the rudder boost tab Center the throw meter on the rudder using the centering marks on the meter to aid with align ment Note Position throw meter to the front of the fin and rudder 7 Gather the Ru...

Page 95: ...or 22 down For 3D flying use the following throws 3D Rate Aileron 5 1 2 or 40 up 5 1 2 or 40 down Rudder 4 or 40 left 4 or 40 right Full rudder deflection is typically recommended for all out 3D Eleva...

Page 96: ...olts hatch bolts servo screws control horn bolts wheel collars and clevis keepers are tight and secure Use Loctite were necessary Covering Check all seems and overlaps are se cure and have not lifted...

Page 97: ...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...

Page 98: ...__________________________________________________________________________ ___________________________________________________________________________ _________________________________________________...

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