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Alien Aircraft Corp K-501, Assembly Instructions Manual, Page: 30 / 45

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Alien Aircraft Corp K-501 Assembly Instructions Manual Download Page 30

109...Slide the wing joiner on the center section into
position in the right wing.  Position it tightly between
the spars and forward against the shear web and glue
the right wing to the center section. Glue the joiner to
the shear web and the top and bottom spars and glue
the rib to the center section.

110...Slide the wing joiner on the center section into
position in the left wing.  Position it tightly between
the spars and forward against the shear web and glue
the left wing to the center section.

111...Sand the joint between the wings and the center
section.  Test fit the wing onto the fuselage and sand
the wing as required to produce a good fit if needed.

At this point there should be gaps between the fuselage
sides and the wing leading edges.  

Page 28

Summary of Contents for K-501

Page 1: ... act of using the user assembled product the user accepts all resulting liability If the buyer is not prepared to accept the liability associated with the use of this product the buyer is advised to return this kit immediately in new and unused condition to the place of purchase WARNING Failure to follow these safety precautions may result in severe injury to yourself and others Use safety glasses...

Page 2: ...LC 501 12 3 32 X 4 X 24 Laser Cut BALSA 2 LC 501 13 3 32 X 4 X 24 Laser Cut BALSA 2 LC 501 14 3 32 X 4 X 24 Laser Cut BALSA 1 LC 501 15 3 32 X 4 X 24 Laser Cut BALSA 1 LC 501 16 3 32 X 4 X 24 Laser Cut BALSA 1 LC 501 17 3mm X 4 X 12 Laser Cut POPLAR PLY 1 LC 501 18 1 16 X 3 X 12 Laser Cut Birch Ply 1 LC 501 19 1 16 X 3 X 12 Laser Cut Birch Ply 3 Fuselage Sheet 1 8 x 4 x 24 Balsa 6 Tail Sheet 1 16 ...

Page 3: ... Material 2 Rolls Covering Material Plus Trim Colors 15 Hinges C A or Pin Style Hinges 1 Radio 4 Channel Radio with Receiver 2 Tail Servos HiTec HS 311 Standard Servos or Equivalent 2 Aileron Servos HiTec HS 81 Micro Servos or Equivalent 2 Aileron Servo Extensions 12 Servo Extensions to fit your radio 1 Aileron Y Connector 6 Y Connector to fit your radio 1 Aileron Servo Extension 6 Servo Extension...

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Page 7: ... x 4 x 24 balsa sheet as shown to make the stabilizer skin 3 Glue this sheet to one side of the stabilizer 4 Trim the sheet flush with S 1 S 2 Now sheet and trim the oppo site side as you did the first Be sure to cut out the rudder slot 5 Use 1 16 balsa to sheet both sides of the elevators S 3 6 Join the elevators S 3 using the 1 4 x 4 1 2 dowel Use the sta bilizer as a guide Trim the dowel if req...

Page 8: ...he front of R 2 R 3 9 Bevel the front edge of R 4 as shown on the plan and sand the other edges round Mark the hinge locations and cut the hinge slots in R 3 R 4 and R 5 Temporarily install the hinges without glue Sand the outside edges round Leave the other edges square Building the Fuselage 10 Assemble the fuselage sides using parts F 1A and F 1B 11 Glue the F 2 and F 3 doubelers to the inside o...

Page 9: ...quare up the fuse lage Glue the left and right fuselage sides tightly against F 6 Make sure that the fuselage is square and completely glue the formers to the fuselage sides 15 Place former F 8 into position and pull the rear of the fuselage sides together Adjust the back end until the fuselage is straight and square Glue the fuselage sides together and glue the former in place 16 Place former F 9...

Page 10: ...ces with the grain going across the fuselage from left to right 19 When the glue is dry trim the sheet flush with the fuselage sides 20 Glue formers F 11 F 12 and F 13 into place in the front of the fuselage There is a small x marked on F 13 This is the top side Use care to keep the fuselage straight and square 21 Glue velcro to the top side of the F 14 battery tray Make a velcro strap and glue it...

Page 11: ...x 4 x 24 balsa to sheet the bottom front of the fuselage This should be done in pieces with the grain going across the fuselage from left to right When the glue is dry trim the sheet flush with the fuselage sides 25 Trim the top of former F 12 away at the dashed lines 26 Use the 1 8 x 4 x 24 balsa to sheet the top front of the fuselage This should be done in pieces with the grain going across the ...

Page 12: ... spruce lower main spar to the plan The ends will extend slightly past the W 3 ribs 29 Glue the two W 1A together 30 Glue the W 1B ribs to each side of the W 1A s Only one of the W 1B s has the support tab on the bottom rear It doesn t matter if you put it on the left or right side 31 Glue the W 3B doublers to the front of the W 3A ribs Be sure to make a left and right as shown Page 10 ...

Page 13: ...d be tight against the rib and aligned with the spar slot in the top of the rib 34 Place the W 3 ribs onto the lower spar They should be tight against the W 2 shear webs The W 3B s should be on the inboard sides When in the proper position glue the ribs to the spar 35 Put the 1 4 x 3 8 x 5 spruce top main spar into place The ends will extend slightly past the W 3 ribs Glue it to the ribs and shear...

Page 14: ...he slots and glue to the ribs 37 Glue the other W 4 into position on top of the ribs 38 Use sandpaper to taper the two W 6 s so they fit into the gap between the two W 4 s They should fit tight and be positioned as far back as possible Glue the W 6 s in place 39 Glue the two W 5B s and W 5A together as shown Page 12 ...

Page 15: ...sheet away from the motor pylon slot in the W 1A ribs 42 Remove the center section from the plan Cut the support tabs from the bottom of the ribs Use the 3 32 x 4 x 24 balsa to sheet the bottom of the wing center section The grain should run left to right 43 When the glue is dry trim the spars and sheet flush with the W 3 ribs and the front of W 5 Sand the top and bottom of the center section smoo...

Page 16: ...d right on the fuselage Hold it tightly in position and using a 3 16 drill bit drill the bolt holes in parts F 15 in the fuselage The drill bit must be centered in the 1 4 holes in the center section and be 90 degrees to the top surface of the center section so the bolt heads will sit flat 48 Use a 1 4 20 tap to cut threads in the holes drilled in F 15 Apply some thin C A to harden these threads a...

Page 17: ...heck the fit on the fuselage again 51 Remove the center section from the fuselage Cut open the 1 4 wide slots in the W 3 ribs between the dashed lines for the wing joiners 52 Glue four wing joiners together to make a single piece 1 4 thick Test fit the joiner into the slot in the W 3 rib on one side The outboard ends of the joiners should angle up The top outboard corner of the joiners is cut off ...

Page 18: ...24 balsa to sheet the windshield area of the fuse lage This should be done in pieces with the grain going across the fuselage from left to right When the glue is dry trim the sheet flush with the fuselage sides 56 Cut the 1 2 x 3 x 4 balsa block in half to make two 1 2 x 1 1 2 x 4 pieces Glue these pieces onto the front of F 13 Center them top to bottom and left to right Page 16 ...

Page 19: ...fuselage sides 59 Test fit the tail surfaces on the fuselage Sand or trim if required to obtain the proper fit 60 Cut out the mounting hole for the arming switch in one side of the fuselage We put it in the left side but either side is OK but only make the cut out in one side NOTE If you are using electric power you MUST USE AN ARM ING SWITCH 61 Cut the battery hatch template from the plan and tap...

Page 20: ...t end and windshield to match Building the Right Wing 65 Cover the right wing plan with wax paper to prevent the parts from sticking to the plan 66 Make one trailing edge by placing W 18 against one of the 3 32 x 1 1 2 x 18 balsa sheets The end of W 18 should be flush with the end of the 1 1 2 balsa When properly positioned glue the two pieces together 67 Place one of the 3 32 x 1 x 18 balsa sheet...

Page 21: ...should be 90 degrees to the building board 71 Glue shear web A into position against the front face of the lower spar and rib W 8 as shown on the plan The small X on the shear web marks the top outboard corners of the shear webs 72 Pin and glue rib W 7 into position The top of the rib should angle slightly toward the wing tip and be in full contact with the shear web Page 19 ...

Page 22: ...t the front face of the lower spar and outboard of rib W 12 as shown on the plan The small X on the shear web marks the top out board corners of the shear webs 75 Glue a W 13B to each side of W 13A 76 Pin and glue rib W 13 into position The top of the rib should angle slightly toward the wing tip and be in full contact with the shear web Page 20 ...

Page 23: ... the remaining shear webs B C D E and G into position Trim the ends to get the proper fit if needed 80 Working from the tip to the center slide the trailing edge under W 17 and then into the slots in the remaining ribs Line up the aileron cutout with the outboard edge of W 13 Make sure that the trailing edge is fully forward in the slots and glue in place Page 21 ...

Page 24: ...own When positioned properly glue the sheet to the leading edge only 84 Moisten the outside of the leading edge sheet with an ammo nia based glass cleaner such as Windex Allow it to soak in for several minutes Roll the sheet back and glue thoroughly to the ribs and main spar 85 Cut two pieces 9 long from one of the 3 32 x 4 x 24 balsa sheet Save the 6 leftover piece for use in the next step Use th...

Page 25: ...ap strips should be centered on the ribs except for W 17 The W 17 cap strip should be flush with the outboard face of the rib and extend inboard 88 Remove the wing from the plan Trim the supports from the trailing edge of the wing ribs 89 Using 3 32 x 3 x 30 balsa sheet the lower leading edge as you did the top 90 Sheet the inboard end of the wing as you did the top Page 23 ...

Page 26: ...strips to the remaining ribs as you did the oppo site side 93 Trim the excess spars and sheet flush with the ribs on both ends of the wing Glue W 21 to W 22 making the wing tip Glue the wing tip to the W 17 rib as shown 94 Sand the leading edge of the wing round to match the profile shown on the plan Sand the trail ing edge and the edges of the wing tip round Leave the edges of the aileron cutout ...

Page 27: ...d so the holes line up with the holes in W 20 Repeat steps 65 thru 96 to build the left wing Building the ailerons Build the right aileron 97 Glue two A 1 s together Trim an angle on the bottom edge of the A 1 s 98 Glue the A 1 onto and flush with the front of A 2 Place it with the angle down so it leans toward the trailing edge Page 25 ...

Page 28: ...Position two A 4 s into position against A 1 and A 3 and glue into place 101 Glue the remaining A 3 s into place 102 Trim an angle on the top of the A 1 s to match the angle on the top of the A 3 s 103 Glue A 5 onto the top of the aileron Sand the ends front top and rear of the aileron flush Page 26 ...

Page 29: ...on the back of the aileron spar W 19 Mark the hinge locations and cut slots for the hinges Use some scrap 1 8 balsa to make the hinge fillers and glue them to the aileron and wing as shown on the plan Temporarily install the hinges and check the aileron for proper fit on the wing Do not glue the hinges at this time 107 Repeat steps 97 thru 106 to build the left aileron Joining The Wing 108 Cut slo...

Page 30: ...ib to the center section 110 Slide the wing joiner on the center section into position in the left wing Position it tightly between the spars and forward against the shear web and glue the left wing to the center section 111 Sand the joint between the wings and the center section Test fit the wing onto the fuselage and sand the wing as required to produce a good fit if needed At this point there s...

Page 31: ...ng Start at W 5 Tack the end down centered on the joint Now pull the tape tight and tack to the trailing edge Wrap the tape around the trailing edge and pull tight for ward and tack at W 5 and trim off any extra Now use thin C A clue to attach the tape to the wing Use adequate ventilation Now sand the wing smooth all over Building the Tip Floats 114 Glue T 1 and T 2 together 115 Glue T 3 T 4 T 5 a...

Page 32: ... 9A and T 9B together as shown 118 Glue T 8 to the bottom of the tip float It will be a little oversize Center it left and right and front and back 119 Slide T 9 down over T 1 Pull the back end of T 9 down and glue it to T 6 Pull the front of T 9 into contact with T 3 Now glue T 9 to T 3 T 4 T 5 and T 2 Page 30 ...

Page 33: ...lengths Glue these to the front of the tip floats Cut the 1 2 x 3 4 x 5 balsa blocks into two 2 1 2 lengths Glue these to the back of the tip floats 122 Sand the front and rear of the tip floats to the shape shown on the plan Then sand the sides flush 123 Glue a T 10 to each side of T 1 Sand the front and back edges round Page 31 ...

Page 34: ...5 Glue the two P 1 s together Glue the two P 2 and the two P 3 s together 126 Press the four 6 32 blind nuts into the holes in the back of the firewall P 3 Secure them with a small drop of thin C A glue 127 Slide P 2 into the slot in P 1 Place P 3 on the front of P 1 P 2 and glue these parts securely together Page 32 ...

Page 35: ...ings from the aileron servo mounts to the center sec tion You will use these strings to pull the servo wires thru the wing after the model is covered Cover the model with a plastic iron on covering material Overlap all seams approximately 1 8 to assure a water tight seal Note After the model is covered you must check the tail surfaces and wings for warps or twists If there are any they can be remo...

Page 36: ...n 133 Carefully cut the covering away from areas on the fin that will make contact with the fuselage Carefully cut the covering away from areas on the fuselage that will make contact with the fin Place the fin into position and make sure that it is straight and square Glue the fin into position 134 Attach the elevators with the hinges and glue in place 135 Attach the rudder with the hinges and glu...

Page 37: ...ngs into the exit slots in the back of the fuselage They should stop 1 3 4 forward of the hinge lines The front ends of the pushrod housings should pass thru the slot in former F 7 and be cut off 2 from the center of the servo arms Glue the housings to the rear exits Seal around them where they exit the fuselage with clear silicone for water proofing Do not glue the front ends to the former at thi...

Page 38: ... 2 56 machine screws and back plates Slide the pushrods into the housings and connect the clevises to the horns 141 Assemble the front ends of the pushrods and connect them to the servo arms The control surfaces should be in neutral when the servos are centered Glue the pushrod housings to former F 7 142 Mount the arming switch to the fuselage side Page 36 ...

Page 39: ...ntroller into the receiver and arming switch 145 Insert the female ends of the motor wire extensions into the holes in the firewall Securely glue them in place with thin C A Use epoxy to build up a fillet in the back side for additional secu rity Secure the the wires where they exit the pylon with epoxy as shown 146 Trim the plastic nacelle halves on the trim lines as shown The bottom edge is 3 32...

Page 40: ...he bottom edge is down against P 1 and on top of P 4 Cut a hole in the lower edge motor wires to pass through Seal the wires in the exit hole with clear silicone 149 Cut the covering away from the pylon slot in the top of the wing Cut a hole in the top and bottom wing sheet for the motor wires 150 Securely glue the pylon to the wing Pass the motor exten sion wires through the hole in the wing Seal...

Page 41: ...he fire wall with 6 32 x 1 2 screws Use a thread locker on all of these screws 154 Fit the cowl onto the pylon Center the prop shaft in the front and make sure the cowl is far enough back to allow pro peller clearance Secure the cowl to the nacelle with three 2 sheet metal screws One centered on the top and one on each side about 1 4 from the bottom The screws should be centered on the P 3 firewal...

Page 42: ...loat slots 157 Glue the servos into position on the W 25 mounting plates The servo arms should be angled 30 degrees forward to the plate when the servo is in neutral Be sure to make a left and a right hand assembly 158 Screw the servo mount plates to the wing The servo arms should be forward and inboard as shown Use the strings in the wing to feed the servo wires through the wing and out the cente...

Page 43: ...AND THE ARMING SWITCH DISABLED Turn the transmitter on Place the throttle stick in the low position Plug the battery into the arming switch Attach the wing to model Check the motor for proper operation and direction of rotation Follow the instructions with the speed controller to make any adjustments 163 Check the servos for proper operation and direction Adjust the control throws to the values sh...

Page 44: ... The battery hatch must be held in place very securely The propeller moves a lot of air over the hatch producing a lot of force trying to pull the hatch free The hatch also has to be waterproof The best way to hold the hatch in place is to use tape on all four sides We recommend using new tape on the hatch for every flight Vinyl tape or pieces cut from trim sheet that matches the covering work wel...

Page 45: ...attended 3 In the event of damage from crashes etc carefully remove to a safe place for at least a half hour to observe Physically damaged cells could erupt into flame and after sufficient time to ensure safe ty should be discarded in accordance with the instructions which came with the batteries Never attempt to charge a cell with physical damage regardless of how slight 4 Always use chargers des...

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