Aviation Design Falcon 7X Assembly Manual Download Page 1

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AVIATION DESIGN

- ZI le Chenet - 91490 MILLY LA FORET – FRANCE - Tel : int+ 33 1 64 98 93 93 - [email protected] – www.adjets.com

Dassault Aviation

FALCON 7 X

for Jet CAT P160

Assembly Manual

AVIATION Design

ZI le chenet, 91490 Milly La Foret, FRANCE

Tel : 33 1 64 98 93 93

Fax : 33 1 64 98 93 88

E-mail :

[email protected]

www.adjets.com

Version 01/08/2008

Summary of Contents for Falcon 7X

Page 1: ...nadoo fr www adjets com 1 Dassault Aviation FALCON 7 X for Jet CAT P160 Assembly Manual AVIATION Design AVIATION Design AVIATION Design AVIATION Design ZI le chenet 91490 Milly La Foret FRANCE Tel 33 1 64 98 93 93 Fax 33 1 64 98 93 88 E mail aviation design wanadoo fr www adjets com Version 01 08 2008 ...

Page 2: ... ducting Fully molded epoxy carbon wings with tube for aluminum spar and gear support already glued Fully molded epoxy carbon stabs with tube already glued 2 Winglets 2 engine nacelles Carbon gear doors 2 carbon stab spars 2 aluminum wing and engine tubes All clear canopy CNC cut Foam floor CNC cut All hardware screws servo cover Instructions in English Parts required to complete the kit Turbine O...

Page 3: ... ADJ 638 Includes four air cylinders electronic gear door cycler 4 way valve tubing connectors door hinges and ball links Not included in the different package Self adhesive foam tape 0 2 kg epoxy and glass fiber ZAP CA DISCLAIMER AVIATION Design assumes no liability for the operation and use of these products The owner and operator of these products should have the necessary experience and exerci...

Page 4: ...a Dremel saw fine saw or with a diamond disk Sand the balsa inserted in the stab into V shape as shown below Drill four x 5 mm holes in the trailing edge stab for the hinge location Drill each stab for the four hinges on the top surface limit Insert and glue with epoxy the four hinges in the balsa rib put some grease or oil on the pin axis to avoid gluing them Drill the corresponding hole in the s...

Page 5: ...graved panel lines for the servo covers Make a 2 mm slot in the control surface for control horn Glue the control horn with epoxy Install glue and screw the servo in the servo cover Insert in the stab the servo extension lead Make a hole in the stab root for the servo lead Connect the servo and the control horn with two x M3 links and M3 threaded rod Apply thread lock There must be no play ...

Page 6: ... is at the front longer at the rear Both must be anhedral Fit the two stabs on each side Check that the distance between the top of the rudder and the tip of the left and right stabs are equal Glue with slow epoxy and microballoon the two carbon spars in the rudder Put some wax in the stab tube and fit the 2 stabs on the fuselage Check again that the distance between the top of the rudder and the ...

Page 7: ...p fin pod is optional on the real airplane The satellite phone antenna is inside If you want to put this pod just sand carefully the fin and glue with epoxy the top pod Fit the rudder underfairing The fin fairing has been added after the first flight on the real airplane If you want to put this fairing just sand carefully the fin and glue it with epoxy ...

Page 8: ...in for the hinge locations Insert and glue with epoxy the three hinges in the balsa rib Drill the corresponding hole in the rudder Insert and glue with epoxy the three hinges in the control surface Check that the control surface can rotate freely All hinges must be perfectly glued Cut the hole in the fin skin according to the engraved panel lines for the servo cover Make a 2 mm slot in the control...

Page 9: ...ww adjets com 9 Engine hatch Cut the engine hatch according to the engraved panel lines with a Dremel saw fine saw or with a diamond disk Cut the engine hatch in 2 half Glue two door hinges on each side of the door Fit engine hatch latches or screws on each side of the doors to have an easy access to the engine ...

Page 10: ...sign wanadoo fr www adjets com 10 Inlet ducting Fit the inlet ducting in the fuselage Fit the plywood ring in the fuselage and fit the fiber ducting through the ring Glue the fiber ducting the plywood ring and the fuselage with epoxy Glue the fiber ring cover on both surfaces with microballoon ...

Page 11: ...acelle axis at the correct location Insert the 25 mm diameter fiber tube in the fuselage Put some wax on the aluminum tube Fit the aluminum tube through the fuselage through the fiber tube and through the plywood reinforcements and fit the two engine nacelles on each side Glue with slow epoxy and microballoon the fiber tube and the two round pin reinforcement plywood pieces Let it dry overnight Gl...

Page 12: ...l three 5 mm holes for the hinges locations Drill each wing for the three hinges at the limit of the top surface Insert and glue with epoxy the three hinges in the balsa rib put some grease or oil on the pin axis to avoid gluing them Drill the corresponding hole in the ailerons Insert and glue with epoxy the three hinges in the control surface Check that the control surface can rotate freely All h...

Page 13: ...rvo extension lead in the wing Connect the servo and the control horn with 2 x M3 links and M3 threaded rod Apply thread lock There must be no play Flaps Flaps can be installed like the ailerons However the flight performance does not change or improve with flaps Flaps fully down do not do much drag and do not improve lift So it is possible not fit the flaps and save 2 servos and some weight ...

Page 14: ...ement Put the front gear on the wood ribs and plywood Drill 4 x 2mm hole through the plywood and wood ribs Screw with 4 x 3mm x 20mm parker screw the front gear on the support Put backward the wood ribs with gear so that the plywood reinforcement touches the plywood frame Put the front strut in the front gear and secure the gear screws Check that the front wheel retract and extend without problem ...

Page 15: ...n the front fuselage the location for the 2 wing aluminum joining tube Drill 2 X 30 mm hole in the fuselage at the correct location Insert the 2 x 30 mm diameter fiber tube in the fuselage The short tube in the front one the rear tube is the long one Mark them front and rear Put some wax on the aluminum tubes Fit the aluminum tubes through the fuselage through the fiber tube and through the plywoo...

Page 16: ...and check that the gear support fit correctly in the wing plywood support Glue with slow epoxy and microballoon the gear wood support tube and the two plywood reinforcements Let it dry overnight Main Gear Assemble the two wings to the fuselage Put the model inverted Put the 2 gear on their supports Check that the gears retract and extend without problem Adjust position if necessary Trim fuselage a...

Page 17: ...s not inverted it can stay on its three gears Main Gear door Assemble the two wings onto the fuselage Put the model inverted Align the gear doors with the fuselage Fuselage door Put 3 gear door hinges in the fuselage on each side Screw the steel ball link on the hinge Screw the link to the 2 air cylinder Adjust the position of the air cylinder and screw it on the plywood frame to have gear door cl...

Page 18: ...ear door to the aluminum gear supports with flat hinges Connect the gear door to the strut with plastic ball link and adjust the length so that the door closes when the gear retracts Check that it opens and closes without problem Front gear door Cut the front gear door in 3 parts according to the photos Put 2 gear door hinges on each front gear door ...

Page 19: ...1 air cylinder Extend the air cylinder Screw the air cylinder with the parker screw to have gear door closed when cylinder is closed Check that it opens and closes without problem Put 2 flat hinges on the rear front gear door Attach the gear door to the front oleo strut so that the door is closed when gear is retracted Landing Gear and door tubing Fit the wheels and brakes on the gears You have no...

Page 20: ...will now have to install the fuel tanks in the front section of the fuselage before proceeding with the assembly There are now two possibilities If you fit the cockpit interior with floor you will have to use the two Kevlar tanks fitted under the two mains wing tubes If you do not fit a cockpit interior it is simpler to use one single large Kevlar fuel tank fitted on the top of the two mains wing ...

Page 21: ...in gear doors Winglets Fit the winglets on the wing tip You can glue them with silicone glue screw them or simply hold them with tape Strobe lights can be installed in the winglets Clear formed covers are supplied with the kit Simply cut the winglet on the engraved location Insert strobe light and wiring and glue the clear cover with ZAP canopy glue Hold them with tape and let dry overnight Canopy...

Page 22: ...to fit the floor First insert and glue the 2 long balsa spares in the pre cut holes in the two plywood frames Glue 2 or 3 balsa rib perpendicular to the long spare to hold the floor Slide and glue the light hard foam floor on the balsa ribs Floor should be cut in two half parts for an easier access All seats and tables can be made from balsa and light foam Always think weight to avoid excess weigh...

Page 23: ...adoo fr www adjets com 23 Access door If you fit the cockpit interior you will have to fit the access door and the stairs Cut the ABS vacuum parts for the steps and glue it to the access door Glue two flat hinges on the bottom of the access door for the rotation Secure the door with small parker screws ...

Page 24: ...lectro valves close to the engine All tubing must be held in the rear fuselage Exhaust tube A very short exhaust tube must be fitted at the back of the airplane to protect the rear of the fuselage Exhaust tube can be made in 0 2 mm aluminum sheet or stainless steel Drawing is given at the end of the manual Glue the exhaust tube with high temperature silicon glue to the rear frame and to the end of...

Page 25: ...AVIATION DESIGN ZI le Chenet 91490 MILLY LA FORET FRANCE Tel int 33 1 64 98 93 93 aviation design wanadoo fr www adjets com 25 ...

Page 26: ...ear doors Connect all the engine tubing to the fuel pump Connect the fuel pump to the fuel tank Connect all the engine connector to the ECU Connect radio and ECU Connect all the retract tubing to the air valve Connect all radio wires Fit the ECU battery and radio batteries as forward as possible Secure all the screws with thread lock Finishing tips Now you have to remove the wax from all the parts...

Page 27: ...ng nose wheel with the rudder Wheel brakes can be mixed with the elevator down Center of Gravity You normally need 4 x 2500 mAh batteries for Rx power and the 1 x ECU battery in the nose about 2 kg lead in the nose to achieve the correct Center of Gravity All batteries and lead must be fitted on the front plywood mounting plate The correct CG is located on the front aluminum gear corner where the ...

Page 28: ...hrust Take off is very smooth Normal flight only requires half power All aerobatic maneuvers roll loops and inverted flight are not recommended Flight must be smooth like the real airplane do not perform high rate of turn Stall the Falcon 7 X will stall badly at very low speed We do not recommend to do it or only do so at high altitude Landing is very easy it is like a very big glider and you can ...

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