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24 BrainCube Aeromodels - Fugly Construction Manual

Repeat the hinging procedure for the rudder and both ailerons. Once complete, your model should look like 

this.

Finish Hinging

Undercarriage - 1

Drill four 3mm holes in the UC leg for mounting to the 

fuselage, and one for mounting the wheel. 
The advanced composite that we have used to build the 

UC legs can be a little “hairy” when drilled. This is normal, 

and nothing to worry about, and unlike fibreglass or 

carbon fibre it won’t hurt your fingers.

Use needle-nose pliers or small 

spanners to hold the nut nearest the 

wheel and tighten up the other nut so 

that both grip the UC leg. The wheel 

should turn freely without rattling 

around.

UC Leg, wheel, axle bolt, flange nuts

Summary of Contents for Fugly

Page 1: ...BrainCube Aeromodels Fugly BrainCube Aeromodels Ltd ...

Page 2: ... 400 grit sandpaper is fine for shaping balsa wood Drill Most holes are pre cut by our laser cutter but there are a couple of occasions where this isn t possible Wood glue This can be PVA aliphatic super aliphatic This will be used for the majority of the construction Thin super glue Also know as Cyanoacrylate or CA glue it comes in a variety of thickness s and speeds Thin CA is thinner than water...

Page 3: ...and 4 should all be performed at the same time to ensure the fuselage core structure is square In these three steps ensure that glue is applied to all the edges which touch FB1 FB2 F4 F4a T nut Before you begin construction make sure you cover your building board with polythene or cling film plastic food wrap to make sure you don t accidentally stick parts to the board ...

Page 4: ...tion Manual Fuselage 3 Fuselage Side F4 F4a Fuselage Side F4 F4a Fuselage 2 Assembly Fuselage 4 Fuselage Side Apply weights on top of the central structure to ensure the joints are square and solid Allow to dry completely before continuing ...

Page 5: ...ght and the fin vertical Do a dry run before glueing to familiarise yourself with the procedure and make sure everything is straight once clamped Tail Fin F5 Before continuing use a sanding block and carefully round off the front edges of the fin and tail Although you can wait until the fuselage is finished before you do this it is much easier before the fin and tail are glued into position ...

Page 6: ...y to the motor or from the front with the prop attached to the shaft via a prop adapter This step shows the front mounting This step shows the rear mounting option for the electric motor Tape the UC Plate into position before clamping the nose together F1 UC Plate Tape the UC Plate into position before clamping the nose together F1 UC Plate F1b F1 Alt F1b UC Plate F1 F1 Alt F1b ...

Page 7: ...eing to form a solid balsa block BS1 3 F7 CH block BS1 BS2 BS3 F7 CH Block Fuselage 8 Tape all parts in position to ensure they conform to the tail s curvature while the glue sets Be careful to ensure that the front edge of BS1 lines up with the front edge of the F3 former If these aren t flush the belly hatch won t fit ...

Page 8: ... gap between TS3 and F6 will be smaller than TS4 so trim TS4 to the correct length before glueing in position F1a TS1 TS2 TS3 TS4 F6 Carefully carve and sand the chin block into a smooth rounded profile Lightly sand the edges of the tail sheeting to round them off Also sand the joins to remove excess glue The primary structure of Fugly s fuselage is now complete and can be carved and sanded to smo...

Page 9: ...BrainCube Aeromodels Fugly Construction Manual 9 Nose Hatch 1 Nose Hatch 2 H3 x4 Clamp together on a flat surface after glueing to form two solid balsa blocks H1 H2 x2 H2 H2 H1 ...

Page 10: ...10 BrainCube Aeromodels Fugly Construction Manual Nose Hatch 3 Nose Hatch 4 Nose Hatch 1 Nose Hatch 2 H3 Nose Hatch 3 H3 ...

Page 11: ... x3 H4 H4 H4 Glue the H4 pieces into place from the H3 former forwards taping them down as you go Sand H3 so that it blends into the rest of the hatch shape Carve and sand the side pieces into a smooth rounded shape Sand the H4 sheets to remove excess glue and blend in the seams ...

Page 12: ...nd your fingers Do not allow the magnets to snap together as they may crack You will also need to ensure the polarity of the magnets are correct otherwise the hatch will not close Epoxy the magnet in position and ensure the glue has fully cured before allowing the other magnet anywhere near it it may be pulled out of the glue otherwise BH1 BH2 BH2 BH3 Magnet When covering note that the rear hole i...

Page 13: ...the balsa regarding orientation Carefully line up the jigsaw ends with the matching sockets and apply firm pressure equally to slide the parts together Be careful not to crush the balsa wood Make sure you cover your building board with polythene sheet or cling film plastic food wrap before you begin each control surface to ensure your parts do not stick to the board when glue is applied Each contr...

Page 14: ...antly Elevators E1 E5 E3 E5 E2 E4 E1 Fugly uses a pair of elevators linked by a wire joiner The construction of both elevators is the same and can be either built at the same time or one after the other Mind your fingers super glue will stick skin in seconds Once the glue has set use a sanding block to sand down all the joints to give a smooth surface for covering later After sanding use a scalpel...

Page 15: ...e there are no holes or tears for excess glue to soak through Ru1 Ru2 Ru3 Ru5 Ru4 Ru6 Ru7 Ru1 Ru7 Once the glue has set use a sanding block to sand down all the joints to give a smooth surface for covering later After sanding use a scalpel and sanding block to carefully bevel this edge so it can move freely once hinged ...

Page 16: ...f ailerons They are identical and can be built at the same time or one after the other Once the glue has set use a sanding block to sand down all the joints to give a smooth surface for covering later After sanding use a scalpel and sanding block to carefully bevel this edge so it can move freely once hinged ...

Page 17: ...he spar web with both upside down Be careful to ensure the spar web is fully inserted into the slot on each rib False LE TE Spar R5 R5 R5 x 2 Spar TE False LE Bolt Plate Bolt Plate Turn the ribs and spar web over Pin the balsa ribs to the board by the rear tab using the False LE and TE to keep them all square Make sure they are flat to the board Once pinned glue the False LE TE Bolt plate spar and...

Page 18: ...curvature of the ribs Ensure that the skin is glued to every rib the top of the False LE and the top of the spar Spar Wing hatch frame R1a x 2 Once the top skin has been glued on and fully dried unpin the wing and flip over Carefully trim the tabs off the bottom of the ribs then pin back down to the board upside down again through the balsa building tabs ensuring it is flat to the board Glue both ...

Page 19: ...Cap WS3 WS3 Bottom TE Cap Rib Caps The rib caps strengthen the wing ribs and provide a larger surface area for the covering to attach to Carefully sand the top of the False LE to match the curvature of the ribs Ensure that the skin is glued to every rib the top of the False LE and the top of the spar ...

Page 20: ... now stiff and strong the structure has become Because WS1 2 attach to the plywood central ribs they need to be taped down while the glue dries Use a sanding block to make sure the wing skins and false LE are flat before glueing the LE part into place Once the glue has fully dried from the previous stage carefully carve and sand the leading edge until it matches the curvature of the wing tips Use ...

Page 21: ... Covering Fugly is designed to be covered in heat shrink film There are many brands available such as Oracover Solar Film Coverite etc Please read and follow the instructions for the particular film that you are using Ensure that all seams are fully sealed to stop them lifting away in flight Make sure that the exhaust vent in the belly hatch is open to help everything stay cool in flight ...

Page 22: ...Cut them into the control surface first then cut the slots in the wing and tail to ensure they line up The hinges should be a firm fit into the slot too tight and they will bend instead of sliding in too loose and the glue won t form a strong bond Keep testing with a hinge as you open up the slots Elevator Joiner Elevator Joiner Wire Elevators Drill 2mm holes into the elevators to take the ends of...

Page 23: ... Do NOT apply glue yet The hinges need to be inserted into the structure DRY Once in place remove the pins Holding the elevators against the tailplane angle them downwards so you can get the nozzle of the thin CA bottle to the hinges Apply drops of glue to each hinge until they are saturated Wait 30 seconds for the CA to dry then flex the elevators up and down a few times to free the up Mind your ...

Page 24: ...and one for mounting the wheel The advanced composite that we have used to build the UC legs can be a little hairy when drilled This is normal and nothing to worry about and unlike fibreglass or carbon fibre it won t hurt your fingers Use needle nose pliers or small spanners to hold the nut nearest the wheel and tighten up the other nut so that both grip the UC leg The wheel should turn freely wit...

Page 25: ...2 Push Rods x 4 Clevises x 4 Linkage Stoppers x 4 Push Rod Clevis Control Horn Linkage Stopper Make sure that the linkage stopper can rotate freely in the servo arm Make sure that you use thread lock on the knurled ring that holds the linkage stopper onto the servo arm as well as the stopper grub screw once the push rod is in place Repeat this installation procedure for the other three servos You ...

Page 26: ...attery does not fall out during extreme manoeuvres Make sure the motor turns in the correct direction once you have fitted it If it doesn t swap two of the connections from the speed controller The top hatch is retained by hooks at the front and a small countersunk screw at the rear The receiver and speed controller should be fixed in place with double sided tape 34 34 50 50 50 50 15 15 20 20 25 2...

Page 27: ... if too far back Fugly will be very hard to control Congratulations your Fugly is ready to fly If you are not an experienced model pilot we recommend you ask one from your club to test fly the plane for you to trim it out Before the first flight make sure you do a range check of the radio with the motor running and a friend holding on to the tail Make sure you have the fail safe set to kill the th...

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