Carf-Models F4U-1D Corsair Page 6 Instructions Manual Download

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Page 6

Instruction Manual F4U-1D Corsair

CARF-Models Ltd. [email protected]

Getting Started!

It is highly recommended to assemble your Corsair following the steps in this instruction manual

closely. A lot of building steps are interacting and there are not too many choices as to what

should be done first, and what last. We recommend to follow this manual closely to avoid time

consuming and expensive mistakes.

CARF-Models offers the F4U-1D Corsair in 3 different versions. This manual starts at the very

beginning of assembling a folding wing kit version (#792000).

Assembling the plug-in wing version (#791000) doesn’t make much difference, to the general

building approach, of course will be simplifying the build a lot. The whole chapter about the

folding wing hardware installation, and also the hydraulics installation and plumbing, can be

skipped.

Most of you will be curious about what amount of building the ARF version (#793000) will

require from you. The photos below show all the parts, which the factory installs for you before

the plane is packed and shipped. If you look at these photos, you will ask, what you still will have

to do? Well, it’s not much anymore.

ARF Corsair Building Jobs: Installing your engine, your servos, and adjusting your

linkages. For transport reasons we do not glue the rudder fin on to the fuselage, but this is a

10 minute job to do. Assemble the 3 torsion linkages and connecting them to the controls

and the servos. Installing the landing gear (actually “bolting it in”), glueing in the clear

canopy and painting the whole plane in the scheme you picked. That’s all. All in all, you

might need to read a few tiny parts of landing gear installation, and then the last 10-12

pages about engine and RC installation. And of course, the finish and the preflight info.

Now, is it worth the extra money to go with

the ARF version? ...it depends on you!

If you are a builder, you will enjoy the build

every bit as much as if you’re more a flyer

and go for the ARF version.

All this is already
installed
in the CARF
Corsair ARF.

Summary of Contents for F4U-1D Corsair

Page 1: ......

Page 2: ...e not in a position to influence the way you build and operate your model and we have no control over the methods you use to install operate and maintain the radio control system components For this reason we are obliged to deny all liability for loss damage or costs which are incurred due to the incompetent or incorrect application and operation of our products or which are connected with such op...

Page 3: ... supplied in the kit Make sure that the Centre of Gravity is located in the recommended place Use the nose heavy end of the CG range for your first flights before you start experimenting with moving the CG back If you find that you need to relocate your batteries or even add weight in the aircraft to move the CG to the recommended position please do so and don t try to save weight or hassle A tail...

Page 4: ...ng of wires needs to be prevented by using rubber grommets where they are fed through the firerwall Do not assume that a radial engine runs without vibration A radial engine with a single sided counter balance on the crank shaft does have very noticable vibrations which seem softer than the vibrations of a single or twin cylinder gas engine but they are just as abrasive to any rubbing components C...

Page 5: ...nt into the structural integrity of the 3 part wing especially keeping in mind that a complex wing folding mechanism is to be used Fuselage and tail planes are a fairly standard design based on the many years of production experience of CARF Models The hard ware is complete and well chosen for the task Much of it is pre installed in the ARF version ...

Page 6: ... version 793000 will require from you The photos below show all the parts which the factory installs for you before the plane is packed and shipped If you look at these photos you will ask what you still will have to do Well it s not much anymore ARF Corsair Building Jobs Installing your engine your servos and adjusting your linkages For transport reasons we do not glue the rudder fin on to the fu...

Page 7: ...ure that the two gear ribs are in the absolutely correct alignment and position so that the wheel will fit nicely into the wing And it s tight back there So we square the mounts by leaving the gear mounting rails and the center wood connected by a few tabs It is a few minutes work to cut this part out Be careful not to damage the top wing skin with the jig saw blade After the center wood is cut ou...

Page 8: ...his area too The front outer corner of the gear unit is surely going to touch the top skin of the wing It s very tight there and you can mill out the 2mm sandwich foam to gain another 2mm space You can also grind the gear unit a little bit to round corners which will give you another one or two mm Cycle the gear by hand to see if strut and wheel do not bind or hit anywhere If the mounting rails ar...

Page 9: ...to mark the holes to be drilled With the gear mounted determine the best wood tab positions for the little sheet metal screws to hold the permanent gear covers in place You can use scrap pieces of 3mm plywood to make the tabs and glue them in place with thick CA Fit the permanent covers with tape and drill 1 5mm holes which will work perfectly for the supplied 2 2mm sheet metal screws Check allign...

Page 10: ...g and slide them on the hinge pin Assemble hinge pins and plastic tubes into the hinges Trial fit the doors with the assembled hinges into the wheel opening You will realize that the doors laminated carbon sheet are thinner than the sandwich material of the wing To create the correct hinge geometry you must remove the sandwich foam around the white plastic tubes so that the gear door surface and w...

Page 11: ...on and glue in with epoxy Usually you do not have to remove the mounts anymore you only have to make sure that you can access the e clip for the pin at any time to remove or replace the cylinder if necessary one day Set the end positions so that the cylinder still has about 1 mm available travel when the gear door is mechanically closed This will hold the gear door tight during flight When the cyl...

Page 12: ...slide back to the outer position in the slot causing the wing to flop back and forth in the wind when folded all the way up To prevent this a keeper is mounted to the locking pin which interlocks with a small pin in the center wing fold mount Incredibly simple but very effective and safe The Haeusl hydraulic system itself has been used in retract systems for many years and has proven its reliabili...

Page 13: ...erfere with the pin and get damaged As soon as the operation is carried out by the cylinder forcing the sliding pin into the end positon before any rotating movement is initiated this problem will not occur anymore Use 6x M5 bolts and stop nuts to bolt each unit in place Check the alignment in the down and up folded position as shown on the photos If the alignment is slightly off honestly there is...

Page 14: ...cceptable you should take the claws off the spar degrease the claws with alcohol or acetone and wax the bolts thoroughly Then apply Aeropoxy or UHU Endfest to the surfaces holes and bolts and permanently install everything finally Attention Do NOT tighten the bolts all the way Leave them turn open to allow the glue to form a perfectly matching bead between the spar and the aluminum part After the ...

Page 15: ...ich is then applied on the joint surfaces Slide the wings right on adjust them perfectly to the surface of the center wing and hold them in place with a full width masking tape Support the wing tip if necessary or use a long piece of masking tape to support it towards the center wing Let the resin set over night Next you should create the permanent fixture of the outer wing on the wing fold spar W...

Page 16: ...d micro ballon During the waiting time for the resin to cure you can disassemble the wing fold and determine the position of the front folding hinge You need to use an extended pin made from aluminum tubes carbon tubes or even a long round wood dowel to carry over the position of the virtual axis of rotation to the front hinge Trial fit the wood spar in the wing and mark the holes to be drilled to...

Page 17: ... sheet metal screws just as you did on the center wing hinge Apply 30 min epoxy with some microballon and or milled fibre to the wood piece which holds the outer front aluminum hinge Even if you do not get the joint perfectly in one shot you can easily create a nice fillet to this short plywood spar later on after you disassembled the front hinge by removing the M6 bolt and temporary nut and slidi...

Page 18: ...to the center and outer wing Glue a little piece of the sleeve tube into the center wing and glue an approx 20 mm piece of tube into the outer wing sleeve so that when the wings fold down it slides approx 6 mm 1 4 into the center wing sleeve We have included some sleeve and some tube for you in the hardware bag Congratulations You have managed to install the wing fold mechanics into your Corsair w...

Page 19: ...ed please fill with epoxy and some microballon Now glue in the two root rib reinforcements into both outer wing panels and center wing where the wing fixing bolt will be located Drill through the root ribs in this area insert an M6 T nut from the inside into the outer wing panel and trial fit the M6 wing bolt from the inside of the wheel wells We recommend to screw one of the white plastic knurled...

Page 20: ...that you align ailerons and flaps when the outer wing panels and the center wing are joined before you finally glue the flap offset hinges and the aileron hinge posts in The ailerons had a set of hinge posts installed in the factory to make sure that the critical hinge axis is placed correctly also that the hinge posts can move freely in the cutouts Mark the hinge post positions to the aileron spa...

Page 21: ...waterproof pen and mark the position of flaps and ailerons You can use some masking tape to protect the surface of the parts Some pens will not be 100 removable from the silver paint of the parts after installation is completed The edges of the wing surfaces need to be sanded from the inside so that the flaps can be installed deep enough into the wing Use a flat permagrit plate or a rough sand pap...

Page 22: ...he wing side of the flap offset hinges and the hinge posts of the ailerons all together Glue in the hinge posts and front parts of the offset hinges You should not use a resin too fast for the job It can take quite some time to align all surfaces properly 5 minute epoxy is definitely NOT suited and 30 minute epoxy can still be too fast Finish one wing first and then start with the opposite wing Do...

Page 23: ...remember that the control rod will need clearance below the 20 mm tube So you might have to cut the outer one of the front hinges short as shown on the photo before you finally glue it in Inner and center hinge of center wing Outer center wing hinge and both outer wing hinges Center hinge of center wing top view Slide every hinge down into the slot until the shoulder touches the wing surface cut h...

Page 24: ... min epoxy and make sure that the glue joint is solid and strong Due to the short arm less than 25mm 1 to the axis of rotation there will be a very high force on the horn and the glue joint during flight If this joint breaks the chances of aileron flutter are high which can lead to loss of control and disintegration in flight Lastly drill mill a hole into the aileron spar of the wing so that the c...

Page 25: ...ther with an M3 bolt or with an M3 secure nut on to the threaded stud Drill mill an elongated hole for the pushrod into the spar Using 2 channels for the flaps you would use 2 y harnesses and combine each inner and outer flap to one channel and vice versa The middle flap moves by a sliding plate interlocking into a slot Mill a long slot in the butting surfaces and glue the phenolic plate into the ...

Page 26: ...s point to make sure that the travel of every control surface is sufficient and that nothing locks or binds If necessary you need to adjust the linkage holes drilled in the spar and mill away some fiberglass material around the control horns Inner Flap Servo Outer Flap Servo Aileron Servo install with an extended screwdriver ...

Page 27: ...r assembly has already been glued in the fuselage Therefore it is important that you first understand the installation method with the slot in the wood and the phenolic shims to be glued to the wood when the installation is finally complete Install the complete tailgear and cylinder temporarily into the wooden framework before you finally glue it into the fuselage Cut a slot into the fin root rib ...

Page 28: ... and attach the springs between the tail gear frame and the control horns You will have to play with gear and doors quite a bit to find the perfect spring tension and the best position for the horns These horns also create a stop towards the fuselage skin inside the gear well You can reshape them if necessary or attach little plywood spacers to the inside of the fuselage where they rest against Fi...

Page 29: ...ame direction of deflection as the rudder Rudder Fin Take the vertical fin and slot its root surface according to the plywood spar penetrating the fuselage s fin fillet Slide the horizontal stab panels on to confirm the correct angle and glue the fin on to the fuselage Sand the surfaces with rough sand paper and clean with alcohol before you glue with 30 min epoxy As soon as the glue has set mark ...

Page 30: ...ts rails for the torsion linkage Assemble the torsion linkage from the prepared parts which you find in your hardware bag according to drawing and photos Don t forget to install the ball bearing with its plywood socket to the rod Dry fit the linkage to the rudders receptacle and mount everything to the fin fuselage Then you can glue the plywood bearing socket into the fuselage The torsion linkage ...

Page 31: ...the tube and over the anti rotation pin secure with tape and let the epoxy set After sufficient time remove the stab check the glue joint of the anti rotation pin and if necessary fill the remaining gaps with glue Mill the slots for the hinge posts into the stab surface s spar Shorten the inner hinge post so that it does not interfere with the stab tube The elevators have to be attached to the app...

Page 32: ...y After the glue has set drill 2 holes through the LEFT elevator torsion linkage with 2 4 mm diameter Tap an M3 thread into each hole counter sink the screw head into the elevator from the bottom side and mount both bolts NOW drill the holes for the opposite RIGHT elevator first adjusting both trailing edges exactly to the fillets on the fuselage you can trust the incidence of this fillet 100 Next...

Page 33: ...r the stab securing bolts You can trim that T nut to fit best inside the tube Wax a long M3 bolt and screw it into the nut during gluing so that the thread stays clean and vertical alignment is maintained The result of your work is a beautifully clean rudder and elevator installation without any visible control horns and linkages You are nearing the closing stages of your building work left is the...

Page 34: ...fy the process however we recommend to use our suggestion First glue on the firewall One 3mm plywood is glued from the inside to the firewall use microballon filled epoxy to fill any gap due to the seam band inside and one 3mm plywood is glued from the outside This outside plywood former is reinforced with a second one smaller in diameter which you need to glue on as well After the glue has set ta...

Page 35: ...glue surfaces well degrease with alcohol and glue with a good epoxy preferably Hysol or UHU Endfest 300 Wax an M4 bolt and turn it into the nut to keep the thread free of glue Alternatively Glue a scrap piece of plywood from the front against the plywood tabs in the cowl enlarge the holes to 5 5mm diameter and install a T nut the right way around Now it s time to mount the engine in our Instructio...

Page 36: ...ations in flight Please use large aluminum plates or washers and glue the T nuts reversed on to these plates They will distribute the load of the bolt better to the firewall s back side Now install the throttle servo and the ignition unit inside the fuselage to the back of the firewall Of course there are plenty of possibilities how and where to install both but please be aware that you MUST make ...

Page 37: ...est a very practical solution with the photo on the bottom of this page Aileron and flap servo extensions can be soldered up using multi pin connectors Standard extension leads of your radio manufacturer can also be used For the outer wing servos you will have to permanently install approximately 50 cm 20 long extension wires into the center wing Make sure that during the wing folding procedure th...

Page 38: ...roduced the use of 2 Jet Tronic valves Air plumbing is straight forward main gear and main gear doors can be permanently connected the cylinder for the tail wheel needs to be T d in with 2 quick disconnectors Please make sure that all air lines are installed clean and tidy so that you can trouble shoot easily if something is not working correctly Make sure that the color coding is clear the UP lin...

Page 39: ...ed on a rotating pin We have included a few milled phenolic parts which you can use for the valve mount Now permanently install the hydraulic lines from the cylinders to the valve Start on the pump side and leave the cylinder sides long and open The right left UP lines come together with a T fitting use only the black push in fittings and push into one connector at the valve block The DOWN lines w...

Page 40: ... priming procedure at this point Come back to this chapter later after the plane is painted Disconnect the return line from the plastic bladder Extend this return line with a 50 cm piece of Tygon tubing into a plastic cup placed beside or behind the center wing Connect a piece of Tygon tube to the return connector of the plastic bladder and fill it with baby oil You should keep the original contai...

Page 41: ...ockets placed right in front of the cylinder s tube fittings forcing them out of the return lines during the cycles This air will collect in the bladder and must be released as the final step of the priming procedure After all air is out slide both outer wing panels on secure them with the fixing bolts and increase operating pressure to 6 bar Then cycle the system again to test the speed of moveme...

Page 42: ...cale plane you re replicating is a restored and shiny bird Now you can scratch the panel lines with a screw driver or steel ruler chip color off the leading edge areas and around rivets and hatches if you want to create a scale patina on your plane The silver top coat of the fiberglass parts will shine through and look like beat up aluminum Finally use a pad of ScotchBrite and rub the surface in f...

Page 43: ...light If you feel that the range with engine running is less then with the engine off please contact the radio supplier and the engine manufacturer and DON T FLY at this time If you fly with 2 4 GHz technology please follow the radio manufacturer s instructions for range checking Always check range before a flying session After starting your engine the first time check for vibrations through the w...

Page 44: ... exactly you ll have a safe and successful first flight and many hours of pleasure with your CARF Models Corsair Important Note NEVER attempt to take off with full power especially when you use powerful engines like a Moki 250 The plane might nose over and this might create expensive damage Under full throttle you will not be able to keep the tail down using the recommended low rate elevator setti...

Page 45: ...bes Also included are 1x fuselage bag 1x wing bag 1x rudder bag and 1x elevator bag Wing Fold Kit Version 792000 This kit includes hardware bag No1 and No2 plus the complete wing fold system Also included are 1x fuselage bag 1x wing bag 1x rudder bag and 1x elevator bag Wing Fold ARF Version 793000 This kit includes hardware bag No2 the hydraulic components from the complete wing fold system as we...

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