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Layout the locations for the servo arm cut out and control horn as shown in photo 28

Using your receiver or servo cycler power up the servo and set it at neutral. Attach the
control arm at a vertical position. Mount servo in fin as shown in photo 27. The slot may
need to be enlarged in size slightly with a small file if the servo arm binds.

Secure control horn with adhesive and let cure.

Construct linkage as shown in photo 29 &30.

After adhesive is dry remove fixture. The servo installs with the
top of the servo mounting tabs making contact with the servo
rails, if the servo has reinforcement on the top tab it may need to
be removed so the servo will sit flush on the mounts. The servo
spline faces the front of fin.

Layout hole positions

Photo 27

Photo 28

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Summary of Contents for FEI BAO

Page 1: ...F E I B A O R A F A L E 1 FEI BAO JETS Rafale Assembly Manual Written By Rich Miller In collaboration with R C Jet Models ...

Page 2: ...urbine pilot to do your maiden flight Very often the first few seconds of a maiden flight are critical until the aircraft is trimmed out and having an experienced pilot at the controls can make the difference between a wrecked aircraft and once that enjoys many hundreds of flights Be sure to select a suitable field for flying take the time to find a large paved runway if at all possible especially...

Page 3: ...e of Hysol is it takes overnight to dry properly It is recommended that you only use a proper Hysol dispensing gun and only the long type mixing nozzles Pneumatic Systems Pneumatic retracts typically are the number one maintenance issue with most models however with proper installation procedures and preventive maintenance this need not be the case All Fei Bao jets uses pneumatic gear doors retrac...

Page 4: ... Fuselage Nose Section Fuselage aft section Canopy Cockpit Tub Forward and Aft Equipment tray Hatch Bypass Right and Left Wing panels Right and Left Elevons Rudder Vertical Stabilizer Right and Left Canard Two Tail Cones Right and Left Fuel Tanks Center Tank Refueling Probe Raised Servo Hatch Wing Servos Two Elevon linkage covers Hinges Linkages Hardware kit Air Kit Gear Doors and Cylinders factor...

Page 5: ...quencer RCBEE from RC Jet Models or equivalent Brake valve or Electronic Actuator Batteries regulator and switch Servo extensions length may vary depending on receiver placement Ordinance Package Construction The order of construction may be changed to suit your personal preference Note any fiberglass surface on the inside of the airframe that requires components to be bonded should be cleaned wit...

Page 6: ...l the hole required for the hinge point photo 4 I used Robart large hinge points for the extra hinges required Now all hinge points can be glued into the surface it is recommended to used some oil on the hinge pin to make sure that adhesive does not work its way in and cause a bind see photo 5 Make absolutely sure that oil does not get on the part of the hinge that will be glued any stray oil can ...

Page 7: ...e hinge point location The additional hinge location will require the TE of the wing to be drilled to fit a dowel rod that will hold the hinge The rod should be a bit longer that the hinge point section to be glued Glue in the dowel rod and let the adhesive fully cure before drilling the hinge point hole Next the control horns need to be positioned and the slot cut out for its mounting Start by in...

Page 8: ... control horn and the control surface any extra adhesive should be removed a toothpick works well for getting into tight spots Trial fit the Elevon into the wing panel see photo 8 the surface should be inserted so free movement is achieved in both direction and no binding exists between the fiberglass TE extensions and the surface If travel is limited by the TE of the wing then using a long sandin...

Page 9: ...del that I built I devised a method to utilize the flat hatches This required structural modifications not covered in this manual see Photo 10 for preview and is covered in detail on the build thread that I started on RC Universe see the following thread for the details http www rcuniverse com forum m_8458710 mpage_1 key_ tm htm A brief synopsis of the modifications Cut out section of wing skin Re...

Page 10: ...iver or servo driver find servo neutral and attach the heavy duty servo arm I use the aluminum arms supplied with the Hi Tec HS 5955TG servos that were used Pull the servos through the wing to the roots the stock leads should be of sufficient length label the servo wires for Elevons Position the servos onto the mounting tabs You may also need to trim the lip of the servo well slightly to provide c...

Page 11: ...he factory intended method concealed and the second will be the author s alternative method The factory intended method for installing the rudder servo features a hidden linkage design the servo will be installed in aft section of the fuselage to give the Rafale a scale look This method requires the use of a pin and socket arrangement to transfer the motion from the servo arm to the rudder The har...

Page 12: ...ted pin onto the top of the fuselage masking tape applied to the fuselage in the area that the marking is needed works well Cut the slot in the fuselage as shown in photo 16 Note It is recommended that a standard sized servo be use for this method Prepare the heavy duty servo arm by mounting the cup assembly as shown in photo 17 Mount The L brackets to the servo the L brackets should be on the rig...

Page 13: ...eavy duty servo arm with the arm placed as shown in Photo 17 Mount the rudder servo to the bulkhead position as shown in photo 19 20 using socket headed wood screws the arm will be facing towards the rear of the fin Verify that the cup receptacle follows the arched cutout in the fuselage Hint a ratchet type angled Allen driver works well in confined spaces see photo 18 Mount servo on this side of ...

Page 14: ...uselage and verify operation using your receiver or a servo driver see photo 21 If the rudder movement is satisfactory then permanently mount fin to fuselage by tightening the rear clamping bolt and inserting the front pin bolt and washer see photos 22 23 Photo 21 Photo 20 ...

Page 15: ...rease rudder deflection and less chance of surface flutter The cut out in bottom of fin measures x 1 7 8 cut slot as shown see photo 24 From scrap wood fabricate a mock up of the servo top case this will serve as a fixture for locating the servo mounting blocks See photo 25 26 the servo used for the subject of this manual was a HiTec HS 245 Material Servo Blocks Front 3 8 sq x 1 Rear 3 8 x 1 4 x 1...

Page 16: ...p servo fixture with the mounting blocks as shown in photo 27 Make sure not to get glue on the mock up servo fixture or it will be difficult to remove later After the adhesive has cured on the mounting blocks remove the mock up servo fixture Blocks that will be glued into place Servo Fixture Photo 26 Photo 25 ...

Page 17: ...larged in size slightly with a small file if the servo arm binds Secure control horn with adhesive and let cure Construct linkage as shown in photo 29 30 After adhesive is dry remove fixture The servo installs with the top of the servo mounting tabs making contact with the servo rails if the servo has reinforcement on the top tab it may need to be removed so the servo will sit flush on the mounts ...

Page 18: ...d will bind as the rudder is actuated Cut a servo lead access hole in the fuselage as shown in photo 31 Connect your servo extension and secure with tape or heat shrink tubing Secure the front of the fin to aft fuselage with the supplied bold and large washers see photo 23 and use Loctite on the threads Secure the clamp bolt on the fin see photo 22 Photo 31 Photo 30 Photo 29 ...

Page 19: ...tilize Velcro straps If a removable air tank installation is desired fabricate the air tank hold down brackets from the attached templates see photo 32 Feed the Velcro straps through the slots and around the tank to secure see photo 33 34 Make sure to prep the area in the fuselage by sanding and cleaning where the plywood hold down plate will be attached Glue in the plywood hold down plate with th...

Page 20: ...20 Photo 36 Photo 34 Photo 35 ...

Page 21: ...m The two saddle tanks may also be connected using tee fittings feeding the main tank this is up to the builder preference as tee fitting are provided with the hardware package All fuel system lines should be properly inserted onto the tubing and safety wired to prevent unwanted and potentially harmful leaks Note Restriction in the fuel system may cause performance issue with your turbine such as ...

Page 22: ...ubing with wire ties before re assembly Once the tanks are back together they should be leak checked before installation in the aircraft Connect extra lengths of fuel tubing to the fuel and vent lines and submerge the tank in water Pinch off one line and gently pressurize the tank by blowing into the other looking for signs of air bubbles If the tank shows evidence of air leakage around the vent c...

Page 23: ...engine mounting rails and slide the saddle tanks in position see photos 44 45 Use Velcro Strap around main tank Spacer block glued under center of tank mounting plate prior to gluing plate to fuselage Spacer Block mounts underside in this area Velcro Strap Sl Photo 41 Photo 42 Photo 43 ...

Page 24: ...ddle tank and bring them together with a Y fitting just above the intakes Repeat this process for the vent tubes in the saddle tanks Run a length of fuel tubing from the Y fitting connected to the fuel pickup tubes of the saddle tanks to the vent tube of the main center tank Attach a length of tubing to the Y fitting connected to the vent tubes on the saddle tanks The vent fitting will be position...

Page 25: ...nnections at this time If you use plastic wire ties Tyraps to bind the fuel tubes together for a neater installation make sure not to over tighten and pinch down on the flexible fuel tubing For a series connected saddle tank system run a length of tubing from pick up line of one saddle tank to the vent line of the other Then run a length of tubing from the pick up of the second tank to the vent of...

Page 26: ...er is installed on the right side of the fuselage and is mounted to the rear hinge To get the proper location of the wooden mounting block connect the cylinder rod to the door hinge temporarily connect the other end of the cylinder to the wood mounting block Blocks shown in photo 53 Extend the rod completely and hold the front door to its maximum open position mark the location of the wood block o...

Page 27: ...27 Photo 49 Photo 51 Photo 50 ...

Page 28: ...28 Photo 52 Photo 53 Photo 54 ...

Page 29: ...29 Photo 56 Photo 55 Spacer ...

Page 30: ...the door cylinders photo 62 are installed as shown in photos To get the proper location of the wooden mounting block connect the cylinder rod to the door hinge temporarily connect the other end of the cylinder to the wood mounting block Blocks shown in photo 63 Extend the rod completely and hold the main doors to in their maximum open position mark the location of the wood blocks on the inside of ...

Page 31: ...31 Photo 59 Photo 58 Photo 60 ...

Page 32: ...32 Photo 61 Photo 62 Photo 63 ...

Page 33: ...en reassemble making sure that the set screws are snug Attach air lines and test the retract unit with a hand pump making sure it will hold air and operates smoothly check for air leaks in a container filled with water see photo 66 If leaks are detected disassemble cylinder and make appropriate repairs Photo 66 Locating Cylinder Photo 64 Photo 65 ...

Page 34: ...cted Modify the E Z connector by chucking it up in a drill or Dremel tool to spin it then while it is spinning sand it on a belt sander or a file to add the 45 degree chamfer on the top The chamfer is needed to ensure the cable loop does not get caught on the edge See photo 68 for details Fasten the E Z connector to the tiller arm using the supplied clips the E Z connectors should be inserted from...

Page 35: ... of the gear Insert a bolt in each hole as it is drilled When all four holes are drilled and you are satisfied with the alignment remove the retract unit 4 40 Allen head bolts and blind nuts were used for this build drill out each hole to be large enough for the blind nut Insert these from the top and snug them down with one of the bolts Apply a little CA to the back of the blind nuts sparingly to...

Page 36: ...r retract cylinders Working carefully to make sure the retract unit stays in this position and aligned equally to either side of the gear opening drill one of the holes closest to the forward former Insert a bolt into the hole to hold this position see photo 73 Proceed to drill the other three holes making sure to maintain alignment of the gear Insert a bolt in each hole as it is drilled Photo 73 ...

Page 37: ...ors Two smaller main doors open 4 Two small nose doors Two smaller main doors closed Operation of the gear door cylinders is up to the builder s discretion as many options exist for this model it was decided to operate the door system with two servo driven two way valves and a electronic gear door sequencer This will be an overview of the process involved The first valve will control the opening a...

Page 38: ... was decided to fabricate a new servo mount to position the steering cables in a straight line from the tiller arm The new mount was placed into the nose section see photo 75 Fabricate the servo mount battery holder as per photos 76 through 80 Inspect all the nose mounting holes in the fuselage to insure they are free from debris Try the bolts and make sure they all thread easily Position the nose...

Page 39: ...39 Photo 76 Photo 77 Photo 78 ...

Page 40: ...40 Photo 79 Photo 80 ...

Page 41: ... undisturbed if a tray needs to be removed for other servicing The pneumatic retract system in the model is operated by three valves The first two way valve controls gear up and gear down the second two way valve controls the gear doors that stay open with retracts down and the third two way valve controls the doors that close with the gear down All three servos are connected to an electronic sequ...

Page 42: ...42 Photo 82 Photo 83 ...

Page 43: ...encer receiver voltage regulator and ECU to name a few can be done using mounting plates glued to the fuselage in positions where space allows Slots cut into the plates allow for the use of Velcro strapping to hold the components see photos 84 through 87 Photo 84 Photo 85 Photo 86 ...

Page 44: ...lind nuts were installed on the cross brace before gluing to the bulkhead to facilitate the tray mounting see photo 90 Even with the rear of the tray doubled it was noted that the tray was still able to flex to stiffen the tray a plywood standoff rear tray brace was fabricated for the back of the tray The brace was mounted to the fuselage via wood screws to a block that was glued to the bottom of ...

Page 45: ...45 Photo 89 Photo 88 ...

Page 46: ...46 Rear Tray Brace Front Mount Doubler Rear Tray Mounting Screw 4 40 Blind Nuts on bottom of cross brace Photo 91 Photo 90 ...

Page 47: ...m the lower former a bit to allow the bypass to move far enough aft to keep the rear of the pipes in position Position your engine on the mounting rails Set the gap between the rear of the exhaust cone and the mouth of the pipe to manufacturer s specifications This is usually around 20 mm You may need to trim some material off the intakes to allow the engine to sit far enough forward If required m...

Page 48: ...a bell mouth that will be used to hold the shape of the pipe inlet attach as per the manufacturers recommendations see photo 93 Step 14 Engine Accessories For ease of maintenance it is recommended that the major engine fuel handling components i e pump solenoids should be mounted on a removable plywood plate Also the ECU should be mounted on its own plate see photos Photo 93 ...

Page 49: ...49 Photo 94 Photo 95 Photo 96 ...

Page 50: ...ed Step 16 Tail Accessories Bolt the exhaust cones to the aft firewall Bolt the center section to the aft fuselage Reference photo 97 this completes the aft fuselage work Step 17 Ordinance The mounting locations for the ordinance are predrilled from the factory Using the supplied hardware to mount the rails to the wing section it is suggested to use Goop between the rails pylons and the wing this ...

Page 51: ...tude on the trim knob VB B or slider control VR D Note The canard trim control could be programmed to one of the side mounted slider controls such as VR D for ease of access to be used to experiment with high AOA landings CH 8 Aux 2 Nose gear steering Mixed with CH 4 VR A was used for trim also Mixed with CH 5 this channel is enabled with Retract Down only Step 19 CG and Control Throws Set the Cen...

Page 52: ...wing tip When looking from the rear of the model it will have the appearance of having down elevator applied Aileron throw should be in low rate the first flight Adjust this in subsequent flights to suit your flying style The Rafale has a tremendous amount of aileron authority and it requires very little control movement to give impressive roll rates Canard throw will be in the 25 mm up and 12 mm ...

Page 53: ...e each flying session Check for proper radio operation slowly cycle all surfaces with the transmitter making sure they are moving in the correct direction and proper deflection Note it is easy to lose a model due to a simple mistake of selecting the wrong model memory in the transmitter Check all linkages use keepers on the quick links Check Canard clamp fitting for tightness Check Vertical fin mo...

Page 54: ...54 Congratulations you have completed construction of your Fei Bao Rafale ...

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