FLIGHT DESIGN EXXTACY Repair And Tuning Manual Download Page 1

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Exxtacy

Repair and Tuning Manual

Construction Basics

D Cell Repair

Rib Repair

Tuning

Exxtacy Construction Basics

The Exxtacy is built with carbon fiber and Kevlar/Aramide honeycomb. The Exxtacy’s main load bearing structure is based on a D cell, aptly
named because of its cross sectional shape.

Summary of Contents for EXXTACY

Page 1: ...ion Basics D Cell Repair Rib Repair Tuning Exxtacy Construction Basics The Exxtacy is built with carbon fiber and Kevlar Aramide honeycomb The Exxtacy s main load bearing structure is based on a D cel...

Page 2: ...area that has been affected will be readily identified by white streaks The spar is the vertical portion of the D cell and is protected by the curved surface to the front The ribs attach to the D spa...

Page 3: ...layers of belts near the nose with decreasing layers toward the tips These belts provide the main load bearing strength in tension and compression with the front or curved portion of the D cell provid...

Page 4: ...ikely to occur to the D cell is a dent or a puncture The surface of the D cell is covered with a fiberglass layer that allows for ease of visual inspection You can sight along the length of the D tube...

Page 5: ...th a knife making sure that the outside edge is cut away at a 45 degree angle to the outside surface Once you have removed the honeycomb inspect the interior layer of carbon fiber for any damage to de...

Page 6: ...ny of the exterior carbon fiber layer that has been damaged Lay a sheet of very thin clear plastic like from a plastic bag over the newly sanded damaged area and using a felt pen draw a circle equal t...

Page 7: ...A circle an arrow and a crosshatch After the first patch that fits onto the interior carbon fiber layer if you find damage to the interior layer and have to go down this far each patch is sized approx...

Page 8: ...ic pieces that is flip the thin sheets of plastic over such that the direction of the carbon fibers match the cross hatch directions indicted by the markings made earlier Measure out epoxy resin and 1...

Page 9: ...ze on the plastic Do not use a brushing motion as this has the effect of pulling the carbon fiber weave apart Also use only enough epoxy resin to cover the cloth cause it to adhere to the clear plasti...

Page 10: ...surface of the D cell Once in position and pressed into place carefully remove the outer clear plastic template If you have removed honeycomb be aware that it is impractical to replace the honeycomb...

Page 11: ...nding surface of the D cell with no excess and no lack of filler Now that you ve placed and interior surface patch and fill above it you can add the next two patches of carbon fiber Be sure to peel aw...

Page 12: ...overing of fiberglass in the same fashion Use heavy duty Mylar to hold the patches in place and to smooth the epoxy resin to conform to the outer surface Tape the Mylar tightly against the outer surfa...

Page 13: ...tly over the Mylar and hold it on with packing tape or duct tape wrapped around the entire spar Afterwards support the spar with the patched area down This allows gravity to keep the interior portion...

Page 14: ...he Exxtacy are constructed of carbon fiber tubes surrounding a foam square Any cracks or breaks are repaired by first lightly sanding the carbon fiber layer on either side to allow for adhesion of the...

Page 15: ...us amount such that the cloth is penetrated thoroughly to the lower layer Plastic vinyl tape is then wrapped tightly over and beyond the resined area The epoxy resin will not adhere to the tape and an...

Page 16: ...Also you can adjust the slackness in the control cables that attach to the corner of the controlbar Turning Adjustment If the glider exhibits a turn in either direction when flown straight and level...

Page 17: ...her and test before adding a thicker one Adding a washer at the bottom of the rib will increase the washout and at the top decrease For instance if the glider has a right turn then place a washer on t...

Page 18: ...ighting along the trailing edge The second factor that determines pitch pressure is the wing sweep This is adjusted by the setting the black straps at the trailing edge of the sail The sweep must be m...

Page 19: ...ular falls within the sweep marks made earlier Typically when the glider has more sweep the pitch forces will be higher Increasing the nose angle will lower the pitch forces Don t increase the nose an...

Page 20: ...20 of 20 Vulture Squadron Productions...

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