Kavan F3RES, Instruction Manual

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4
(Fig. 2)
◊ Put the tail surfaces aside for now; they will be finished after the tailplane
seats are installed to the tail boom.
Fuselage (Glider Version)
◊ Trial fit the parts of the fuselage– no glue yet! Sand as necessary to obtain
perfect fit
(Fig. 3)
◊ Glue the liteply reinforcement plates F3 and F5L to the inner side of the
F17L
fuselage side (with the large opening for the
F16
hatch); glue the
plates F3 and F5R to the inner side of the F17R fuselage side (without the
hatch opening). (Fig. 4)
◊
Glue the F6 locking plate to the front of the F16 hatch; the locking plate
has to match the position of a notch in the F5L reinforcement plate and
the hatch matched the opening in the
F17L
fuselage side. The pair of
F21
magnets will be epoxied into the F16 hatch and F5L plate only after the
fuselage is covered – otherwise the high temperature of your sealing iron
might de-magnetize the magnets.
(Fig. 14)
◊ Epoxy together the tail boom holder consisting of the liteply part F13 and
plywood parts
F10
and
F14
. Attach the
F9
wing bolt plate with the M5
aluminium captive nut epoxied in place. Insert the entire assembly of the
tail boom holder between the fuselage sides. Now you can start gluing
the fuselage from the rear to the nose.
(Fig. 6)
◊ Glue together the nose part of the fuselage; do not forget bevelling the
edges of the fuselage formers and
F18
and
F19
liteply braces as required.
(Fig. 9)
◊ Epoxy the F9 wing bolt plate and the tail boom holder assembly in place.
◊
Bevel the F1 nose blocks and glue in place.
◊ Partially cut (ca 1 mm deep) and crack the fuselage sides along the front
edge of the
F2
fuselage former and glue them to the
F1
blocks (the cut
line is to be soaked with thin CA before the final sanding).
◊ Epoxy the tow hook plate F15 in place. Glue the F20 carbon ballast tube
into the holes in F7 and F8 formers. (Fig. 10)
◊ Glue the upper and lower 2.5 mm balsa sheeting to the fuselage. Slide the
tail boom tube
F22
onto the tail boom holder – do not glue yet. Fit and
glue the balsa fairing plates F11 and F12 in place. Carefully match all the
parts so the tail boom had a tight fit but remained still easily detachable.
(Fig. 11) (Fig. 12)
◊ Sand the entire front part of fuselage; take care all the parts including the
F11/F12
fairing created a smooth transition between the fuselage and
the tail boom. (Fig. 14)
◊ Insert the V16 carbon rods into the pre-drilled holes in the tail boom;
glue them in place. The bottom ends or the rods should stick out by ca
0.5 mm from the tail boom (there is an opening in the bottom side of the
tail boom in order to accommodate the tail skid
V12
) – refer to
Det. D
.
(Fig. 2)
Fuselage (Electric Version)
◊
The building sequence of the electric version fuselage is basically the
same as with the glider version except for the firewall, nose and servo
tray; also the
F20
ballast tube is not to be used.
◊
Instead of liteply F3 reinforcement plates, glue the balsa triangular sticks
E4 along the edges of fuselage sides
F17L
and
F17R
.
(Fig. 5) (Fig 7)
◊
Epoxy the E3 servo tray behind the F7 fuselage former.
◊ Epoxy the firewall E2 in place. Before you epoxy the firewall in, make
sure the openings and holes in the firewall match your motor – make any
changes as necessary or cut a new firewall to match your motor perfectly.
◊
Once the bottom and upper sheeting is in place cut the fuselage sides
flush with the front edge of the
E2 firewall. Temporarily install your mo-
tor and use the spinner as a jig to align the E1 plywood ring; once satis-
fied, epoxy it in place. Sand the nose to the desired shape matching your
spinner.
(Fig. 9) (Fig. 10)
Tail Surfaces - continued
◊ Glue the V9 pins into the tailplane seats V8L and V8R . (Fig. 15)
◊
Slide tailplane seats V8L and V8R onto the V16 carbon rods.
◊ Insert the V13 tailplane locks into the notches in the stabilizers (do not
glue yet).
(Fig. 16)
◊
Slide the stabilizers onto the V16 carbon rods and push against the V8R/
V8L seats until you hear the click announcing the V13 lock has engaged
the V9 pin of the stabilizer seat. Tack glue the locks into the stabilizers
with a few drops of CA. (Fig. 17)
◊
Push the stabilizers together with the tailplane seats to the tail boom and
tack glue the seats to the tail boom (apply the cyano sparsely; keep away
from the locks and
V16 carbon rods).
◊
Remove the stabilizers and epoxy the V8R/V8L seats to the tail boom.
Work thoroughly, but apply the epoxy sparsely; prevent the glue from
running into the openings for the stabilizer locks.
◊
The ruddervator horns V11 as well as the V12 tail skid will be glued in
later, after the tail surfaces are covered.
Wing
Wing Centre Section
◊
Epoxy together the wing central ribs
W3
and
W4
; insert 3 mm beech
dowels into the holes in order to obtain correct match. Note: Make a left
and right pair of ribs.
(Fig. 20)
◊
Epoxy the W10 wing fixing bolt plate between the central ribs. (Fig. 21)
◊ Epoxy together the parts of the W13 main spar shear webbing; the short
0.8 mm ply
W11
joiner (with a hole in the centre) to the front side, the
W12 long joiner to the rear side. (Fig. 22) (Fig. 23)
◊
Make bays for
P32
wing carbon joiners; epoxy together the
W14
front
(shorter) 0.8 mm ply plate, 5 mm ply central plate W15 and rear 0.8 mm
ply (longer, slanted edge) W16 plate. Prevent the epoxy hardening inside
the bays – put the parts together with the
P32
carbon joiner inserted,
then immediately remove the joiner (do not forget cleaning the joiner
using a paper tissue and rubbing alcohol before the glue sets).
(Fig. 24)
◊
Slide all ribs onto the mains spar shear webbing (no glue yet!). Bind the
joiner bays with the provided Kevlar thread and soak with medium CA.
(Fig. 25) (Fig. 26)
◊
Insert the W27 rear spar, trial fit the W30 leading and W17 trailing edges.
Sand to fit if necessary. Once satisfied with the fit, glue all the parts of the
wing centre section with medium cyano over the building plan protected
with a sheet of thin clear plastic film (you might find better gluing ribs to
the
W13
main spar shear webbing with an aliphatic resin).
◊
Edge glue together the W24 upper D-box sheeting (1.5 mm balsa) and
the
W26
upper 8x2 mm spruce stick main spar; once cured glue it to the
wing using aliphatic resin. Use a hardwood stick positioned along the
leading edge to push the balsa sheeting straight and even to the
W30
leading edge.
◊
Glue the W26 lower 8x2 mm spruce stick main spar in place.
◊
Bevel both two
R5
end ribs of the wing centre section using the supplied
7° dihedral jig. Then glue the W6 3 mm liteply end ribs. You might find
easier doing it later; with the P32 joiners inserted and finished wing outer
panels attached.
◊
Glue the W21 airbrake frame to the upper side of the wing; insert and
glue the airbrake bay reinforcement plate
W20
(balsa 1.5 mm) into
W5
,
W7 and W8 ribs. Cyano the W34 fibreglass bushings for the airbrake tor-