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Sapac T-45 Goshawk Composite V2, Assembly Manual, Page: 1 / 35

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Assembly Manual

Assembly Manual

 

 

The World’s Finest Electric Aircraft 

www.SapacAmerica.com 

Specifications 

Material: 

Length: 

Wing Span: 

Wing Area: 

All Up Weight: 
Wing Loading: 

EDF: 

Recommended Motor: 

Recommended ESC: 

Recommended Battery: 

Radio System: 

T

T

-

-

45 Goshawk Composite V2

45 Goshawk Composite V2

 

 

Composite Fuselage, Balsa Wings 
39.3 in 
37.4 in 
1.937 ft² 
54 - 65 oz 
27 - 33 oz/ft² 
70mm with 5 Blade Fan 
2842MB1 @ 3200KV (1100W) 
80A+ 
LiPo, 4s 3300 - 3700 mAH 
4 - 6 Channel (optional retracts) 

Summary of Contents for T-45 Goshawk Composite V2

Page 1: ...ing Area All Up Weight Wing Loading EDF Recommended Motor Recommended ESC Recommended Battery Radio System T T 45 Goshawk Composite V2 45 Goshawk Composite V2 Composite Fuselage Balsa Wings 39 3 in 37 4 in 1 937 ft 54 65 oz 27 33 oz ft 70mm with 5 Blade Fan 2842MB1 3200KV 1100W 80A LiPo 4s 3300 3700 mAH 4 6 Channel optional retracts ...

Page 2: ...modification of or to any part of the Product This warranty does not cover damage due to improper installation operation maintenance or attempted repair by anyone other than Sapac Return of any goods by Purchaser must be approved in writing by Sapac before shipment SAPAC SHALL NOT BE LIABLE FOR SPECIAL INDIRECT OR CONSEQUENTIAL DAMAGES LOSS OF PROFITS OR PRODUCTION OR COMMERCIAL LOSS IN ANY WAY CO...

Page 3: ...d Optional 11 Build Gear Mounts 11 Cut Slots in Wing for Gear Mounts 11 Prepare Gear Mount Covers 12 Bond Main Gear 13 Main Gear Final Assembly 14 Main Gear Retractable Optional 15 Select Retractable Gear Strut Geometry 15 Cut Openings in Wing for Mounts and Gear 16 Mount Gear 17 Route and Connect Air Lines 18 Final Assembly 18 Wing Belly Pan 19 Fit Wing Bolt Reinforcement 19 Trim and Fit Belly Pa...

Page 4: ...tors 44 Fan Installation 45 Assemble Fan Unit 45 Mount Fan Unit 46 Wire and Mount ESC and BEC 48 Thrust Duct 49 Assemble Thrust Duct 49 Insert Thrust Duct in Fuselage 50 Bond Thrust Duct Locating Ring 50 Bond Thrust Duct to Inside of Fan Shroud 51 Trim Away Excess Thrust Duct 51 Radio Installation 52 Radio Installation Overview Diagram 52 Wire and Mount BEC and or Receiver Battery 52 Mount Receive...

Page 5: ...ponents o o o o F Main Fuselage o o o o E Stabilizers Elevators o o o o W Wing o o o o W1 Wing Belly Pan o o o o C Cockpit Canopy Additional Kit Components The following are the additional components included with the T 45 Kit Additional kit components o o o o H1 Main Hardware Bag o o o o H2 Thrust Duct Elevator Hardware o o o o M EDF Electric Ducted Fan Unit o o o o D Decal Set ...

Page 6: ...ed Landing Gear Hardware Main o o o o F1 Fixed Landing Gear Hardware Nose o o o o F2 Rudder Option Wooden Elements o o o o F3 Hook Loop Fastener for Battery o o o o F4 Hinges o o o o T Wheels Tires Thrust Duct Elevator Hardware Bag Contents H2 The following are the components packed in the Thrust Duct Elevator Hardware Bag H2 Thrust duct elevator hardware o o o o M1 EDF Unit Shroud o o o o M2 Thru...

Page 7: ...ble Landing Gear 4S 3300mAH 3700mAH Lithium Polymer Battery Lithium Polymer Battery Charger Building supplies and tools as referenced in each assembly step Available Optional Components To complete your T 45 the following components are recommended by SAPAC as they are designed to work seamlessly with this model Motor SAPAC 2842MB 1 Kv3200 Dynamically balanced 3200Kv outrunner motor designed speci...

Page 8: ... Assembly Sequence 4 T 45 Goshawk Composite A As ss se em mb bl ly y S Se eq qu ue en nc ce e Assembly sequence for SAPAC T 45 Goshawk Composite V2 ...

Page 9: ...up to the desired position Make sure you have a small gap between the flap and the wing around both edges and there is no rubbing or binding Using thin CA glue with a thin applicator place a few drops on each side of the hinges By using thin CA you will make sure that the glue is wicked up the complete surface of the hinge for a tighter bond Avoid the use of accelerator in this joint since you don...

Page 10: ...rvo bays Reinforce the cover mounting holes in the wing with thin CA adhesive to add strength to the plywood and provide the cover screws a stronger surface to attach to Reinforce screw holes with CA adhesive Using a sharp hobby knife trim away the covering from the servo arm slots in the servo covers Remove covering from servo arm slots Using a hand drill with a bit slightly larger in diameter th...

Page 11: ...ation of the holes Use a hand drill to avoid splitting the wood and make sure that you use a bit that is only slightly smaller in diameter than your servo mounting screws Tip when drilling the pilot holes for the servos in the mounting posts drill then in such a way that you will be able to mount the servos flush to the servo covers This will allow for maximum clearance for the servos inside the t...

Page 12: ...using Epoxy adhesive Mount control horns with Epoxy adhesive Route Servo Wires Required Parts o o o o Wing W o o o o Aileron Servo Assembles 2 W3 o o o o Flap Servo Assemblies 2 W3 o o o o Servo Cover Mounting Screws 8 W3 o o o o Any required servo extensions and or Y harnesses Required Tools and Adhesives Hobby Knife Flashlight String Wire Small Weight Magnets for running wires through the wing S...

Page 13: ... Required Tools and Adhesives Ruler Needle Nose Pliers Z Bend Pliers optional Screwdriver Starting with the flap servos manually center the flaps and measure the distance between the holes in the servo arm and the control horn Use the hole in the servo arm closest to the servo that still provides the necessary clearance for a full range of motion Bend a V into the control rod halfway between the t...

Page 14: ...y are in the completely retracted position as you will use them as a reference for centering the ailerons when creating the aileron control rods Create the aileron control rods in the same way the flap control rods were created Insert the aileron control rods and mount the aileron servos using all four servo cover screws ...

Page 15: ... with the mounting of the gear Cut Slots in Wing for Gear Mounts Required Parts o o o o Wing W o o o o Main Gear Cover for measuring W5 Required Tools and Adhesives Hobby Knife Pen Flashlight Locate the opening for the main gear on the bottom side of the wings close to the flap servos You will notice the balsa wood sheeting has been removed over the gear mounts Using a sharp hobby knife cut away t...

Page 16: ... Adhesives Hobby Knife Thin CA Adhesive Hand Drill Drill Bits Screwdriver Using a hand drill with a bit sized to drill pilot holes for the main gear cover screws drill four holes in each cover at the marked locations Pilot holes in Gear Cover Using a sharp hobby knife cut away the covering over the strut hole in the Main Gear Covers Temporarily assemble the gear struts and the gear cover to the ge...

Page 17: ... W5 Required Tools and Adhesives 12 Minute Epoxy Adhesive Disassemble the gear mount assemblies you will bond the gear mounts into the wing on their own Bond the completed main gear mounts using Epoxy adhesive The following picture shows the places where Epoxy adhesive needs to be applied Epoxy adhesive locations for main gear mounts You may need to temporarily insert the main gear strut to guide ...

Page 18: ...o o o Main Gear Tires 2 T o o o o Main Gear Collets 2 W5 Required Tools and Adhesives Screwdriver Hex Wrench Thread Locking Compound Mount the main gear struts to the main gear mounts using the main gear covers and the main gear cover screws Completed main gear assembly Mount the tires to the main gear struts using the supplied collets Use thread locking compound so that the wheel collets won t co...

Page 19: ...or landing gear strut geometry 1 You can use the straight struts provided with the retractable landing gear unit and bend to suit 2 You can adapt the fixed gear struts to the retractable landing gear units If you choose to use the straight struts provided with the retractable landing gear you will use the following cutout geometry labeled For scale Straight strut wheel location Straight strut cuto...

Page 20: ...the square void under the covering denoting the location of the landing gear mounts trim away the covering using a hobby knife Lay the template on top of the wing using the landing gear mount cutout to determine the correct location You will be using the template to locate the score marks laser etched into the sheeting under the covering Use the gear mount to place the template Use an erasable pen...

Page 21: ...hand drill with a small bit to drill pilot holes for the mounting screws Drilling pilot holes for retractable landing gear mounting screws Once the holes have been drilled reinforce the holes and the mounts using a couple of drops of thin CA adhesive Make sure you use screws long enough to go through the entire gear mount but not through the wing s top balsa sheeting Don t be tempted to use the sc...

Page 22: ...to length leaving just a little slack and attach them to the retract units Air line connected to the retract unit This is a good time to test the retract units you can do this by temporarily attaching your retract pump to the wing quick release valve Final Assembly Required Parts o o o o Wing W o o o o Main Wheels T o o o o Wheel Collets W5 o o o o Landing Gear Struts 2 Required Tools and Adhesive...

Page 23: ...semble wing and measure for squareness Once you are happy with the wing placement mark the location of the wing bolt reinforcement plate This will guide you later when trimming away the covering from the balsa sheeting Trim and Fit Belly Pan Required Parts o o o o Wing W o o o o Wing Mounting Hardware W2 o o o o Main Fuselage F o o o o Wing Belly Pan W1 Required Tools and Adhesives Hobby Knife or ...

Page 24: ...ing bolt reinforcement plate Make your cut on the line or slightly outside the line to make sure that your reinforcement plate is completely bonded to the wood You can use a sharp hobby knife for this but make sure that you take a shallow cut to avoid scoring the balsa sheeting and weakening the wing Another option is to use a hot knife to melt through the covering without damaging the balsa sheet...

Page 25: ...n place remove them and clean them before the Epoxy is dry Tip apply some petroleum jelly or lithium grease to the bolt threads for extra insurance against bonding Bond the wing bolt reinforcement plate with Epoxy adhesive Make sure you hold the plate in position firmly with clamps since there is a slight curvature to the wing this will ensure a strong bond Clamp the wing bolt reinforcement plate ...

Page 26: ...on the fuselage in its final position Use thick CA or other adhesive of choice on the exposed balsa sheeting to bond the belly pan to the wing Bonding the belly pan to the wing Ensure that the Belly pan is aligned with the body and tape it in position while the adhesive dries When the bond is dry remove the wing and run some adhesive along the front and rear edges of the belly pan to increase the ...

Page 27: ... to have a small gap both at the top and at the bottom of the rudder to avoid binding Reinforce Rudder Required Parts o o o o Rudder F o o o o Rudder option wooden elements F2 Required Tools and Adhesives Sharp Hobby Knife Hobby Saw Sandpaper 12 Minute Epoxy Adhesive Thin CA Adhesive Thick CA Adhesive Now that the rudder has been separated from the fuselage reinforce it with the provided wood elem...

Page 28: ...ols and Adhesives Pen Sharp Hobby Knife Hobby Saw or Small Rotary Cutter Needle files Screwdriver 12 Minute Epoxy Adhesive Before you bond the vertical stabilizer reinforcement pieces you need to install the servo The servo will be bonded in position in the inside of the vertical stabilizer Find the best location for your servo making sure it will not interfere with the existing plywood spar locat...

Page 29: ...is If you bond the servo to both sides you will deform the vertical stabilizer and may disrupt the smooth operation of the rudder Once the Epoxy adhesive is dry test the servo to make sure it did not seize up due to any stray adhesive Reinforce Vertical Stabilizer Required Parts o o o o Fuselage F o o o o Rudder option wooden elements F2 Required Tools and Adhesives Sharp Hobby Knife Hobby Saw 12 ...

Page 30: ...it moves freely and without any binding if you need to make any adjustments now is the time While the rudder is still fitted to the fuselage mark the position for the control horn Dry fit hinges and mark location for control horn Remove the rudder and mount the control horn using whatever mechanism is called for by the control horn If using a wooden control horn like the one shown in the picture t...

Page 31: ...rvo arm or the control horn to mount the control rod you will have to use a control rod with a removal mechanism on one end This could be a threaded clevis a linkage stopper or as seen in the picture below a simple E Z Link Use a control rod with a removal mechanism here we used one with an E Z Link on the end Measure the desired length of the control rod and bend it to shape Completed rudder modi...

Page 32: ...teering control horn to the end of the set screw Once you are happy with the position and the geometry remove the top collet from the strut Use a sharp hobby knife to clear away the flashing from the nose gear hole enlarge the hole until the strut will pass through it Insert the strut through the hole in the bottom of the fuselage and all the way through the two plywood supports Attach the collet ...

Page 33: ... servo to achieve the desired steering geometry and sensitivity Make Control Rod Required Parts o o o o Fuselage F o o o o Fixed Landing Gear Hardware Nose F1 o o o o Linkage Stopper Optional Required Tools and Adhesives Ruler Needle Nose Pliers Z Bend Pliers optional Screwdriver With the servo in position temporarily connect your radio and check which side of the servo arm you will want to connec...

Page 34: ...age F o o o o Fixed Landing Gear Hardware Nose F1 o o o o Wheels Tires T Required Tools and Adhesives Hex Wrench Thread Locking Compound Attach the nose wheel to the strut using the collet you set aside earlier Use thread locking compound to ensure the collet does not come loose Completed nose wheel assembly ...

Page 35: ...e picture Place the template in front of the hole and centered on the fuselage draw the outline of the template on the tape Using a sharp hobby knife hobby saw or small rotary cutting tool cut out the opening for the retractable nose wheel as shown in the picture below Once the opening has been cut clean up any edges and corners using needle files Nose wheel cutout complete After the nose wheel op...

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