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Stevens Aero Model Built It! Daddy-O 525, Build Instructions

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Stevens Aero Model Built It! Daddy-O 525 Build Instructions Download Page 8

Laser Cut Parts Inventory

Build Instructions                                                                                                             

Daddy-O 525

 - Build Instructions © 2010 Stevens AeroModel, all rights reserved.

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Page 8

SAK-D525 13/29

SAK-D525 14/29

SAK-D525 15/29

SAK-D525 16/29

SAK-D525 17/29

SAK-D

52

5 

18

/2

9

SAK-D525 19/29

SAK-D525 20/29

Summary of Contents for Built It! Daddy-O 525

Page 1: ...Daddy O 525 Wing Span 52 5 inches Wing Area 485 square inches Average Flying Weight 36 ounces Build Instructions Version 1 24 revised 06 08 2015 ...

Page 2: ...s kit immediately in new and unused condition to the place of purchase THIS PRODUCT IS NOT INTENDED FOR CHILDREN 12 YEARS OF AGE OR YOUNGER WARNING This product may contain chemicals known to the state of California to cause cancer and or birth defects or other reproductive harm PRODUCT SUPPORT This product has been engineered to function properly and perform as advertised with the suggested power...

Page 3: ...e Bag 5 x 8 in 1 Aluminum tubing 3 16 in diameter x 6 in length 2014 1 Retractable ball point pen 1 Elevator Joiner E7 laser cut basswood 1 Package Du Bro RC Mini EZ connectors DUB845 4021 1 Package Du Bro RC Control horns DUB107 1 Tail wheel 3 4 in diameter Sullivan 4010 1 Pair foam wheels 2 1 2 in diameter DUB250SL 1 Wheel bushings 2 in length of 5 16 in diameter aluminum tube Small Hardware Bag...

Page 4: ...in CA Glue CA glue accelerator kicker Balsa filler Hobby Knife with ample supply of 11 blades Sanding block with 400 and 600 grit paper Heat Gun and Covering Iron Small Needle Nose Pliers Small Round Rat Tail file 2 ea 1 8 in dia Drill Bit 1 2 in or 12mm Socket 1 in x 12 in length sticky back velcro 2 3 Rolls AeroLITE or AeroFILM covering 1 Roll of AeroTRIM self adhesive trim sheet Suggested Build...

Page 5: ...e assembly process Protecting your worktable Use the poly tube that this kit was shipped in as a non stick barrier between your worktable and the product assembly Promptly clean up any epoxy spills with rubbing alcohol and a disposable towel Bonding the assembly As this product tabs notches and otherwise interlocks like a 3D puzzle we suggest that when fitting parts you dry fit use no glue the par...

Page 6: ...ut Parts Inventory Build Instructions Daddy O 525 Build Instructions 2010 Stevens AeroModel all rights reserved Page 6 SAK D525 01 29 SAK D525 02 29 SAK D525 03 29 SAK D525 04 29 SAK D525 05 29 SAK D525 06 29 ...

Page 7: ...ut Parts Inventory Build Instructions Daddy O 525 Build Instructions 2010 Stevens AeroModel all rights reserved Page 7 SAK D525 07 29 SAK D525 08 29 SAK D525 09 29 SAK D525 10 29 SAK D525 11 29 SAK D525 12 29 ...

Page 8: ... Build Instructions Daddy O 525 Build Instructions 2010 Stevens AeroModel all rights reserved Page 8 SAK D525 13 29 SAK D525 14 29 SAK D525 15 29 SAK D525 16 29 SAK D525 17 29 S A K D 5 2 5 1 8 2 9 SAK D525 19 29 SAK D525 20 29 ...

Page 9: ...ut Parts Inventory Build Instructions Daddy O 525 Build Instructions 2010 Stevens AeroModel all rights reserved Page 9 SAK D525 21 29 SAK D525 22 29 SAK D525 23 29 SAK D525 24 29 SAK D525 25 29 SAK D525 26 29 ...

Page 10: ...Laser Cut Parts Inventory Build Instructions Daddy O 525 Build Instructions 2010 Stevens AeroModel all rights reserved Page 10 SAK D525 27 29 SAK D525 28 29 SAK D525 29 29 ...

Page 11: ...s at flange using medium CA glue Set F1 aside Install F000 wing saddles to pre cut holes in F0 as illustrated Tack glue F000 only at tab and notch joints Locate ply former F2 etching forward and top side up within F0 as illustrated It will be necessary to slightly bow F0 and F2 until F2 interlocks with pre cut notches within F0 Do not use excessive force when fitting parts When properly located F2...

Page 12: ...e of F2 and F0 Test fit LG3 within fuselage on top of LG2 interlocking part with F2 and LG1 Note LG3 is designated a or b match a b designation to a b designation on parts F2 and LG1 Laminiate glue LG3 into position using thick CA glue Test fit LG4 on top of LG3 then using thick CA glue laminate LG4 on top of LG3 Build up a fillet of glue along dashed lines as illustrated below Complete previous s...

Page 13: ...ve gear legs Fit balsa former F3a to fuselage assembly as illustrated Pay close attention to FRONT TOP designation Retain part by tack gluing with medium CA glue at tab and notch joints Assemble two fuselage sides from parts Fa Fb Fc and Fd Glue along dove tail and finger joints using thin or medium CA glue Completed assemblies given in illustration Add fuselage truss work matching etched parts A ...

Page 14: ...F3a where the parts tab and notch together Align and bond with thick CA LG8 within fuselage side to capture LG7 Use photos below to reference location Detail of properly installed LG7 LG8 Now fit opposite fuselage side to assembly Match fuselage side to tab and notch joints in formers F1 F2 F3a and center crutch F0 Retain side to fuselage assembly by tack gluing at notches first then revisit with ...

Page 15: ...it at bottom of fuselage assembly between formers F1 and F2 An arrow is etched on F8 indicating proper forward orientation of part Inspect parts for proper and complete fit within fuselage assembly then bond Seat and bond three parts F9 to top of fuselage assembly spanning formers F1 and F2 as illustrated An arrow is etched on F9 to indicate proper forward orientation of part Fit part F11 spanning...

Page 16: ...ing formers F3a F4a F5a F6a and F7 F10 seats 3 32 in proud of all formers but F3a and F7 From two 24 in lengths of 3 32 x 3 16 in strip wood stock cut six 8 in lengths Now install two of these lengths to right and left of fuselage passing through former F4a F3a and captured by LG8 as illustrated below Bond with medium CA glue Next bond two more lengths to right and left of fuselage spanning LG8 an...

Page 17: ...rts F14 moistened gently wrap to meet at the fuselage centerline and retain with masking tape Do not glue until dry To pass the time while parts F14 are allowed to dry proceed to install stringer work to bottom of fuselage from six 24 in lengths of 3 32 x 3 16 in balsa strip wood stock Use a sharp knife to remove plug from center notch of former F6a on right and left of former Now bond two 24 in l...

Page 18: ...ith fuselage side and previously installed stringer Use a razor saw and sanding block to cut and sand excess strip wood flush with front surface of former F3a From four 24 in lengths of 3 32 x 3 16 in strip wood stock cut fourteen 8 in lengths Soak cut lengths of strip wood with glass cleaner to soften then fit to notches in formers F1 F1a and F2 at underside of fuselage Retain strips of wood with...

Page 19: ...and bond all turtle deck parts with medium CA glue Install turtle deck strip wood stringers in the same manner as used on fuselage underside using six 24 in lengths of 3 32 x 3 16 in strip wood stock Begin by using a sharp knife to remove plug from right and left center notch at F6b as illustrated below Bond length of strip wood stock to right and left center notch of turtle deck spanning formers ...

Page 20: ... as illustrated Once stringer work in nose of model has dried Remove rubber bands seat and bond stringers to formers then cut and sand stringers flush with the outside surfaces of formers F1 and F2 Once F14 sheeting has dried Remove tape then fit and bond sheeting to supporting structure F1 F2 and F9 Sand F14 flush with outside surfaces of formers F1 and F2 Install pushrod guide tubes from Du Bro ...

Page 21: ...ck CA glue to retain Finally cut tube flush with side of fuselage Battery Hatch Bond H1a to H1b to create part H1 Bond two each parts H2 to H1 as illustrated below Note H2 is tabbed to fit only one direction within H1 Fit then bond hatch formers H3 H4 H5 H6 and H7 to assembly as illustrated below Note formers are not intended to install perpendicular to H1 Build Instructions Daddy O 525 Build Inst...

Page 22: ...rs to hatch using H7 and H6 to locate the strip wood Note These stringers run the length of the hatch leaving one open notch in between stringer runs at formers H3 H4 and H5 From three 24 in lengths of 3 32 x 3 16 in strip wood stock cut eight 8 in long stringers Fit and bond stringers to hatch in previously skipped notches Finish stringers at point mid way between H5 and H6 as illustrated Cut and...

Page 23: ...pit Using medium CA glue bond H10a and H10b together over a flat work surface to create part H10 Fit parts H19 to slots at narrow end of H10 built in previous step then key to hatch former H14 Tack glue to retain parts Tip Sand a slight chamfer to tabs on H19 to make fitting of these parts easier Fit hatch formers H11 and H12a to assembly as illustrated Rounded tops of formers should all locate to...

Page 24: ...7a and H17b creating part H17 cockpit sheeting Make two parts H17 Fit part H17 to right and left of cockpit assembly aligning tabs in H10 with notches in H17 Bond H17 along lower portion of H11 and sides of H10 to stand perpendicular to work table as illustrated below Moisten H17 with glass cleaner allow 3 min working time for wood to soften then wrap H17 over assembly and retain with masking tape...

Page 25: ...e so that flat of washer measures 3 4 in from outside edge of wire at bend Disassemble ball point pen and retrieve spring for use in latch assembly Slip ply part H12c over wire against previously installed nylon washer follow with spring from ball point pen Finish by sliding second nylon washer over wire to capture and slightly tension spring See illustration Once H17 has dried remove tape align a...

Page 26: ...ward edges of H21 prior to installing Ply part H12c on latch assembly locates within bottom center hole of H12b hole is keyed As latch is installed to cockpit assembly wire must pass through nylon tubing as illustrated With latch fully seated within cockpit assembly latch wire should extend forward of H11 by 1 8 to 3 16 in Make any adjustments to fit of latch assembly then bond H12c latch within H...

Page 27: ...ed to both Battery Hatch and Cockpit assemblies It will be important to match the proper orientation polarity of the remaining 3 magnets to their respective catches and locations Begin with battery hatch catches C1 tall and and C2 short Test fit C1 and magnet to wide end of Battery Hatch at H3 Test fit C2 and magnet to narrow end of Battery Hatch at H7 Once satisfied that catches are located to pr...

Page 28: ...per lightly sand cockpit to fit and flow with fuselage shape Fit battery hatch within fuselage between F2 and F3b Use a sanding block with fine grit paper to lightly sand Battery Hatch to fit and flow with fuselage shape Now lightly sand fuselage with 400 grit paper in preparation for covering Balsa filler may be required to fill small gaps at notch points along fuselage sides this is especially t...

Page 29: ...ustrated Reference first two bends flat to your work table then make final bend 2 1 2 in from 45 degree bend perpendicular to worktable Slip provided 3 4 in dia tail wheel over last bend Using needle nose pliers make a sharp 90 degree bend in wire to retain wheel Trim excess wire beyond wheel Completed tail gear should appear as below Note the etched L shape in Rudder parts R1 and R2 Use a scrap o...

Page 30: ...ation below Horizontal Stabilizer Complete Vertical Stabilizer by sanding leading edge of Vertical Fin round Sand square trailing edge of both Fin and Rudder Finish sand right and left side of parts with a sanding block and 400 grit paper Assemble outer frame work of Horizontal Fin from parts HS1 HS2 HS4 and HS5 Fill in center of fin with HS3 HS6 HS7 and truss parts marked C and D Assemble outer f...

Page 31: ...eaving the trailing edge square Square the trailing edge of the elevator Do not glue Elevator Halves together This concludes assembly of the major fuselage components Any imperfections you leave on the surface of the fuselage will be highlighted by the covering Thus check your work for quality and finish Re bond any areas of the frame work that were not properly bonded Remove glue residue from the...

Page 32: ...a back on top of R1 aligning notches edges and alignment holes Remove alignment dowels Your completed R1 rib should appear as below Right R1 rib pictured Repeat for left R1 rib Place WM1a on a solid work surface with etched TOP side up Drive two 8 32 blind nuts through WM1a from the TOP down as illustrated Stop driving blind nuts through part when they bottom out on the work table Now place part W...

Page 33: ...embly beneath WM2a and between ribs R1 as illustrated Use 1 8 in alignment dowel holes to assist in positioning of part Use medium CA glue to fit and bond ply part WM2b within hole in TE2a that s keyed to receive part Support trailing edge of wing assembly using a 1 2 in socket centered under WM2b while driving one 8 32 Blind Nut through hole in WM2a passing through WM2b Bond blind nut at flange u...

Page 34: ...g scarf joint Bond parts with medium CA to create one T1 turbulator jig Fit T1 turbulator jig to top side of ribs at forward most notch point Note When properly seated T1 will fit flush with top profile of ribs R1 but stands 1 16 in proud of top profile of ribs R2 through R7 Fit a right and left rib R3 to wing assembly first at T1 turbulator then at S1a spar jig Finally fit TE3 to TE1 and join R3 ...

Page 35: ...and tack with medium CA glue Now fit S1b to S1a spanning R4 and R5 and tack glue at ribs Fit servo pocket SR1a to R5 and S1b and tack with medium CA Finally draw S1a and S1b together at scarf joint and bond with CA glue Repeat for opposite side of wing Tab ribs R6 and R7 to wing assembly first at T1 then at S1b finally at TE5 Remember T1 stands 1 16 in proud of ribs Tack with medium CA glue to ret...

Page 36: ...ong dove tail joint to create S2 top spar jig Fit top spar jig S2 to wing assembly interlocking triangular tab notches with lower spar jig between ribs R1 and triangular tab notches between ribs R7 and R8 Once properly seated to all ribs tack with medium CA glue to retain Using heavy shears or an abrasive cut off wheel cut one of the provided 24 in lengths of flat carbon stock to exactly 12 in in ...

Page 37: ...t instruction on this page to fit 10 in length of carbon flat stock This time spanning bottom recess between left and right ribs R1 and R2 and located beneath S1 lower spar jig Bond carbon to spar jig with medium CA glue Use second 48 in length of 1 8 x 1 4 in balsa strip wood for bottom spar cap Start lower spar cap centered to the right rib R7 and allow cap strip to overhang left side of wing Ho...

Page 38: ... has been shown for top spar cap Repeat for opposite side of wing using second length Fit truss rib parts marked X to wing assembly Beginning with rib R2 the wide end of rib will locate centered between the top and bottom spar cap against inside edge of rib and forward of shear web The notched pointed end will rest against the leading edge of the next inside rib Tack glue wide end of truss rib whe...

Page 39: ...th of 1 8 x 3 16 in balsa stock to underside of wing Join with strip wood centered to left R3 and finish beyond right wing tip Dry fit two 36 in lengths of 1 8 x 3 16 in balsa stock to top of wing at center and aft notches in ribs Start centered to right and left R3 and finish beyond right and left wing tip designates start point Dry fit two 24 in lengths of 1 8 x 3 16 in balsa stock to top of win...

Page 40: ...ding edge of wing tip flowing curve of wing tip through parts Repeat for top bottom of right left wing tip Cut two 12 in lengths from remaining 1 8 x 1 4 in balsa strip wood Soak 12 in strips with glass cleaner tape into position shown at wing tip and allow to dry and take shape of bend Once dry bond strips centered to leading edge of both right and left wing tip to form wing tip lamination Cut ov...

Page 41: ...webs at sides of ribs X truss ribs at spar web X truss ribs at leading edge Wing mount at ribs R1 Trailing edge at center section Use a sharp knife and sanding block to remove riser tabs from bottom of all wing ribs Shape leading edge of wing using a razor plane and a long sanding bar loaded with 400 grit paper A nice round not sharp leading edge is preferred When shaping the leading edge test fit...

Page 42: ... fill pocket within A5a with glue Create two aileron control horn pocket parts Lay out aileron assemblies mirrored as below fit aileron control horn pocket ribs to assembly at the second notch from A4 ribs Attention Make certain that pocket to receive control horn faces down Fit remainder of aileron ribs A5 A6 and A7 Check for proper fit of all parts and tack with medium CA glue Build Instructions...

Page 43: ...eron assembly in channel cut to A2 Bond with medium CA glue Tip Lightly sand cutting residue from balsa bond area Glue then tape carbon part one rib bay at a time beginning with A7 A6 rib bay and ending at A5 A4 rib bay Use a sanding block to taper A1 leading edge to match thickness of A2 trailing edge at tip Lightly sand aileron assemblies in preparation for covering Locate control horn pocket fa...

Page 44: ...dge of cockpit Use a pin vice or scrap of 1 32 wire and drill hole at this location Repeat on opposite side Remove protective plastic from windscreen Drive 0 x 3 16 in screw through hole in windscreen then through hole in cockpit side Capture screw threads on inside of cockpit with one ply washer Repeat to opposite side Seat lower edge of wind screen against top of cockpit deck Use remaining holes...

Page 45: ...er servo With servos centered use hardware that shipped with your servo to mount from top down through servo pockets in fuselage center crutch with tabs resting on top of crutch Prepare servo horns Locate the long single sided control horn that shipped with your HS 65HB MG servo Install Du Bro RC Micro E Z Connector DUB845 through second hole from inside of horn Mount prepared servo horns to cente...

Page 46: ...eys to assist with location of parts Repeat for numeric parts in 2 9 order Fit and bond ply part WP1 to receiving pocket within each wheel pant assembly using thick CA glue Use a 1 8 in dia drill bit passed through hole in wheel pant opposite WP1 to properly locate WP3 plywood bushing within wheel pant as illustrated Repeat for opposite wheel pant assembly Use a sharp knife razor plane and sanding...

Page 47: ... pant Cover or seal and paint wheel pants and ply parts WP2 to match trim scheme of aircraft Wheel bushings Cut two 3 4 in lengths from the provided 2 in length of 5 16 in dia aluminum tubing Install one bushing in each main wheel Tack bushing centered within wheel using medium CA glue Do not allow glue inside of bushing Example of properly installed bushing Note Bushing may be lubricated with a l...

Page 48: ...h thin CA glue Then install wire landing gear leg through wheel pant capturing foam wheel within pant Secure wire gear leg within pant using ply part WP2 and four 2 x 1 4 in sheet metal screws Do not over tighten screws Repeat assembly for opposite gear leg Build Instructions Daddy O 525 Build Instructions 2010 Stevens AeroModel all rights reserved Page 48 Wheel Gear Leg 2 screws WP2 Wheel Pant Ha...

Page 49: ...a sanding block to match top and bottom edges of fairing to fuselage side and wheel pant Cover fairing to match trim scheme of model Then remove covering from gear leg slots in right and left fairing Fit trimmed fairing to wire gear on designated side Retain fairing with self adhesive AeroTRIM or clear tape placed over top of gear wire Tip you may elect to use a flexible adhesive Shoe Goo to secur...

Page 50: ... fillet interior joints of mount with thick CA glue Test fit then using thick CA bond M3b with FRONT side facing up as illustrated When bonding M3b keep glue well clear of blind nut threads Mount Hacker A30 16M Stevens AeroModel SA Sport BL 10 or other suitable 350W motor using radial mount hardware provided by manufacturer of motor and four of the provided 4 40 x 3 8 in machine screws in preparat...

Page 51: ...xcellent battery pack seat belt Fit cowl over fuselage center motor shaft hole in cowl to output shaft of motor and temporarily retain with masking tape Drive four 2 x 1 4 in sheet metal screws two on each side through cowl and into long tabs on fuselage Remove tape screws and cowl Harden screw holes with thin CA glue then re install cowl Install an 8 in length of 3 4 in wide self adhesive hook an...

Page 52: ...g a 1 64 in gap between parts at hinge line Optional Seal along hinge line with covering material Use methods described previously to locate and fit CA hinges to right and left Elevator and Horizontal Stabilizer use a minimum of three CA hinges per Elevator Optional Seal hinge gap with covering film Bond hinges within RIGHT Elevator and Horizontal Fin leaving a 1 64 in gap between parts at hinge l...

Page 53: ...overing if desired Use a sharp knife to remove covering over vertical fin pocket on top and back of fuselage Mount vertical fin within pocket and secure with Medium CA glue From sheet 29 1 32 ply select two A8 parts of crossing wood grain Matching parts along edges bond on top of each other to create an aileron control horn with a final thickness of 1 16 in Repeat to make two A8 horns Open slot ab...

Page 54: ...embly instructions With cockpit removed from fuselage Mount wing centered over wing saddle Pass three wing mounting bolts through center crutch Two bolts installed at right and left of fuselage near wing leading edge One bolt installed between servos near wing trailing edge Adjust bolt sleeve in length as required to just pull wing snug within saddle Do not cut sleeves too short With wing installe...

Page 55: ...enter servo With servos centered use hardware that shipped with your servos to mount through right and left servo pockets in wing Prepare servo horns Locate the long single sided control horn that shipped with your HS 65HB servo Install Du Bro RC Micro E Z Connector DUB845 through second hole from inside of horn Mount prepared servo horns to centered servos with horn perpendicular to servo body an...

Page 56: ...of Vertical and Horizontal Fin With surfaces centered tighten set screws in Micro E Z connectors at Rudder and Elevator servos Trim excess push rod wire 1 2 in forward of servos Final Assembly Concluded Congratulations this concludes the final assembly of your StevensAero Daddy O 525 We hope you have enjoyed the build just as much as we ve enjoyed designing it for you To ready your Daddy O 525 for...

Page 57: ... of always pre flighting your models before each and every flight Weight and Balance Refer to the Flight Control Setup section for balancing your model correctly Ensure that the Daddy O 525 s CG is in the appropriate location for your experience level Check Weather Daddy O 525 s first flight should be in zero wind conditions Daddy O 525 is comfortable flying in winds up to 15 mph so long as the pi...

Page 58: ...ight was a bit more exciting than you d have liked and you re having problems with erratic flight performance please inspect your equipment and airframe for damage improper installation and or twists and warps The most common mistake is to mis identify or ignore a warped wing Trying to fly with a warped or twisted wing will reduce the solid feel imparted by this excellent design Daddy O 525 is cap...

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