Stevens AeroModel SkyBoy 600 Manual Download Page 6 | Manualshive

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Laser Cut Parts Inventory

SkyBoy 600 © 2010 Stevens AeroModel all rights reserved.

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Summary of Contents for SkyBoy 600

Page 1: ...SkyBoy 600 By Stevens AeroModel Length 36 inches Span 48 inches Wing Area 640 inches2 Flying Weight 36 oz Version 12 03 2010 SkyBoy 600 2010 Stevens AeroModel all rights reserved Page 1 of 55 ...

Page 2: ...not prepared to accept the liability associated with the use of this product the buyer is advised to return this 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 S...

Page 3: ...n x 045 wire SUL S97254 2 12 in x 1 2 in paper tube 5 x 8 Hardware Bag 6 32 rubber bands 4 Razor Control Horns DUB936 3 3 16 in x 4 5 in hardwood dowels 2 Wing Tip Skids DUB990 1 Pkg Large Rubber Bands HBZ7127 1 3 4 in tailwheel 1 Pkg 1 8 in wheel collars DUB139 1 1 32 in laser cut ply grill Part F16 1 1 16 in laser cut ply wing trailing edge reinforcement Part W9 1 3 16 in laser cut basswood elev...

Page 4: ...Hyperion G3 7 4V 2100mAh 2 cell LiPo Battery HP LG325 2100 2S SkyBoy 600 2010 Stevens AeroModel all rights reserved Page 4 of 55 Required Building Supplies and Tools Pair 4 1 2 in Big Lite Wheels DAV5740 1 oz Medium CA Glue 1 2 oz Thick CA Glue 1 oz Thin 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...

Page 5: ...Laser Cut Parts Inventory SkyBoy 600 2010 Stevens AeroModel all rights reserved Page 5 of 55 ...

Page 6: ...Laser Cut Parts Inventory SkyBoy 600 2010 Stevens AeroModel all rights reserved Page 6 of 55 ...

Page 7: ...Laser Cut Parts Inventory SkyBoy 600 2010 Stevens AeroModel all rights reserved Page 7 of 55 ...

Page 8: ...Laser Cut Parts Inventory SkyBoy 600 2010 Stevens AeroModel all rights reserved Page 8 of 55 ...

Page 9: ...Laser Cut Parts Inventory SkyBoy 600 2010 Stevens AeroModel all rights reserved Page 9 of 55 ...

Page 10: ...ock wood sizes run several thousandths of an inch over sized slightly reduces the thickness of each sheet Leave your pre sanded parts in the sheet until required in the 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 disposab...

Page 11: ...ach end of HS2 Bond HS4 to HS1 assembly and parts HS3 to complete outer frame Bond cross piece HS5 and B diagonals to each side to complete Horizontal Stabilizer Elevator Build one half at a time Start by bonding E1 to E2 SkyBoy 600 2010 Stevens AeroModel all rights reserved Page 11 of 55 HS1a HS1b HS4 HS2 HS3 HS3 HS2 HS1 HS3 HS3 HS5 E1 E2 HS1 B Diagonals ...

Page 12: ...rt E6 Bond with medium CA Vertical Stabilizer Bond parts V1 V2 and V3 together to form Vertical Stabilizer frame Rudder Using a short length of 045 wire scrape out the etched areas on parts R1 and R2 to create a recess for the tail wheel wire The recess should be just deep enough for the 045 in wire to seat snuggly SkyBoy 600 2010 Stevens AeroModel all rights reserved Page 12 of 55 E2 E3 E1 E3 E4 ...

Page 13: ...3 Finally bond R5 to R4 and R1 to form Rudder outer frame Bond part R6 and A diagonals to complete Rudder Frame Tailwheel Cut a length of 045 in wire to 5 1 2 in long SkyBoy 600 2010 Stevens AeroModel all rights reserved Page 13 of 55 R1 R2 R2 R3 R3 R4 R5 R1 R4 R6 A Diagonals 5 1 2 in Long ...

Page 14: ...er 45 degree bend 90 degrees from the plane of the first two bends Make another 45 degree bend 1 4 in from the last bend Make a 90 degree bend 1 2 in from the last bend Trim any excess wire 1 2 in from the last bend SkyBoy 600 2010 Stevens AeroModel all rights reserved Page 14 of 55 A 1 1 8 in A B 7 8 in A B C 2 0 in D C 1 4 in C D E 1 2 in E 1 2 in D C ...

Page 15: ...red with medium CA Using thick CA bond R7 to base of rudder trapping wire Ensure holes for rudder horn line up and are not fouled with glue Bond remaining R7 to the other side of the Rudder with thick CA Bevel leading edge of rudder and elevator at a 45 degree angle SkyBoy 600 2010 Stevens AeroModel all rights reserved Page 15 of 55 45 deg R7 R2 R1 R7 45 deg ...

Page 16: ...rt of F3 up to the notches behind F2 Carefully twist F3 into place Tabs on F3 will rest on top of F1 crutch DO NOT GLUE Fit F4 to slots in F1 just behind F3 Prongs on F4 point in the same direction as the tops of F2 F3 DO NOT GLUE SkyBoy 600 2010 Stevens AeroModel all rights reserved Page 16 of 55 F1 F2 F3 F3b F3 F2 F1 F2 F3 F1 F1 F4 Top Top Up Top Tab Top View Top View ...

Page 17: ...UE Bond F6b to bottom of F6 with thin CA Fit F6 to taps at the end of F1 DO NOT GLUE The completed fuselage crutch assembly should appear as below Ensure that all formers are positioned correctly with their tops up then tack glue with medium CA SkyBoy 600 2010 Stevens AeroModel all rights reserved Page 17 of 55 F5 F5b F6 F6b F5 F1 F6 Top Top View Tab Tab Top F6 F2 F3 F4 F5 ...

Page 18: ... 32 in bond with thin CA With etching on fuselage doubler facing up fit fuselage crutch to doubler Ensure tabs on crutch extend through forward part of doubler 3 32 in as shown Tack glue crutch to doubler with medium CA Cut longeron from 18 in length of 3 16 in square balsa to and fit to slots in formers and fuselage doubler Tack glue at formers F2 and F3 only SkyBoy 600 2010 Stevens AeroModel all...

Page 19: ...d later DO NOT GLUE Fuselage Side Fit and bond parts FSa and FSb together with thin CA Fit and bond FSc to FSb Fit and bond FSd to FSc and FSb Fit diagonal braces in slots in fuselage side SkyBoy 600 2010 Stevens AeroModel all rights reserved Page 19 of 55 F4 Longeron F6 Longeron FSa FSb FSa FSb FSc FSc FSb FSd Diagonals ...

Page 20: ...ll parts Remove fuselage side and coat doubler with thick CA then immediately re fit fuselage side pressing doubler side together on a flat surface Hold assembly on a flat surface and bond all mating surfaces with medium CA Motor Mount With the etched back side facing up drive the four blind nuts in the circled holes of F7 with a hammer SkyBoy 600 2010 Stevens AeroModel all rights reserved Page 20...

Page 21: ...n flush with the back of F6 Fit and tack glue F8 to right fuselage side trapping longeron Left Fuselage Doubler With etching facing up fit and bond together parts FDa b c Left On a smooth flat surface fit FDd Left to previous assembly Ensure that etching on all parts face up SkyBoy 600 2010 Stevens AeroModel all rights reserved Page 21 of 55 F7 FDd F6 FDc FDb FDa Left Side Bond Trim Do Not Cut Thr...

Page 22: ... to F2 and F3 Do not glue to any of the other formers Allow longeron to extend past F6 a little This will be trimmed later DO NOT GLUE Fuselage Side Refer to steps on pages 14 and 15 and complete the second fuselage side in the same manner Temporarily fit fuselage side and check alignment and fit of all tabs SkyBoy 600 2010 Stevens AeroModel all rights reserved Page 22 of 55 F6 Do Not Glue Longero...

Page 23: ... bond all remaining mating surfaces on the left side with medium CA Trim left longeron flush with rear of F6 Aft Fuselage Fit and tack glue F9 to one fuselage side Bring sides together and tape fitting and tack gluing F9 in place Do not glue aft and of fuselage at this time SkyBoy 600 2010 Stevens AeroModel all rights reserved Page 23 of 55 F6 Bottom View F9 Top View Do Not Glue F9 Tape ...

Page 24: ...k glue F9a F10 assembly to top rear of fuselage Fit and bond one part F12 to F9a and F10 Fit and bond the other part F12 creating a pocket for the vertical stabilizer The rear portion of F12 will overhang the fuselage sides slightly This will be sanded off later SkyBoy 600 2010 Stevens AeroModel all rights reserved Page 24 of 55 Bottom View F13 Top View F9a F10 F10 F9a F9a F10 F12 F12 Overhang F9a...

Page 25: ... are numbered 1 2 and 3 Fit and bond one stringer 1 into top slots in F6a and F9a Slot numbers correspond with stringer numbers Fit and bond remaining stringer number 1 on the other side SkyBoy 600 2010 Stevens AeroModel all rights reserved Page 25 of 55 F11 F10 F11 F10 F6a F10 Stringer 1 Stringer 1 F6a F9a F6a Stringer 1 1 1 2 3 2 F9 F9 Top View Top View Top View ...

Page 26: ...ts in the top of F6a and F9a Do not allow piece to extend into pocket for vertical stabilizer Align extreme end of fuselage sides and bond with medium CA Bond all mating surfaces in the rear fuselage with medium CA Sand forward ends of stringers flush with F6a SkyBoy 600 2010 Stevens AeroModel all rights reserved Page 26 of 55 F12 Stringer 1 2 3 3 16 square Balsa F6a F9a F6a Stringer 2 stands prou...

Page 27: ...it around the fuselage When sheeting in in position and dry bond it with thin CA Repeat the process for the nose sheeting NS positioning it between F2 and F3 Assemble and bond the hatch catches from parts Ca and Cb Insert a neo magnet in each catch assembly Bond from the back with medium CA SkyBoy 600 2010 Stevens AeroModel all rights reserved Page 27 of 55 F8 CS F2 NS Ca Cb Neo Magnet Top View To...

Page 28: ...N3 through N6 creating a wedding cake that will later be shaped into some pleasing curves Fit and bond hardwood landing gear mount in slots in fuselage doubler The groove should line up with the slots in the fuselage sides Fit and bond F14 to F3 overlapping landing gear mount but not the groove SkyBoy 600 2010 Stevens AeroModel all rights reserved Page 28 of 55 F8 N2 N1 F2 F14 Top View Top View To...

Page 29: ...s of recessed fuselage doublers with thick CA and lay the grill down between fuselage sides Hold in place with tape until CA sets Hatch Begin hatch by fitting parts H2 to H1 Join assemblies with spine H3 Fit former H4 to spine H3 Square on a flat surface and bond all parts with thin CA SkyBoy 600 2010 Stevens AeroModel all rights reserved Page 29 of 55 F14 F15 F15 F16 F15 F16 H2 H1 H3 H4 H3 F2 ...

Page 30: ...CA Fit and bond assembly to hatch base H5 Fit one half of hatch sheeting HS to spine H3 Align edge of HS down the center of spine H3 and tack glue with thin CA Wet sheeting wrap around formers and tape in place Allow to dry Ensure assembly is square and tack glue sheeting in place Repeat process to attach the other half of HS SkyBoy 600 2010 Stevens AeroModel all rights reserved Page 30 of 55 Neo ...

Page 31: ...ushrod housing through the rear most slot on the RIGHT side of the fuselage Pass pushrod housing through the furthest LEFT hole in F9 through left hole in F6 and finally 1 8 in through left hole in F5 Bond housing at each former and at the exit point in the fuselage side with a drop of medium CA SkyBoy 600 2010 Stevens AeroModel all rights reserved Page 31 of 55 Bottom View Bottom View Bottom View...

Page 32: ...the RIGHT holes in F6 and F5 leaving 1 8 in extending beyond F5 Bond at each former and fuselage exit Trim pushrod housings flush with fuselage sides Final sand your fuselage Round the nose to a pleasing shape and round off the edges of the fuselage leaving the wing saddle area square SkyBoy 600 2010 Stevens AeroModel all rights reserved Page 32 of 55 Bottom View Bottom View Bottom View F5 F6 Left...

Page 33: ...lower spar cap align ends with etch marks on W1 and fit into slots in R1 s DO NOT GLUE Assemble trailing edge from from part W2a and two parts W2b Bond with thin CA Fit ribs R1 to center slots in trailing edge W2 and tack glue Fit ribs R2 to main spar and trailing edge tack gluing in place SkyBoy 600 2010 Stevens AeroModel all rights reserved Page 33 of 55 W1a W1b R1 W2a W2b W2b W2 R2 R2 R1 W1 Etc...

Page 34: ...3 s in place Cut upper spar cap from 1 4 in square balsa 26 in long Fit into slots on top of ribs centering ends in the middle of ribs R3 Slide diagonal brace W4 through slot in sub rib R1a DO NOT GLUE Fit sub rib R1a to main spar Tack glue R1a to main spar only SkyBoy 600 2010 Stevens AeroModel all rights reserved Page 34 of 55 R2 R1 R3 W3 W3 R1 W2 W3 W2 R3 Upper Spar Cap Center of Rib W4 R1a R1a...

Page 35: ...h medium CA Fit and tack glue turbulator spar to front notches in the ribs Cut remaining spars from 36 in lengths of 3 16 in square balsa stock Trim so that spar ends align with the center of ribs R3 when spar is centered Install spars to middle and aft notches of the ribs Square wing on a flat surface and bond all spars to each rib with medium CA SkyBoy 600 2010 Stevens AeroModel all rights reser...

Page 36: ...s in aft portion of ribs R1 R2 and R3 Center tubes so that they extend slightly beyond ribs R1 and R3 DO NOT BOND Square wing on a flat surface and glue W4 s to leading edge and notch in rib R1a Bond all mating surfaces between spars cap strips ribs leading trailing edges with medium CA Assemble center sheeting S1 from parts S1a and S1b Bond with thin CA SkyBoy 600 2010 Stevens AeroModel all right...

Page 37: ...S3 from parts S3a S3b and S3c Bond with thin CA Fit and bond S3 to top of ribs between trailing edge upper spar cap and ribs R1 With S3 now installed Bond paper tubes within wing assembly using medium CA glue Press S3 flat against trailing edge and bond with thin CA SkyBoy 600 2010 Stevens AeroModel all rights reserved Page 37 of 55 S1 Leading Edge Spar Cap R1 S2a S2b S2c S2 Trailing edge Bottom V...

Page 38: ...p up one end of the wing so that outer spar rests flat on the table Fit and tack glue rib R4 to spar Fit and tack glue sub spar W5 to ribs R3 and R4 Square wing tip and bond ribs to spars with medium CA Cut lower spar cap from 1 4 in square x 5 7 8 in long balsa stock Tack glue at ribs only SkyBoy 600 2010 Stevens AeroModel all rights reserved Page 38 of 55 W9 S3 R4 R4 R3 W5 Main Spar Lower Spar C...

Page 39: ...length from 3 16 in square balsa stock Spars should end flush with outer face of rib R4 Cut leading edge from 3 8 in square balsa stock 8 in long Sand one end of stock to fit center section leading edge at rib R3 Tack with thin CA Fit ply servo pocket part W6b to slots in Rib R3 and sub spar W5 Bond with medium CA SkyBoy 600 2010 Stevens AeroModel all rights reserved Page 39 of 55 Main Spar Upper ...

Page 40: ... R3 and R4 Assemble wing tip sheeting W8 from parts W8a W8b and W8c Bond with thin CA Tack glue tip sheeting W8 in place fitting tabs and slots to those in W5 and R4 Roll sheeting forward tack gluing as you go fitting into slots tabs on forward part of rib spar tab and leading edge Square wing tip on a flat surface and bond all mating surfaces with medium CA SkyBoy 600 2010 Stevens AeroModel all r...

Page 41: ...ard a little at a time towards leading edge securing with masking tape as you go Allow to dry Tack glue cap strip between tapes Remove tape then bond with medium CA Trim and sand cap strip flush with W5 and leading edge Do not round off Sand top of cap strip flush with tip sheeting With wing held flat on your building surface revisit all tack glued joints and spar cap to spar joints with CA glue S...

Page 42: ...b A4 in the middle slot in A6 Then tack glue the shorter rib A5 to A6 Fit trailing edge A1 to ribs Square aileron on a flat surface and bond all parts with medium CA Fit control horn plate A2 to trailing edge A1 rib A3 and spar A6 Bond with medium CA SkyBoy 600 2010 Stevens AeroModel all rights reserved Page 42 of 55 A3 A6 A6 A4 A6 A5 A1 A6 A1 A2 A3 ...

Page 43: ...3 16 x 6 1 2 in balsa stock in warm water to soften Tape 3 16 in face of wood against trailing edge and aileron tip A7 Allow to dry Tack glue cap strip to tip A7 Remove tape then bond with medium CA Using a razor plane and or sanding block reduce stiffener until it is flush with top surface of ribs and top of spar Sand A7 flush with face of spar A6 SkyBoy 600 2010 Stevens AeroModel all rights rese...

Page 44: ... opposite aileron Use a razor plane and sanding block to round off leading edge Use the wing saddle profile in the fuselage to check the contour of the leading edge Round leading edge into the wing tip Round edges of the wing tip cap strip Leave trailing edge of wing square SkyBoy 600 2010 Stevens AeroModel all rights reserved Page 44 of 55 Check Fit ...

Page 45: ...ough F6 or through side of fuselage Plate fits against the fuselage bottom behind F6 between the fuselage sides Press in place and allow CA to cure bonding mount firmly to fuselage bottom After covering the fuselage the bottom and mount may be drilled out to suit the mounting system and floats of your choice SkyBoy 600 2010 Stevens AeroModel all rights reserved Page 45 of 55 Bottom View F6 F6 ...

Page 46: ...ke a 90 degree bend 3 16 in from one end Fit the straight end into the push rod housing in the radio compartment Feed the wire through carefully puncturing the covering at the exit point Remove wire then re insert from the exit point so that the bent end remains outside of the model SkyBoy 600 2010 Stevens AeroModel all rights reserved Page 46 of 55 Bottom View ...

Page 47: ...in radio compartment and feed pushrods through the E Z Connectors Connect motor and ESC Feed ESC and wiring though nose below motor mount and through hole in bottom part of F3 Fit a 4 40 x 1 2 in machine screw in each of the holes on the left side of the mounting plate Install three ply washers from sheets 17 and 30 on each screw Lightly thread the two screws into the motor mount Install the remai...

Page 48: ...udder two on the vertical stabilizer and one in the fuselage Ensure all slots align with those on the opposite surface Cut CA hinge material into pieces about 3 8in x 5 8 in You should be able to get three out of each CA hinge insert into slots Join surfaces together align and bond hinges to surfaces with thin CA Flex surfaces back and forth as CA cures to ensure free movement Open holes in coveri...

Page 49: ...t soldering or covering iron Mount tail surfaces on fuselage horizontal stabilizer first Temporarily install main wing and square tail surfaces with wing Bond with medium CA along the seams Cut a 1 8 in long piece of the silicone tubing and slide onto pushrods Connect pushrods to control horns with a Micro E Z Link DUB849 Safety the connection by sliding the silicone tubes over the E Z Links SkyBo...

Page 50: ... to match your covering Center dowels in fuselage and bond with medium CA Mount wheels on pre bent landing gear with the provided wheel collars DUB139 Retain landing gear with size 32 rubber bands Wrap each band at least three times around gear wire and lug dowel Tape windscreen in place just behind the hatch Position so that it is centered and the mounting holes are 3 32 in below top edge of the ...

Page 51: ...f thin CA Peel protective coating from windscreen Mount windscreen with provided 0 x 3 16 in screws Open holes in bottom of ailerons and insert a control horn DUB936 Bond with thin CA Attach aileron with a strip of 3 4 in clear tape leaving a 1 32 in gap all the way around aileron SkyBoy 600 2010 Stevens AeroModel all rights reserved Page 51 of 55 Tape ...

Page 52: ...gh servo pocket and into paper tube within wing Mount servo in pocket with control horn positioned away from aileron Pull servo extension through the hole in the center of the wing Using the long single armed control horn install an E Z Connector through the 1st or 2nd hole from the outside SkyBoy 600 2010 Stevens AeroModel all rights reserved Page 52 of 55 Tape ...

Page 53: ...Cut a 1 8 in length of silicone tubing and slide onto the pushrod Connect pushrod to horn with a Micro 2 E Z Link DUB920 Secure connection by sliding the silicone tubing over the E Z Link and pushrod Repeat steps marked beginning on page 46 to install the other aileron servo Open holes in trailing edge near aileron with a warm soldering iron Mount wing skid DUB990 and bond with thin CA SkyBoy 600 ...

Page 54: ...sider using when developing your own pre flight check list Get in the habit 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 SkyBoy 600 s C G is in the appropriate location for your experience level Check Weather SkyBoy 600 s first flight should be in zero wind conditions...

Page 55: ...mproper installation and or twists and warps The most common mistakes are to try and fly with a warped or twisted wing With such a fat chord and short moments a small warp can cause big in flight problems Make certain that your wing is straight before you fly SkyBoy 600 has a great deal of side area Coupled with the low wing about 10 degrees of right thrust is required for stable flight DO NOT ATT...

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