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Stevens AeroModel SkyBuggy, Manual

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Stevens AeroModel SkyBuggy Manual Download Page 11

Fuselage Construction

☐  ☐  

Cut 7 in. long fuselage stiffener from 1/8 x 

1/4  x  24  in.  balsa  stock.    Slide stiffener 

through notch in F5, then through notch in 

F4  and  into pocket  in  Fuselage Doubler.  

Bond to formers and FS with medium CA.

☐

Fit remaining FD, Fuselage Doubler and bond 

to Crutch Assembly

Again... Tabs  in crutch assembly will protrude 

slightly to locate Fuselage Side.

☐

Test fit remaining  FS,  Fuselage Side.    Now, 

coat  outside  of  Fuselage  Doubler,  and  all 

mating surfaces, with thick  CA and install FS 

over FD / Crutch assembly. 

☐

Repeat  “

☐

 

☐

”  step  on this  page  to cut  and 

install second fuselage stiffener.

☐

Cut 10mm square hardwood motor  mount to 

2 in. length.

SkyBuggy © 2010 Stevens AeroModel all rights reserved. 

Page 11 of 30

Stiffener

Pocket

Stiffener

FS

F5

F4

FD

FS

2 inches

F5

FS

F4

View: Bottom

Summary of Contents for SkyBuggy

Page 1: ...By Stevens AeroModel Length 24 inches Span 32 inches Wing Area 280 inches2 Flying Weight 12 14 oz Version 07 08 2010 SkyBuggy 2010 Stevens AeroModel all rights reserved Page 1 of 30 ...

Page 2: ...ot 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 SU...

Page 3: ...dwood Dowel Wing Mounts 2 Micro Razor Control Horns and Back Plates DUB 936 6 32 Rubber Bands Small Hardware Bag 2 x 3 in 1 1 in length of fuel tubing EZ link retainer 1 2 x 1 4 in sheet metal screw to secure motor 2 Mini E Z Connectors DUB 845 2 Micro E Z Links DUB 849 2 3 16 in Neo Magnet 2 Rubber Wheel Retainers 6 Mini Rubber Bands Landing Gear Retention MAIN GEAR WHEELS NOT INCLUDED We suggest...

Page 4: ...le 7 4V 2S1P ThunderPower Pro Lite V2 910mAh or equivalent Brushless System A20 26M APC 9x4 7SF 10x4 7SF Propellor Thunderbird 18 ESC 7 4V 2S1P ThunderPower Pro Lite V2 910mAh or equivalent E flite Outrunner Stick Mount EFLM1915 ATTENTION If using a power system other than specified above we suggest closely matching specs for weight KV Input Voltage and propellor diameter and pitch Best results ar...

Page 5: ...Laser Cut Parts Inventory SkyBuggy 2010 Stevens AeroModel all rights reserved Page 5 of 30 ...

Page 6: ...Laser Cut Parts Inventory SkyBuggy 2010 Stevens AeroModel all rights reserved Page 6 of 30 ...

Page 7: ...uced as a result of the laser cutting process and as we have found that most stock 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 ...

Page 8: ...A Bevel leading edge of Elevator at a 45 degree angle in preparation for hinging Build Vertical Stabilizer and Rudder from parts V1 V3 and RD1 RD5 and A trusses Bevel leading edge of Rudder at a 45 degree angle in preparation for hinging SkyBuggy 2010 Stevens AeroModel all rights reserved Page 8 of 30 H1 H2 H3 H4 B Trusses E1 E2 E3 E4 C Trusses Elevator Joiner V1 V2 V3 RD1 RD2 RD3 RD4 A Trusses 45...

Page 9: ...sembly through lower hole in F4 and seat in notch Tack glue with thin CA Ensure TOP faces up Assemble two FD Fuselage Doublers from parts FDa and FDb Tack glue crutch assembly to FD Fuselage Doubler Note Tabs on crutch assembly will protrude slightly on the other side of FD Fuselage Doubler These tabs will locate the Fuselage Side SkyBuggy 2010 Stevens AeroModel all rights reserved Page 9 of 30 FD...

Page 10: ...ich extend through FD will engage fuselage sides Note Use 3 16 in and 1 8 in drill bits in wing mount hole and landing gear lug hole to help with alignment Dry fit F1a to F1 and FS do not glue Dry fit F1b to F1a and FS do not glue Fit F5 to F1b and FS Square assembly on a flat surface then bond all parts where they contact the FS and each other SkyBuggy 2010 Stevens AeroModel all rights reserved P...

Page 11: ... Again Tabs in crutch assembly will protrude slightly to locate Fuselage Side Test fit remaining FS Fuselage Side Now coat outside of Fuselage Doubler and all mating surfaces with thick CA and install FS over FD Crutch assembly Repeat step on this page to cut and install second fuselage stiffener Cut 10mm square hardwood motor mount to 2 in length SkyBuggy 2010 Stevens AeroModel all rights reserve...

Page 12: ...rk motor mount 3 16 in from one end Install motor mount through formers F2 and F3 Align mark flush with rear face of F3 Build up a fillet of medium CA around motor mount on both sides of F2 and F3 Install F8 on top of FD Fuselage Doublers between FS Fuselage Sides and interlocking with tabs on F2 and F3 Coat F8 with thick CA and install F9 on top of F8 tabbing into fuselage sides Bond WSS Windshie...

Page 13: ...from FS Install fuselage top F7 Bond to forward end of FS fuselage sides and formers back to just behind slots for F12 Do not close aft end of fuselage at this time Install F12 wing mount doublers to slots in F7 and bond to FS fuselage sides Tack glue former F6 to fuselage top F7 SkyBuggy 2010 Stevens AeroModel all rights reserved Page 13 of 30 F12 F7 F6 WSa WSb WSc WSc Bond F12 Slots F7 FS FS F7 ...

Page 14: ...slot on left side rudder from bottom slot on right side Install pushrod housings through FS and F5 Leave 1 8 in extending forward of former F5 Trim pushrod housings flush with fuselage sides Align holes and bond tail skid doubler F14 to fuselage bottom F13 with thick CA Install Fuselage bottom F13 enclosing F14 within fuselage SkyBuggy 2010 Stevens AeroModel all rights reserved Page 14 of 30 F13 F...

Page 15: ... forward over F2 tabs and against nose Bond with thick CA glue Fit F11 sheeting F11 starts at rear of landing gear openings creating a slot for the landing gear wire to rest in and fits over tabs in F4 Bond with Thick CA glue Assemble Hatch Retainer from ply parts H4 and H5 Install one magnet to hole in H5 Install hatch retainer in slots in F5 SkyBuggy 2010 Stevens AeroModel all rights reserved Pa...

Page 16: ...ling within the battery hatch To identify the proper installation polarity of second magnet allow second magnet to snap against magnet installed within Hatch Retainer and mark the outside surface of second magnet with a permanent marker Now fit second magnet within H2 marked side facing inside pocket Once again test the parts to ensure that magnets attract and do not repel each other Once satisfie...

Page 17: ...t center notches in spar Tack glue Seat trailing edge of R1 within notches at center of W2 trailing edge Tack glue Fit gussets W3 to ribs R1 and trailing edge W2 and bond with CA glue Fit ribs R2 R3 and R4 to right and left of wing assembly Tack glue SkyBuggy 2010 Stevens AeroModel all rights reserved Page 17 of 30 W1a W1b W2a W2b R1 R1 W3 W3 R2 R3 R4 Second W1b not shown Second W2b not shown W1 R...

Page 18: ... across R1 ribs as per photo designates start point Important Balsa stock should start in the center of the rib as shown Cut remaining 24 in length of 1 8 x 3 16 in balsa stock into two 12 in lengths then fit to notches in rib as per photo with joints centered to ribs Hold wing flat against your work table and bond turbulator spars with CA glue SkyBuggy 2010 Stevens AeroModel all rights reserved P...

Page 19: ...ngth of 3 15 16 in Fit 3 15 16 in length of spar stock to notches within ribs at top of wing assembly over W1 designates spar start point centered over right rib R3 and finishing flush with the outside edge of the right rib R4 Inspect fit of spar joint ensuring that joint is centered over right rib R3 Bond spar stock to W1 using medium CA glue Align and bond W9a and W9b together at scarf joint to ...

Page 20: ... rib R4 See DETAIL1 2 DETAIL 1 W5 is captured by W1 spar leading edge stock and in between R1 and R2 ribs Do not bond W5 within assembly DETAIL 2 Bond leading edge stock to wing assembly with stock centered to left rib R3 Bond remaining 12 in length of 1 4 in square leading edge stock to wing assembly designates leading edge stock start point centered over the left rib R3 and finishing well beyond...

Page 21: ...Install stub spars W6 outside of ribs R4 Bond W7a W7b and W7c to create W7 wing tip sheeting Tack glue rear of W7 wing tip to rib R4 and tab of W6 Working in small increments of 1 2 in at a time bend W7 forward tack gluing to R4 Now turn wing over and permanently bond to rib spars and leading edge SkyBuggy 2010 Stevens AeroModel all rights reserved Page 21 of 30 Do not trim leading edge R4 R4 W6 W...

Page 22: ...itical to exactly match profile simply remove the harsh angle creating a more blunt round leading edge Bond W8 ply trailing edge reinforcement within center notch at W2 trailing edge Use a sanding block loaded with 600 grit paper to lightly sand wing in preparation for covering Cover wing with a high quality covering film We recommend Stevens AeroModel AeroLITE SkyBuggy 2010 Stevens AeroModel all ...

Page 23: ...kid DUB853 with medium CA The following steps detail final assembly of the Horizontal Stabilizer and Elevator This assembly process will be repeated for the Vertical Stabilizer and Rudder Empennage Sand leading edge of stabilizer round leaving trailing edge of control surface square Cover with film Tape stabilizer and control surface to a flat surface bevel side down leaving a 1 64 in gap between ...

Page 24: ...levator Repeat the previous eight steps for the Vertical Stabilizer and Rudder mounting the horn on the right side of the Rudder Install Micro Razor control horn DUB936 and secure with medium CA Slide retention plate over posts and secure with medium CA Trim posts to about half of their length Use a hot soldering iron or covering iron to press down posts creating rivets to further secure control h...

Page 25: ...retain battery and receiver Clip three of the four arms of the small four way control horn supplied with your HS 55 servos Mount a Mini E Z Connector DUB 845 to outside hole in servo arm Electronically center servos and mount arms perpendicular to servo Mount servos in fuselage with arms extending outward Open covering over pushrod guide exits using a length of 1 32 in wire pushrod SkyBuggy 2010 S...

Page 26: ...and pass ESC through hole in F2 Install motor on motor mount Drill a 1 32 in pilot hole through gearbox housing motor mount stick Secure motor with a 2 1 4 in screw Mount wheels on pre bent landing gear and secure with rubber wheel retainers Cut off excess wire Mount landing gear through slot on fuselage and retain to landing gear lug with mini black rubber bands Wrap rubber bands around lug and l...

Page 27: ...o should be controlled by the Aileron channel of your radio as rudder on this model also controls roll of the aircraft Rudder should follow Aileron stick travel i e moving Aileron stick to right should move Rudder to right of aircraft Likewise left Aileron stick input will move Rudder left Elevator servo will be controlled by Elevator channel of your radio Pulling back on the Elevator stick should...

Page 28: ...s hinges and servo mounting hardware Pre Flight Cont Check wing attach points for damage and or wear Inspect rubber bands that they are installed correctly and in good condition to adequately retain wing Check landing gear and replace worn or rotten landing gear retention rubber bands Check that tires are properly inflated and retained if using Trexler wheels Inspect battery for full charge Never ...

Page 29: ...ake is 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 SkyBuggy tricks SkyBuggy is capable of most common Rudder Elevator Throttle aerobatics including Snaps Spins Stalls Wing Overs Stall Turns Chandelles Barrel Rolls Lazy 8 s and Loops You ll find that SkyBuggy...

Page 30: ...Use this two view drawing to sketch up covering ideas SkyBuggy 2010 Stevens AeroModel all rights reserved Page 30 of 30 R i g h t L e f t F r o n t B a c k Top Bottom ...

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