Sapac Viper Jet MKII Composite Assembly Manual Download

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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:

Viper Jet MKII Composite

Composite Fuselage, Balsa Wings
39.9 in
40.2 in
1.91 ft²
54 - 65 oz
28 - 34 oz/ft²
70mm with 5 Blade Fan
2842MB1 @ 3200KV (1100W)
80A+
LiPo, 4s 3300 - 3700 mAh
5 - 6 Channel (optional retracts)

Summary of Contents for Viper Jet MKII Composite

Page 1: ...Wing Area All Up Weight Wing Loading EDF Recommended Motor Recommended ESC Recommended Battery Radio System Viper Jet MKII Composite Viper Jet MKII Composite Composite Fuselage Balsa Wings 39 9 in 40 2 in 1 91 ft 54 65 oz 28 34 oz ft 70mm with 5 Blade Fan 2842MB1 3200KV 1100W 80A LiPo 4s 3300 3700 mAh 5 6 Channel optional retracts ...

Page 2: ...cation 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 CONNECTE...

Page 3: ... 12 Main Gear Final Assembly 13 Main Gear Retractable Optional 14 Cut Openings in Wing for Retract Units and Gear 14 Mount Gear and Connect Air Lines 15 Retractable Landing Gear Final Assembly 16 Nose Gear Fixed Optional 17 Assemble Nose Gear Mount 17 Mount Servo and Steering Arm 18 Installation of Nose Gear Mount and Nose Gear 19 Nose Gear Retractable Optional 21 Cut Opening in Fuselage for Retra...

Page 4: ... Rods 40 Install Elevator and Rudder Control Rods 40 Mount BEC and or Receiver Battery 41 Mount Receiver and Connect Servos 41 Test Radio Installation and Set up Control Throws 42 Fins Cockpit Canopy and Decals 43 Install Fins 43 Install Pitot Tube 44 Install Main Cockpit 45 Bond Main Canopy to Cockpit 46 Install Front Cockpit and Canopy 47 Apply Decals 48 Before You Fly 50 Set Up Center of Gravit...

Page 5: ...selage o o o o F1 Fan Access Hatch Cover o o o o W Wings o o o o E Stabilizers Elevators o o o o R Rudder Additional Kit Components The following are the additional components included with the Viper Jet Kit Additional kit components o o o o H1 Main Hardware Bag o o o o H2 Thrust Duct Decals o o o o H3 Wing Tube Horizontal Stabilizer Mounting Tubes o o o o H4 Control Horns Control Rods o o o o C C...

Page 6: ...bon Fiber Pitot Tube o o o o F5 Hook Loop Fastener for Battery o o o o W1 Fixed Landing Gear Hardware Main o o o o W2 Wing Servo Hardware o o o o H5 Spare Hinges o o o o T Wheels Tires Thrust Duct and Carbon Tubes Bag Contents H2 The following are the components packed in the Thrust Duct Carbon Tubes Bag H2 Thrust duct retract templates o o o o M Motor EDF Electric Ducted Fan Unit o o o o M1 Thrus...

Page 7: ...required to complete and fly your Viper Jet 5 to 6 Channel Computer Radio Channels are throttle ailerons elevator rudder nose wheel steering and flaps retractable landing gear is optional 6 8 Servos 8g 10g range Any necessary servo extensions and Y harnesses 70mm Fan and Motor 80A Electronic Speed Control ESC 4S 3300mAH 3700mAH Lithium Polymer Battery Lithium Polymer Battery Charger Building suppl...

Page 8: ...ly for models in the size and weight range of the Viper Jet this gear fits into the provided mounts without any adjustments P N SAP14000 Optional SAPAC Rz180 retractable landing gear Scale Struts SAPAC Sz180 v Designed specifically for models in the size and weight range of the Viper Jet these Scale Struts fit the Rz180 Retractable Landing Gear without any modifications P N SAP12601 Optional SAPAC...

Page 9: ...ll gap between the aileron and outside of the wing and there is no rubbing or binding Tip the hinges can be held in position with T pins if they shift when inserting the control surface Remember to remove the T pins before bonding the hinges Note If any hinge slots are missing hinges add them from the supplied spare hinge bag H5 Using thin CA adhesive with a fine applicator place a few drops on ea...

Page 10: ...orce the cover mounting holes in the wing with thin CA adhesive This will add strength to the plywood and provide the cover screws a stronger attachment point Reinforce screw holes with CA adhesive Using a sharp hobby knife trim 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 than the mounting ...

Page 11: ... to the servo covers This will allow maximum clearance for the servos when mounted inside the thin wing Tip when drilling the pilot holes orient the end grain of the servo posts so it will be the side bonded to the servo cover This will give the strongest bond as well as a stronger grip for the screws Drill pilot holes in servo mounting posts Once the holes have been drilled reinforce them with a ...

Page 12: ...r the ailerons rudder and elevators Fiberglass control horns Separate the control horns from each other with a hobby knife Clean up the edges using some sand paper or a small file Set aside 3 control horns for the rudder and the elevators these will be used later Control horns separated and cleaned up Find the control horn mounting slots in the control surfaces and remove the covering using a shar...

Page 13: ...ured distance The V will allow for minor adjustments of the control rod length Tip for greater ease of adjustability a control rod adjustment mechanism such as threaded clevises or linkage stoppers can be used Remove the aileron servo cover thread the control rod through the control horn and the servo arm and re mount the flap servo cover with all four screws Feed the servo wire through the channe...

Page 14: ...e gear to the wing structure Set aside and make sure the adhesive is thoroughly dry before proceeding 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 W1 for measuring Required Tools and Adhesives Hobby Knife Flashlight Pen Locate the opening for the main gear on the bottom of the wings close to the flap servos Notice the balsa w...

Page 15: ...tep Prepare Gear Mount Covers Required Parts o o o o Wing W o o o o Main Gear Struts 2 W1 o o o o Main Gear Mount Assemblies 2 W1 o o o o Main Gear Covers 2 W1 Required Tools and 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 Drill...

Page 16: ... Main Gear Mount Assemblies 2 W1 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 image shows the places where epoxy adhesive needs to be applied Epoxy adhesive location for main gear mounts You may need to temporarily insert the...

Page 17: ...o o o o Main Gear Tires 2 T o o o o Main Gear Collets 2 W1 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 on the set screws in the wheel c...

Page 18: ...into the balsa wood wing sheathing The easiest way to locate it is to shine a flashlight from the root rib into the wing this will easily highlight the outline Locate the cutout for the retractable landing gear Use an erasable pen to trace around the template defining the location of your cutout Mark the location of the retract cutout Cut out the location for the landing gear using a hobby knife C...

Page 19: ...nded Don t be tempted to use the screws provided to affix the fixed gear covers since they are not long enough to go through the entire mount and could result in the retract units breaking loose during takeoff or landing Cut two air lines to sit inside the wing and into the fuselage Attach them to the retract units Tip cut the internal air lines a little long you can always trim them when you are ...

Page 20: ...l in its final retracted location and measure the length of the struts Measure the length of the struts Using the struts provided with the retract units bend and trim the landing gear struts to the desired shape Test the retract motion and make any adjustments to ensure smooth operation You may have to trim the landing gear opening to match your strut Bend and test the struts and trim the opening ...

Page 21: ...g mount components The first step in setting up the nose gear is to assemble the mount First assemble the strut side of the mount the required components are shown in the next image Note the components are shown in their assembly orientation the curved corners face the servo side of the mount Strut mount components The assembled strut side of the nose gear mount is shown in the images below Bond t...

Page 22: ...o Start by placing the servo in position and drilling pilot holes for the mounting screws Remove the servo and reinforce the wood with some thin CA adhesive Mount the servo to the steering mount using the screws supplied with the servo Once the servo is mounted install a linkage stopper on the servo arm so it faces the bottom of the servo Put a drop of thick CA adhesive on the nut to ensure it doe...

Page 23: ...urposes only it needs to be removed before inserting the steering assembly into the fuselage Test the assembly before installation to ensure there are no problems with the steering motion Installation of Nose Gear Mount and Nose Gear Required Parts o o o o Fuselage F o o o o Fixed Nose Gear Mount F2 o o o o Nose Gear Mount attachment Screw F2 o o o o Nose Gear Strut F2 o o o o Nose Wheel T o o o o...

Page 24: ...Nose gear mount in position and attached With the fuselage upside down insert the long collet through the hole for the nose gear it should engage with the short shaft and seat up against the nose gear mount Tighten the set screw on the inside of the fuselage using a hex wrench through the hole in the side of the fuselage Tighten the inside set screw of the long collet Complete the assembly by atta...

Page 25: ... cutout for the retractable nose gear use the panel lines etched on the fuselage Panel lines showing location of nose wheel cutout Place some removable tape on the fuselage over the location of the nose gear cutout this will protect the paint when cutting Using the panel lines as a guide use a pen to mark the location of the cutout on the tape This will make the lines more visible and the cut easi...

Page 26: ...he servo and reinforce the pilot holes with thin CA adhesive Mount the servo in the final location using the screws supplied with the servo Servo and retract unit mounted and air line connected Dry fit the nose wheel retractable landing gear unit in the location provided as shown in the image below The unit will fit with the assembly bolts clearing the plywood at the notches Once the unit is in pl...

Page 27: ...set up the steering linkage Assemble Pull Pull Steering Required Parts o o o o Fuselage F o o o o Pull Pull System Cables and Crimps Required Tools and Adhesives Ruler Needle Nose Pliers Crimping Pliers Thin CA Adhesive Screwdriver Hex Wrench Thread Locking Compound Before installing the pull pull steering test the direction the servo will steer the nose gear If you find that the nose gear steers ...

Page 28: ... are not remove the assembly and make any necessary adjustments Once you have the necessary tension and geometry crimp the remaining two crimp sleeves Re install the steering assembly and attach the servo arm to the servo with the supplied screw Adjustments can be made to the tracking of the plane by loosening the set screw in the nose wheel retract unit and rotating the nose wheel strut slightly ...

Page 29: ...e the pilot holes with thin CA adhesive Mount the servo to the bulkhead using the screws supplied with the servo Mount Actuator Valve and Linkage Required Parts o o o o Fuselage F o o o o Retractable Gear Actuator Valve o o o o Main Gear Quick Connect Valve o o o o Retractable Gear Fill Valve o o o o Retractable Gear Air Line o o o o Retractable Gear T Fittings 2 o o o o Actuator Valve Mounting Sc...

Page 30: ...ntrol rod linkage installed Install the control rod and servo arm and test the motion of the actuator valve with your radio Make any necessary adjustments to the control rod length and servo arm position Once you are happy with the operation attach the servo arm to the servo using the screw supplied with the servo Mount Air Tank Required Parts o o o o Fuselage F o o o o Retractable Gear Air Tank R...

Page 31: ...ervo using blue air line in the images After attaching the wings connect the main gear air lines to the remaining connections on the t fitting feeding the retractable gear units Test the operation of the retractable landing gear You should be able to get 12 20 full actuations from a full tank You should also be able to get at least 2 hours of holding time from a full tank If you don t get both che...

Page 32: ... and right elevators Separate the elevator from the horizontal stabilizer Look for the hard point where the control horn will be attached it will be close to the root of the elevator Cut away the covering from the slot where the control horn will be bonded Separate rudder from vertical stabilizer and remove the covering from the control horn slot Dry fit the control horn in the slot make any adjus...

Page 33: ...orizontal stabilizer making sure the hinges remain straight and centered Tip the hinges can be held in position with T pins if they shift when inserting the control surface Remember to remove the T pins before bonding the hinges Bond elevators using thin CA adhesive Note If any hinge slots are missing hinges add them from the supplied spare hinge bag H5 Once the control surface is in place and you...

Page 34: ...with rubbing alcohol Remove paint and roughen mounting area Dry fit the horizontal stabilizer assembly the longer tube goes aft If the stabilizers don t seat properly trim the tubes slightly until the desired fit is achieved Stabilizer mounting tube locations Use sand paper to roughen both ends of the carbon fiber mounting tubes This will ensure positive adhesion when assembling the horizontal sta...

Page 35: ... position Horizontal stabilizer in its final position Clean any excess adhesive using a rag with rubbing alcohol Clean any excess adhesive using a rag with rubbing alcohol Ensure the horizontal stabilizers are parallel and level in all directions Tape the stabilizers in place while the adhesive dries ensuring the alignment is still true after taping Horizontal Stabilizers held in place while adhes...

Page 36: ...clearance To mark the proper mating slot on the side of the wing seat temporarily place the wing in position using the wing tube Use the cutout profile on the wing root rib to trace the profile of the area to be cut on the fuselage Remove any flashing from the wing tube hole and ensure the wing tube fits properly Remove the paint and roughen the surface where the wings will be mounted see second i...

Page 37: ...y excess adhesive using a rag with rubbing alcohol Clean any excess adhesive using a rag with rubbing alcohol Ensure the wings are parallel and level in all directions Tape the wings in place while the adhesive dries ensuring the alignment is still true after taping Wings held in place while adhesive dries Once the adhesive has cured and if you are installing retracts you can now complete the retr...

Page 38: ...nsure undisturbed airflow and optimal thrust If the tabs are on the inside of the thrust duct they will create turbulence and reduce the output of the power system Once the duct is bonded it will attain a round cross section Flatten the overlap in the thrust duct along the length of the duct using a piece of tape between each of the tabs Bond the edge of the thrust duct using thin CA adhesive pres...

Page 39: ...e outer edge of the fiberglass inlet ducts without the rotor getting too close to the inside edge of the ducts If you are using the SAPAC 70MM EDF unit the duct clearance is set at the factory If you are using any other fan unit you may have to remove material in the area shown in the image below Use a rotary tool with a grinding or sanding attachment or other similar approach to create the proper...

Page 40: ...st duct in fan shroud and EDF unit Insert the EDF unit in position through the fan access hatch You may have to feed it in motor end first and then turn it in position to get it to fit Temporarily seat it in position with the wires facing upwards but don t attach it yet Insert the thrust duct through the tail of the airplane by folding it into a U shape as shown in the image below Fold the duct on...

Page 41: ...ct back to where the motor wires point straight up towards the bottom of the airplane Place it in its final position pushed as far forward as possible and with the notches in the fan unit engaged with the inlet ducts Tighten the zip ties around the fan unit by hand until they are snug Don t over tighten the zip ties as this may deform the fan housing potentially causing the fan blades to rub again...

Page 42: ...ounted in position Feed the ESC wires around the inlet ducts and connect them to the motor wires Tip this is a good time to run up the motor and verify that it spins in the correct direction If the motor spins backwards simply swap two of the wires coming from the ESC Trim the fan access hatch cover to size using the inscribed panel lines Test fit the fan access hatch cover make any necessary adju...

Page 43: ...CA Adhesive Screw Driver The elevator and Rudder servos are mounted in the rear of the cockpit in front of the turtle deck The mounting process is the same for the other servos pre drill the mounting holes and reinforce them with thin CA adhesive before mounting the servos with the screws supplied with the servos If you will be using different servos for elevator and rudder the elevator servo goes...

Page 44: ... Stopper H6 Required Tools and Adhesives Screw Driver Hex Wrench Thick CA Adhesive Slide the control rods into their sleeves from the rear of the aircraft forward Attach the control rods to the elevator halves and to the rudder Control rods installed on the tail surfaces Install the provided linkage stoppers on your servo arms using the holes closest to the center you may adjust them later if you ...

Page 45: ... 6 channel setup retracts The installation can use as many as 8 servos and 9 channels plus receiver battery or BEC There are also multiple mixing options possible with modern computer radios Depending on your gear and configuration you will decide which radio installation is best suited for your model Connect all the leads in the cockpit to the receiver and its corresponding extensions Mount the r...

Page 46: ... motion The following diagram shows the recommended control throws Note All control throws are measured at the widest point of the control surface Control throw reference diagram Aileron Control Throw 8mm each way Elevator Control Throw 10mm each way Rudder Control Throw 16mm each way Take off Flap Control Throw 20mm Landing Flap Control Throw 30mm This is also a good time to test all other system...

Page 47: ...and Drill Drill Bits Hole Reamer 5 Minute epoxy Adhesive There are three types of fins for the Viper Jet two ventral fins one fuselage fin and two rudder fins There are three types of fins for the Viper Jet The location and orientation of the fins is shown in the images below Ventral fin locations Fuselage fin location Rudder fin location The locations are etched into the fuselage with panel lines...

Page 48: ...ns Bond all the fins using 5 minute epoxy adhesive Bond the fins with 5 minute epoxy Install Pitot Tube Required Parts o o o o Fuselage F o o o o Carbon Fiber Pitot Tube F4 Required Tools and Adhesives Thin CA Adhesive The nose of the Viper Jet has a hole drilled in it for mounting of the Pitot tube Insert the Carbon Fiber Pitot tube into the slot and bond with thin CA adhesive Hole in the nose of...

Page 49: ...anel lines supplied Note that the panel lines are more visible on the inside of the cockpit Trim carefully just to the inside of the panel lines Trim the cockpit to the panel lines Lay the cockpit on the fuselage and make any adjustments to the cockpit until you get a good fit Dry fit the cockpit and make any adjustments Assemble the front pin components using CA adhesive as shown in the image bel...

Page 50: ...uired Parts o o o o Fuselage F o o o o Cockpit Canopy C Required Tools and Adhesives Scissors Wax Paper or Low Tack Tape Canopy Glue Trim the canopy carefully just to the inside of the panel lines Trim the canopy to the panel lines With the cockpit mounted on the body dry fit the canopy and make any necessary adjustments To get the best fit for the cockpit canopy bond the canopy to the cockpit wit...

Page 51: ...ponent acts as a visor and extends out past the instrument panel on the lower cockpit component An image of this is shown below Bond the upper cockpit component to the lower cockpit component with CA adhesive Hold the front canopy and the front cockpit assembly is place in the fuselage Determine how the pieces align and remove them from the fuselage for assembly Bond the front canopy to the front ...

Page 52: ...ne o o o o Decals D Required Tools and Adhesives Low Tack Tape To apply the decals first remove the surrounding waste around the decals leaving only the parts which will be applied to the airplane Decal ready to be applied to airplane Place a piece of low tack tape over the decal this will hold the pieces of the decal together as you apply it to the airplane Place a piece of low tack tape on the d...

Page 53: ...with the placement squeegee any excess water using a credit card or similar implement and dry the excess water with a paper towel If you do use water wait for the water to dry completely and for the decal to be well adhered before attempting to remove the tape Decal placed in position Remove the low tack tape Remove tape The following image shows the decal positions for the Viper Jet Decal locatio...

Page 54: ...r nose wheel steers opposite from your rudder you will need to cross the pull pull steering wires in case of retracts Alternate solutions are to use two channels and a custom program mix on your radio a reversing Y Harness or a servo matching box As a reminder the control throws are as follows Aileron Control Throw 8mm each way Elevator Control Throw 10mm each way Rudder Control Throw 16mm each wa...

Page 55: ... has a broad flight envelope and can execute a high speed pass at over 120mph as well as slowing considerably for landing The glide path is shallow make sure you set up for a long landing The Viper Jet composite is not a beginner s aircraft If you have limited RC flight experience we recommend you seek the aid of a more experienced pilot or an instructor to handle the first few flights and to vali...

Page 56: ...2431 F5 Hook Loop Fastener for Battery SAP11548 E Stabilizers Elevators SAP12447 SAP12448 SAP12449 W Wings SAP12444 SAP12445 SAP12446 W1 Fixed Landing Gear Hardware Main SAP12434 SAP12435 SAP12436 W2 Wing Servo Hardware SAP12450 H3 Wing Tube Horizontal Stabilizer Mounting Tubes SAP12455 H4 Control Rods SAP12451 H5 Spare Hinges SAP12424 H6 Control Horns Wing Control Rods Control Rod Clips Linkage S...

Page 57: ...odel aircraft using only radio control frequencies currently allowed by the Federal Communications Commission FCC Only individuals properly licensed by the FCC are authorized to operate equipment on Amateur Band frequencies 5 I will not knowingly operate my model aircraft within three 3 miles of any preexisting flying site without a frequency management agree ment See AMA Document 922 for Testing ...

Page 58: ...se contact your local dealer for support Please contact your local dealer for support SAPAC America The World s Finest Electric Aircraft 3071 NW 64th Ave Sunrise FL 33314 1 800 976 7004 www SapacAmerica com ...

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