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Aeroworks 30cc Laser 200 Assembly Manual

HARDWARE NEEDED TO

COMPLETE

Engine Option 1: DLE 30

◊

1 - DLE 30 Rear Carb w/ 60mm Standoffs

◊

1 - J’Tec Wrap Around Pitts Muffler

◊

8 - Fender Washers

◊

8 - Engine mounting bolts

◊

1 - 18x8 Propeller

Servo Option 1 : Sport Performance

Hitec 7985MG Servos may be used for sport flying.
If flying more aggressive aerobatics please see
Servo Option Two below.

Note:

Servos available through Aeroworks

◊

5 - Hitec 7985MG Servos for flight surfaces

◊

1 - Hitec 635HB Servo for throttle

Servo Option 2: Unlimited Performance

Hitec 7954SH Servos are recommended for unlim-
ited flying. These servos will provide the best per-
formance possible.

Note:

Servos available through Aeroworks

◊

5 - Hitec 7954SH Servos for flight surfaces

◊

1 - Hitec 635HB Servo for throttle

Recommended Spinner:

◊

1 - 3.5” Custom Spinner-Aluminum

Note:

Spinner available from Aeroworks

Electronic Accessories : Receiver

A 6 or 8 channel receiver is recommended, using a
receiver with 6-8 channels will allow the builder to
mix both the aileron and elevator servo together in
the radio. Mixing these functions will result in a great
flying, well trimmed airplane.

◊

1 - 6-8 Channel 2.4 GHz or PCM Receiver

Engine Option 2: DLE 35RA

◊

1 - DLE 35RA w/ 60mm Standoffs

◊

1 - Stock DLE 35RA Muffler

◊

8 - Fender Washers

◊

8 - Engine mounting bolts

◊

1 - 19x8 Propeller

Содержание 30cc BRAVATA ARF-QB

Страница 1: ...30cc Laser 200 ARF QB Quick Build ASSEMBLY MANUAL AEROWORKS 4903 Nome Street Denver CO 80239 Phone 303 371 4222 Fax 303 371 4320 E mail info aero works net ...

Страница 2: ... By the act of using the user assembled product the user ac cepts all resulting liability Aeroworks does not accept any responsibility for structural failure Warranty Period It is important to notify Aeroworks of any damage or problems with the model within 30 days of receiving your airplane to be cov ered under warranty All returned parts must be shipped in their original shipping boxes and insur...

Страница 3: ...11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 Item Description Landing Gear Mounting Hardware Main Wheel Set Pull Pull Assembly Replacement Covering Axle Set Aluminum Control Horn Set CG Buddy 15oz Fuel Tank w hardware Ball Link Set Tail Wire Set Throttle Choke Pushrod Set Rubber Grommet Set Foam Velcro Mounting Pack Throttle Servo Mount Carbon Fiber Wing Tube Laser Cut Engine Mounting ...

Страница 4: ...os are recommended for unlim ited flying These servos will provide the best per formance possible Note Servos available through Aeroworks 5 Hitec 7954SH Servos for flight surfaces 1 Hitec 635HB Servo for throttle Recommended Spinner 1 3 5 Custom Spinner Aluminum Note Spinner available from Aeroworks Electronic Accessories Receiver A 6 or 8 channel receiver is recommended using a receiver with 6 8 ...

Страница 5: ...Recommended Extensions 22 AWG extensions are recommended throughout the 30cc Laser 200 The following sizes will be used 2 3 Extensions For Receiver to Ailerons 2 6 Extensions For Ailerons 2 24 Extensions For Elevators TOOLS ADHESIVES NEEDED TO COMPLETE Allen wrenches US and Metric Electric drill and selection of bits Razor saw Flat head screwdriver Hobby heat gun Hobby iron and covering sock Maski...

Страница 6: ...ll be re warded with a long lasting beautifully covered model TIGHTENING AND RESHRINKING THE COVERING 2 Using your covering iron with a soft sock gently apply pressure and rub in the covering If any bubbles occur your iron may be to hot Reduce heat and work slowly 3 If bubbles persist use a small pin to punch holes in the bubble to relieve trapped air and reheat 4 Use your heat gun with extreme ca...

Страница 7: ... fuel proofing is not necessary IMPORTANT It is the responsibility of the purchaser operator to check the covering seams and overlaps for security and a good seal Aeroworks is not responsible for failure of covering seams or overlaps during flight Note If covering continues to lift apply a small amount of thin CA underneath the covering Then using a clean rag apply pressure to secure One of the mo...

Страница 8: ... Wrench Phillips Screw Driver 1oz Bottle Gap Filling CA Glue 34oz Bottle Blue IC Loc Thread Locker AILERON SERVO INSTALLATION 2 Attach the 6 extension to the servo lead and secure with an Aeroworks Safety Clip Ensure the plugs will not come apart from vibration or light tension 3 Layout the servo and extension on the wing to test fit the installation and ensure servo lead is the correct length 4 R...

Страница 9: ... control horn assem bly as shown The ball link goes between the left and right sides of the control horn sides and is secured with a nylon lock nut Brass spacer goes between servo arm and ball link and is not installed between the right and left control horns 11 Align the control horns over the factory drilled holes 12 Use a drop of thick CA glue on each screw to prevent screws from loosening due ...

Страница 10: ...s to the servo case Note Tape aileron in place to help keep aileron centered during pushrod adjustment 15 Finished aileron servo installation shown below Repeat all previous steps for the remaining ai leron servo HORIZONTAL STAB INSTALLATION 1 Gather the items shown below for the installation of the Horizontal Stabilizer The elevator has been pre hinged but not glued to the Stab Elevator installat...

Страница 11: ...resulting in an accurate wing to tail measurement 5 Measure the trailing edge of the stab from the fuse side to the stab tip These distances must be equal before gluing the stab in place 6 Using a tape measure attach the end hook to the T pin in the aileron and measure to the trailing edge of the stab at the tip as shown Repeat this step for the other side of the stab Ensure that the measurement i...

Страница 12: ...e check the stab alignment between the wing tip and stab tip using the same method as shown in step 6 Make any adjustments to the stab s position to ensure it is properly aligned with the wing 12 Allow 30 minute epoxy to fully cure checking stab alignment periodically as the epoxy dries 1 Gather the items shown below for the installation of the Vertical Stabilizer The rudder has been pre hinged bu...

Страница 13: ...ile the epoxy cures ensure that the vertical stab is sitting flat to the top of the fuse Masking tape may be used to hold ver tical stab in place until epoxy cures 5 Cut 8mm strip of covering from the supplied spare covering sheets Use a trim iron to seal covering over the vertical stab and fuse joint as shown This will completely hide the vertical stab fuse seam 6 Repeat for remaining colors and ...

Страница 14: ...mm Wood screws Required Tools and Adhesives 1 5 64 Ball Driver 1 3 32 Ball Driver 1 Pushrod Adjustment Wrench 1 Phillips Screw Driver 1 1oz Bottle Gap Filling CA Glue 3 Align the control horns over the factory drilled holes 4 Use thick CA on each screw prior to installing to lock screws in place Note CA glues have a fast drying time Remember to work quickly 5 Align the left and right sides of the ...

Страница 15: ...ory drilled holes 4 Pass the 2x16mm Phillips head bolts through one control horn and then through the pre drilled holes in the rudder 5 Install the remaining control horn and secure in place with six 2mm nuts 6 Secure nuts with a drop of thick CA This will prevent them from coming loose in flight 2 Prep all hinges for installation by applying Vase line petroleum jelly or light oil to the hinge joi...

Страница 16: ...of each hinge and insert the hinge Completely into the hole Ensure the hinge axis is vertical and parallel to the trailing edge of the fin before epoxy cures Wipe away excess epoxy with alcohol wetted wipes 6 Mix epoxy in mixing cup and use a tapered stick to apply the epoxy inside the pre drilled holes in the leading edge of the rudder Apply epoxy to trailing edge of each hinge 7 Carefully slide ...

Страница 17: ...lation of ball link to servo arm shown below Note Flat washer will prevent ball link from coming loose from brass ball 9 Assemble pushrod to servo arm assembly as shown 10 Attach pushrod to ball link and control horn 11 A pushrod adjustment wrench has been in cluded this will allow the pushrod length to be extended or shortened with out removing the servo arm Adjust the pushrod length so the con t...

Страница 18: ...W0209 recommended Required Tools and Adhesives 1 5 64 Ball Driver 1 3 32 Ball Driver 1 Electric Drill 1 1 16 Drill Bit Pliers 1oz Bottle Thin CA Glue 2 Install servo in servo well with the output shaft towards the front of fuse as shown below 3 Using a 1 16 drill bit drill holes for servo screws 4 Install servo with servo mounting screws 7 Pull the rudder cables from the fuse tail to the rudder se...

Страница 19: ... are two types of 4 40 couplers supplied two are for the throttle and choke pushrods and four are for the pull pull system The couplers with the solid base are to be used for the pull pull assembly 14 A drop of thin CA may be applied to the swage tube to help secure the cable 13 Crimp the brass tube with a crimping tool or pliers 12 Use pliers to pull looped cable tight as shown below 11 Loop the ...

Страница 20: ... cables can bind or slow servo movement Adjust cables to allow for some slack Note Due to temperature change and normal wear it may be necessary to tighten the cables over time 22 Finished pull pull installation shown below 20 Pull cable snug and attach pull pull cable to rear ball links 19 Tape the rudder in the neutral position as shown This ensures the rudder is straight when the ca bles are at...

Страница 21: ...ing wire in place Install and tighten lock nut after lower flying wire has been installed 5 Align the lower flying wire with the predrilled hole in the bottom of the fuse Apply a small drop of thick CA to the provided wood screw 2 Align one upper flying wire with the pre drilled hole in the fin Pass one mounting bolt through the flying wire mount and into the fin do not install lock nut at this ti...

Страница 22: ...ather the following items shown below for the main landing gear assembly Required Parts 1 Aluminum landing Gear Strut 2 3 Foam Tires 2 Axles With Lock Nuts 2 Wheel Collars 2 Wheel Spacing Washers 4 6 32 Mounting Bolts 4 6 32 Lock Washers 4 6 32 Flat Washers 2 Gear Cuffs 2 Gear Cuff Supports 2 Wheel Pants 4 4 40 Bolts 4 4 40 Lock Washers 4 4 40 Flat Washers Required Tools and Adhesives 9 64 Ball Dr...

Страница 23: ...blue Loc tite on landing gear bolts before attaching the landing gear 4 The tapered edge of the landing gear goes to the back of the airplane GEAR CUFF INSTALLATION 7 Gather the following items shown below for the gear cuff installation Required Parts 2 Fiberglass Gear Cuffs 2 Gear Cuff Supports Required Parts Not Supplied 4 Small Rubber Bands Required Tools and Adhesives Silicone Sealant ...

Страница 24: ...to the gear this rub ber band will act as a clamp to hold the gear cuff in place while the silicone dries Remove this rubber band once the silicone has fully cured 12 Slide landing gear cuff onto landing gear use caution not to move the gear cuff support 8 Slide rubber band onto landing gear as shown The rubber band may need to be wrapped around the gear multiple times to achieve a tight fit 9 Sli...

Страница 25: ...lat sides of the axle flange should be paral lel to the landing gear as shown below 20 Slide wheel spacing washer onto axle as shown 19 Securely tighten axel to gear strut 14 Repeat gear cuff installation for remaining gear cuff 15 Finished landing gear cuff installation shown below 16 Install the axle into the gear strut with lock nut Lightly tighten axle lock nut at this time ...

Страница 26: ...nt mounting bolts Use blue Loctite on the bolts before final tightening 23 Final installation of wheel pant with two mount ing bolts 1 Gather the tail wheel assembly items as shown below Required Parts 1 Tail Wheel Assembly 3 Tail Wheel Mounting Screws 1 Steering Tiller 2 Tiller Mounting Screws 2 Steering Springs Required Tools and Adhesives Phillips Screw Driver 1oz Bottle Gap Filling CA Glue Wir...

Страница 27: ...s 3 Apply a drop of thick CA to the mounting screws before inserting into the tiller mounting holes 2 Place tail wheel steering tiller over the pre drilled holes in the bottom of the rudder 7 Mount the tail wheel strut using three wood screws 6 Place a drop of thick CA on tail wheel strut mounting screws before inserting in the pre drilled mounting holes on the bottom rear of the fuse ...

Страница 28: ...e steering spring to the rudder tiller Center the spring between both tail wheel and steering tillers 8 Tape rudder to fin This will hold the rudder at neutral allowing the tail wheel springs cables to be easily installed 13 Finished tailwheel installation shown below Ensure tailwheel springs are not too tight and allow for free movement of the rudder 12 Repeat spring installation for other side ...

Страница 29: ...ce This will insure that the mounting bolts stay in place over time 4 Use a 3 16 drill bit to drill the engine mounting holes in firewall ENGINE INSTALLATION 1 The 30cc Laser 200 will accept a wide range of engine types The DLE 35RA engine with stock Muffler was used for the test flights Gather the following items needed for engine installation Required Parts 3 Plywood Mounting Templates 4 6 5mm A...

Страница 30: ...der Coupler 2 4 40 Ball Links 2 4 40x16mm Hex Head Bolts 2 4 40 Lock Nuts 1 Brass Spacer 2 3mm Flat Washer Required Parts Not Included 1 Throttle Servo 4 Servo Mounting Screws Micro Fastener Part number STW0209 recommended 1 3 4 Servo Arm Required Tools and Adhesives 1 Pencil Felt Tip Pen 1 Phillips Screw Driver 1 5 64 Ball Driver 1 Electric Drill 1 1 16 Drill Bit 1 7 64 Drill Bit 1 Rotary Cutting...

Страница 31: ...k half way onto pushrod to allow for proper adjustment during final installation 7 Slide pushrod through hole drilled in firewall and attach ball link using 4 40 bolt flat washer and lock nut 8 Assemble brass threaded coupler to 4 40 ball link Assemble ball link and brass spacer to the servo arm as shown below 9 Temporarily place throttle servo mount inside fuse with 3 4 servo arm attached to thro...

Страница 32: ...he center or half throttle position Mark the cut location for the throttle push rod 12 Remove pushrod from throttle arm on carburetor and cut throttle pushrod to length 13 Gather the soldering tools as shown below Note For best results we recommend a high quality silver solder like Sta Brite Silver Solder 14 Lightly sand end of pushrod for best bond 15 Solder the threaded brass coupler to the end ...

Страница 33: ... 8x80x300mm Foam Pad 1 10mm Rubber Grommet 2 Small Nylon Ties 4 Large Nylon Ties Required Parts Not Included 1 Ignition Module 1 Battery 2600mah Li Ion Shown 1 Ignition Regulator Smart Fly Shown 1 Ignition Switch MPI Shown 4 Aeroworks Safety Clips Required Tools and Adhesives 1 Pencil felt tip pen 1 Electric Drill 1 1 16 Drill Bit 1 Wire Cutter IGNITION INSTALLATION 2 Position the ignition module ...

Страница 34: ... shown below 7 Roll the supplied foam rubber to make a 4 layer pad as shown Make the pad slightly larger than the ignition module 9 Pass ignition power lead through the rubber grommet and into the fuse as shown 8 Secure ignition module with nylon tie as neces sary 4 Use a 1 4 bit to drill the ignition module mounting holes Drill the rubber grommet hole at this time ...

Страница 35: ...he Smart Fly ignition regulator to the mo tor box side 13 Final ignition regulator installation shown be low 14 Slide switch into switch mount as shown It may be necessary to increase switch mounting hole depending on switch brand Note Internal switch mounts have been built into the fuselage for both the radio and ignition switches Using these switch mounting locations will require removal of the ...

Страница 36: ...lation Kit available separately from Aeroworks 16 Install switch with mounting hardware provided by switch manufacturer Refer to switch manu facturer for specific mounting instructions 17 Connect plug cap to spark plug and tie back any excess plug cap wire using a nylon tie as shown FUEL TANK ASSEMBLY Fuel Line Installation Kit available separately from Aeroworks 2 Install the fuel tubing and clun...

Страница 37: ...uired Tools and Adhesives Pliers Wire Cutter Electric Drill Various Drill Bits for Fuel Dot Installation 1oz Bottle Gap Filling CA Glue FUEL TANK INSTALLATION 2 Install the fuel pick up and fuel filler lines to the fuel tank Note It is recommended you always use a fuel filter on your gas can filters should not be installed inside the airplane Inline fuel filter can clog and cause your engine to qu...

Страница 38: ...bles from engine vibration 9 Use a 17 64 drill bit to slightly enlarge the fuel dot sleeve as shown This will allow easier re moval of the fuel dot during refueling 10 Glue the fuel dot into the predrilled hole inside the fuselage This mounting location will require the removal of the canopy for refueling 11 Feed filler line through dot and plug line into filler plug as shown 12 Apply a small amou...

Страница 39: ...ow 15 Route the vent line on top of the fuel tank and secure with small nylon ties as shown This will stop excess fuel from draining out the vent line during an extended down line or when lifting the tail 18 Use a hobby knife to cut a hole in the bottom of the fuse rear of the landing gear plate to allow the fuel vent exit dot to pass through 17 Use a hole template to mark a 3 8 hole in the desire...

Страница 40: ... Secure open end of vent tubing to the nylon tie as shown 22 Use wire cutters to remove excess fuel tubing fuel tubing should extend out of fuse 1 1 2 to allow easy installation of the vent exit dot 21 Pull nylon tie and fuel tubing back through vent exit dot hole 24 Use thick CA to secure fuel vent exit dot in fuse 23 Use safety wire Supplied to secure fuel tubing to fuel vent exit dot ...

Страница 41: ...2600mah Li Ion Shown 1 Regulator Fromeco Sahara Shown 1 Receiver Switch Smart Fly Shown 1 Adhesive backed Velcro Required Tools and Adhesives Pencil Felt Tip Pen Electric Drill 1 16 Drill Bit Wire Cutter Masking Tape 2 If using the Smart Fly Super Switch HD it may be necessary to trim the switch mount Locate the switch back plate and use this as a guide to mark the needed opening for the switch 3 ...

Страница 42: ...r installation shown below Ensure that regulator is securely held to radio tray a one wrap strap can be placed around the regulator and through the fuse floor to secure it in place if necessary 9 Install receiver using foam padding and one wrap strap as shown below Follow radio manu factures instructions for antenna orientation 10 Finished radio installation shown below 4 Install switch using hard...

Страница 43: ...rial and into the bottom cowl mounting blocks 5 Mark the side of the template that will come in contact with the cowling This will help when transferring the cut out locations onto the cowl COWL INSTALLATION 1 Gather the following items for the cowling in stallation Required Parts 1 30CC Laser 200 Cowling 1 8 x 11 Card Stock for Muffler Template Required Tools and Adhesives Felt tip pen Masking Ta...

Страница 44: ...se a drop of blue loctite to prevent the bolts from loosening due to engine vibration 11 Reinstall engine to standoffs as shown below Be sure to reconnect throttle linkage and fuel line 6 Trace around the head of the engine being care ful to keep the template in the same location 7 Use a hobby knife to cut out the engine cylinder exit opening as shown 9 Remove engine from standoffs as shown below ...

Страница 45: ...cohols or other paint removers always test on painted parts before using 17 Remove the template and use a rotary cutting tool and sanding drum to cut out the openings in the cowl Note Take care not to cut or scratch the cowl 12 Reinstall the cowl template and mark the loca tion of the muffler exit stingers at this time 13 Extend hot air exit past the marks made in the previous step Hot air exit sh...

Страница 46: ... shown below Note Aeroworks has found this method to provide sufficient cooling for the DLE 35 gas engine It is still important to check motor temperatures to ensure it is not running too hot If your engine does run hotter than the manufacturer suggests additional cooling holes may need to be made in the cowling 1 Gather provided choke installation items shown below Required Parts 1 4 40 Metal Rod...

Страница 47: ...e will allow the pins to be installed and re moved easily 3 Gather 2 6 32 wing mounting bolts 2 6 rub ber backed washers and 4 hairpins for prepara tion of mounting the wings 4 Slide the wing tube in the fuse wing tube sleeve Slide the wings on the wing tube and plug in the aileron servo connectors Slide the rubber backed washers on the wing mounting bolts and insert bolts through the fuse side an...

Страница 48: ...nded you apply thin CA glue to the front hold down dowels This is a High vibration area and can loosen the front dowels Always check the front dowels are secure before each flying session 8 The canopy is secured by a spring loaded latch as the rear of the canopy hatch assembly This latch must be pulled all the way back when in stalling and removing the canopy 1 Gather the items listed below for th...

Страница 49: ...r the CG Buddy as shown below CHECKING CG WITH CG BUDDY CG Can also be measured at the wing tip CG is located 3 from the leading edge at the wing tip 2 Slide wings away from fuse and install the CG Buddy on the wing tube and front rotation dowel as shown The cable attachment should be on the top side of the wing Make sure the CG Buddy is securely latched to the wing tube and dowel before moving fu...

Страница 50: ...inst fuse insuring both wings are pushed firmly against fuse Low Rate Medium Rate Aileron 1 1 2 or 18 up 2 1 2 or 30 up 1 1 2 or 18 down 2 1 2 or 30 down Rudder 20 left 30 left 20 right 30 right Elevator 3 4 or 11 up 1 1 4 or 20 up 3 4 or 11 down 1 1 4 or 20 down For 3D flying use the following throws High Rate Aileron 3 1 2 or 45 up 3 1 2 or 45 down Rudder 45 left 45 right Full rudder deflection ...

Страница 51: ... inches 2 Use the widest part of the elevator as shown to measure the elevator throw in inches 3 Gather the Aeroworks Rudder Throw Meter Supplied and clear tape 4 Slide the throw meter under the rudder boost tab 5 Secure the tabs to the fin using clear tape 6 Degrees are measured at the tip of the boost tab as shown below ...

Страница 52: ...er not supplied to measure the throws in degrees Prop up the tail of the aircraft until the fuselage is parallel to the table top 8 Use the widest part of the aileron to measure the aileron throw in degrees 9 Use the widest part of the elevator to measure the elevator throw in degrees ...

Страница 53: ...hecking these items will result in an airframe that lasts for many years Covering Seams and Overlaps Glue Joints Engine Mounting Bolts Prop Mounting Bolts Servo Mounting Screws Servo Gears Hinges Control Horns By checking each of the above listed items before each flying session your airplane will last for many season These guidelines are a great way to check any airplane in your hangar to prevent...

Страница 54: ...l associated with flying the model aircraft are allowed at or in front of the line In the case of air shows demonstrations straight line must be established An area away from the line must be maintained for spectators Intentional flying behind the line is prohibited 5 I will operate my model aircraft using only radio control frequencies currently allowed by the Federal Communications Commission FC...

Страница 55: ... 2 M6 lock nuts 2 4mm i d Wheel Collars with set screws 2 3 75mm Dia Main Wheels Lite Type 4 4 40x10mm hex style bolts for mounting wheel pants 4 3mm flat washer for mounting wheel pants 4 3mm split ring lock washer for mounting wheel pants 4 6 32x20mm hex head bolts for mounting main landing gear 4 3 5mm flat washers for mounting main landing gear 4 3 5mm split ring lock washers for mounting main...

Страница 56: ...ing the template for cutting of cowling 1 Paper Degree Meter for the Rudder 4 25 1 12mm Aluminum Insert 6 Rubber Grommets 2each 6mm 8mm 10mm Fuel line and wire guide 4 6 35mm Aluminum Engine Stand Offs 13 1 C G Buddy 14 1 300x300mm True Red Covering 866 1 300x300mm White Covering 870 1 300x300mm Midnight Blue Covering 885 2 20x1500mm transparent covering 15 1 Manual CD 16 1 Decal Set 17 Tail Flyin...

Страница 57: ...ctly on the 30cc Laser 200 The carbon leaf spring adds tre mendous strength compared to the stock aluminum tail wheel at a reduced weight Aeroworks Safety Clips Made from flexible plastic the Aeroworks Safety Clips provide a easy and safe way to secure your servo connections 2 5 Gallon Hand Crank Gas Fuel System The 2 5 gallon hand crank gas fuel system is perfect for pilots venturing into gas pow...

Страница 58: ... engine RPM while conveniently mounted inside the airplane Vent Exit Dot Clean up your fuel vent exit on the bottom of your model with these clean looking vent exit dots Ma chined from high quality aluminum these exit dots are compatible with all fuel types 30cc Laser 200 Custom Dash Panel Dress up the cockpit of your 30cc Laser 200 with this 3 dimensional dash panel Made from rigid plastic this d...

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