AeroWorks 100cc YAK-54 ARF-QB, Assembly Manual

Page 1: ...1 100cc YAK 54 ARF QB Quick Build ASSEMBLY MANUAL AEROWORKS 401 Laredo St Unit D Aurora CO 80011 www aero works net...

Page 2: ...lear covering to the leading edge of wings and stabs 10 Wing Assembly 13 Stab and Elevator Assembly 21 Rudder and Tail wheel Assembly 26 Main Landing Gear Assembly 38 Engine Muffler or Canister and Th...

Page 3: ...orkmanship at the date of purchase This warranty does not cover any component parts damaged by use or modification In no case shall Aeroworks liability exceed the original cost of the purchased kit Fu...

Page 4: ...h this assembly manual carefully before starting the as sembly of your new 100cc YAK 54ARF QB Inventory and inspect all parts and hardware for any imperfections or damage Please notify Aeroworks immed...

Page 5: ...f the canopy base 4 3mm split lock washers for the mounting of the canopy base 1 3 5 o d x1250mm Antenna guide tube installed 2 3 5 o d x70mm rudder pull pull exit tubes installed Left Wing with Ailer...

Page 6: ...readed pushrod with nuts and clevises for elevators 2 4 40x300mm Threaded pushrod Throttle and Choke 2 4 40 solder coupler 2 4 40 Metal clevises 8 Brass spacers 4 for ailerons 2 for elevators 1 for th...

Page 7: ...ness 2 x 6 2 x 12 2 x 18 2 x 36 1 Receiver PCM 1 x Receiver battery min 6 0 volt 1700ma 1 x Ignition battery min 4 8 volt 1700ma 2 switches with charge jacks 22 Gauge min Tools Allen wrenches US and M...

Page 8: ...educe heat and work slowly IMPORTANT Go over any and all seams and color overlaps with your iron to assure good adhesion of the covering to the wood This is especially im portant at the leading edges...

Page 9: ...nge gaps Use covering iron to seal the clear covering snugly into the bottom of the hinge lines as shown for air tight hinge seals Note The clear covering does have a transparent protective backing Th...

Page 10: ...sure a clean surface for the covering to stick to Note Wing pictured in the following steps may be a different color and model However the procedure for applying the clear covering to your model will...

Page 11: ...stabs later 7 Remove the clear backing from the covering Note Do not skip this step There is a backing to the covering Take time to remove this backing to get the correct adhesion to the already appli...

Page 12: ...Clear covering is centered on trim colors Using the same method complete the remaining wing and stabs IMPORTANT It is the users responsibility to check the covering seams and overlaps for security and...

Page 13: ...Y 2 Layout the servos extensions and Y harness on the wing to test fit the installation and ensure servo leads are the correct length Minimum recommended servo 180 in oz Metal geared Digital 3 Attach...

Page 14: ...onnectors will not come apart from vibration or light tension 7 Fasten the pull string from the inboard servo hole to the male connector of the Y harness Secure with tape so that the string pulls from...

Page 15: ...or other method Ensure the connectors will not come apart from vibration or light tension 10 Tuck the excess servo wires inside the wing root as shown 11 Install servo in servo well with the output ar...

Page 16: ...ing panel Note There is also a Carbon tube for reinforcing the pushrod not pictured This will be installed during a later step 2 Assemble two pushrod and control horn assemblies as shown The ball link...

Page 17: ...trol horns to the mounting holes and secure using six wood screws as shown 6 Attach 4 40 ball link to the under side of the servo arm using 4 40 bolt brass spacer and lock nut Note 1 servo arm is reco...

Page 18: ...he servo arms are parallel to the aileron hinge line Adjust the length of the pushrods so that the aileron is at the neutral position when the servo arms are parallel to the aileron hinge line Carbon...

Page 19: ...from the control horn 3 Using a Dremel cut off wheel cut the carbon tube to correct length 5 Remove the 4 40 ball link from the pushrod 6 Slide carbon reinforcing tube over the 4 40 pushrod and reass...

Page 20: ...20 7 Final pushrod assembly shown below 8 Repeat installation steps for all aileron pushrods...

Page 21: ...ssemblies 2 brass spacers 2 left and 2 right side control horns and 12 wood screws Note There is also a Carbon tube for reinforcing the pushrod not pictured This will be in stalled during a later step...

Page 22: ...se 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 Install servo in servo well with the output arm toward the leadin...

Page 23: ...levator is in the neutral position when the servo arm is parallel to the elevator hinge line A 1 1 2 servo arm is recommended to achieve full deflection of the elevator bevel Ensure the servo does not...

Page 24: ...ink from the control horn 2 Mark cut location onto carbon tube Carbon tube should fit between 4 40 ball link lock nuts Note Model shown may be different form yours However the carbon reinforcement tub...

Page 25: ...25 7 Final pushrod assembly shown below 8 Repeat installation steps for other elevator pushrod 6 Slide carbon reinforcing tube over the 4 40 pushrod and reassemble ball link to pushrod end...

Page 26: ...light oil to the hinge joint This ensures no epoxy gets into the hinge during assembly 3 Mix epoxy in mixing cup and use a tapered stick to apply the epoxy inside the pre drilled holes in the trailing...

Page 27: ...ply the epoxy inside the pre drilled holes in the leading edge of the rudder Apply epoxy on to each hinge 7 Carefully slide the rudder onto each hinge and against the trailing edge of the fin Wipe awa...

Page 28: ...e 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 2 Gather the rudd...

Page 29: ...to aft rudder servo leads and secure with safety wire string tape or other method Ensure the connectors will not come apart from vibration or light tension 3 Install the aft rudder servo with the outp...

Page 30: ...ws Rudder Pull Pull Cable Installation 1 Gather the rudder control linkage parts shown below 2 Rudder cables 2 threaded metal RC links 4 threaded couplers and 4 brass swag ing tubes 2 Feed the rudder...

Page 31: ...k through the brass swage tube as shown 5 Loop the cable back through the brass swage tube as shown 6 Tighten the second loop through the brass swage tube and crimp the brass tube with a crimping tool...

Page 32: ...g the rudder servo Y harness into the rud der channel of the receiver and power up Turn on transmitter to center rudder servos 10 Use 4 40 rod and 4 40 easy links to connect two servos together Note R...

Page 33: ...sem bly is shown below Use 4 40 ball links and 4 40 all thread with copper brass or carbon tubes over the all thread rod to give adequate strength Note Rudder coupler hardware is not supplied 14 Tape...

Page 34: ...ge tube on both sides With the rudder servos powered up and centered pull light tension on the cable through the coupler on both sides as shown 18 Loop the cable back through the brass swage tube as s...

Page 35: ...in or out on the threaded cou plers and or ball links Make all adjustments with the rudder servos still powered up and centered and the rudder still taped in the neu tral position Ensure the servos do...

Page 36: ...nting holes 3 Mount the tail wheel steering tiller using two wood screws 4 Stack the tail wheel leaf springs on the tail wheel strut Position the tail wheel and leaf springs on the bottom of the fuse...

Page 37: ...ottom of fuse 8 Attach the steering springs on both sides of the tail wheel to the rudder tiller and tail wheel tiller Center the springs between both tillers Use pliers to twist spring ends closed ar...

Page 38: ...bolts with washers MAIN LANDING GEAR ASSEMBLY 2 Remove the landing gear cover by removing the two screws on the lower part of the front former 3 Note that the trailing edge of the landing gear strut i...

Page 39: ...sure tapered edge of the gear strut is facing toward the rear 6 Reinstall the landing gear cover Wheel And Wheel Pant Installation 1 Gather the 2 wheels 2 axle assemblies and 4 wheel collars as shown...

Page 40: ...en align the wheel pant slot over the axle bolt as shown below 5 Install and tighten the wheel pant mounting bolts to hold the wheel pant in place DO NOT use Loctite at this time 6 Now tighten the axl...

Page 41: ...Use a drop of blue Loctite on the wheel collar set screw and tighten the wheel collar in place 9 Install the wheel and outer wheel collar Use blue Loctite on the wheel collar set screw be fore final t...

Page 42: ...42 11 Install wheel pants with two mounting bolts 12 Repeat above steps for other wheel and wheel pant...

Page 43: ...the DA 100 or 3W 100 106 Note If other engines are used the templates may be modified to fit you engine selection Center your engine over the laser marked thrust lines on the template Mark and drill t...

Page 44: ...own below Note The prop hub will stand out from the front of the cowling approximately 1 2 This is Normal for all Yak s and is required to achieve proper C G location and engine performance 8 Insert t...

Page 45: ...anister mufflers are to be used gather the pre cut balsa canister tunnel baffles and included silicone tubing as shown below 3 Remove the landing gear cover as shown be low 4 Dry fit the front tunnel...

Page 46: ...d 6 Dry fit the rear tunnel balsa floor baffle for proper fit Apply medium CA glue to baffle and install 7 Slide baffle under wing tube and under the tank floor as shown below 8 Top view of the instal...

Page 47: ...for proper fit Apply medium CA glue to edges of the baffle 10 Install the lower rear former tunnel baffle as shown below with CA glue 11 Lower rear former tunnel baffle installed 12 Canister tunnel se...

Page 48: ...pre cut for you if so skip this step 14 Slide the silicone tubing vibration isolators into the plywood cutouts in the pre installed canister mount 15 Using a hobby knife follow the pre marked and tab...

Page 49: ...cover Use a sealing iron to ensure the covering is bonded to the bottom of the fuse frame around the pre cut air exit holes 19 Use a hobby knife to remove the covering from the canister tunnel pre cut...

Page 50: ...la tors Temporarily attach the header pipes to the engine as shown to check for proper align ment and fit Throttle Servo Installation Now is a good time to think about installing your throttle servo 1...

Page 51: ...o cut out the throttle servo mounting hole Note Cover engine with a towel or cloth to protect from any debris getting into the carburetor or cylinders 5 Install the throttle servo with pushrod attache...

Page 52: ...ther the soldering tools as shown below Note For best results we recommend a high quality Silver Solder like Sta Brite silver solder 8 Solder the threaded coupler to the throttle pushrod wire 9 Instal...

Page 53: ...the throttle pushrod with the 4 40 ball links and secure Power up the receiver and throttle servo and adjust pushrod for proper operation Ensure the servo or rod does not bind or jam at closed or full...

Page 54: ...engine using blue Loctite as shown Note Use a gasket to ensure good seal 15 Firmly tighten the header mounting screws to the engine 16 Reinstall the landing gear cover as shown 17 Typical standard st...

Page 55: ...ottle and Chock Servo Installation 1 If a rear carburetor engine is used or you pre fer to have the throttle and choke servos installed inside the fuse Locate the servo mounting brackets servos and pu...

Page 56: ...out excess tension or chafing Mark the loca tion for the nylon tie holes IGNITION MODULE INSTALLATION 2 Use a 1 4 drill bit to drill the nylon tie mount ing holes as shown 3 Roll the supplied foam rub...

Page 57: ...he firewall as shown 6 Enlarge the holes as necessary to pass the igni tion timing plug through the firewall 7 Secure the ignition timing connectors with safety wire string tape or other method En sur...

Page 58: ...This will keep the weight of the fuel clunk from pulling the fuel line off the brass tube Barbs Not Supplied 3 Insert the rubber stopper into the tank with the vent tube at the top of the tank Secure...

Page 59: ...nting holes 4 Install the foam rubber and nylon ties for mounting the fuel tank 5 Cinch the nylon ties securely to hold the tank against the foam on the fuel tank floor Note If you are not using canis...

Page 60: ...ine carburetor intake nipple You will need an after market fuel T and fuel filling dot Note We recommend using a fuel filter in the line going to the engine carburetor 9 Install the fuel filling dot a...

Page 61: ...f the fuel tank as shown to prevent fuel spilling when the model s tail is lifted or flying a down line We have found this will give you longer flying times with the same size fuel tank 12 Use a 5 16...

Page 62: ...vent exit hole in the landing gear cover 15 Install a rubber grommet in the fuel vent exit hole as shown 16 Remove the landing gear cover and pass the fuel vent tubing through the rubber grommet as sh...

Page 63: ...63 18 Fuel vent line installed on bottom of fuse...

Page 64: ...om of the cowl as shown Note Take care and test painted areas prior to using any type of paint remover rubbing alcohols or cleaners to remove any pen lines 4 Remove the templates and use a rotary cutt...

Page 65: ...o cut exhaust stack holes and may need more air flow exiting the bottom of the cowling for proper cooling 7 Cowl cooling air exit holes and canister tunnel air exit holes in bottom of the fuse 6 If ne...

Page 66: ...le folder hobby knife ruler tape marker and pencil 2 Mark center line of engine box floor 3 Using a square transfer center line from box floor to front of fuse former 4 Mark center line on file folder...

Page 67: ...back side of file folder 6 Aligning center marks tape template to bottom of fuselage 7 Template should fit over cowl ring support of front former 8 Lift the template so that it contacts the bottom of...

Page 68: ...locations easier 10 Extend holes towards fuse former by drawing a 2 1 2 long hole This will allow the cowling to slip over the stacks Allow a 1 4 clearance around the outside edge of the exhaust stac...

Page 69: ...Align the center mark of template with the center mark on cowl Fit flush with rear of cowl 15 Trace the sides of the air scoop on bottom of cowl 16 Cut slots in template on both sides of the air scoop...

Page 70: ...te Take care and test painted areas prior to using any type of paint remover rubbing alcohols or cleaners to remove any pen lines 19 Use a rotary cutting tool and sanding drum to cut the exhaust stack...

Page 71: ...ly remove the three rear air exit holes 23 Use a felt tip pen to trace the cowl cut outs on to the bottom of the cowl as shown Note Remember not to cut away the front air exit holes Note Take care and...

Page 72: ...ard style mufflers Note We have found this to be adequate cooling for the DA100 Depending on your engine s operating temperature you may need to allow for more exit air cooling for your engine to run...

Page 73: ...e ignition switch battery and regula tor if used first Switch location is at the dis cretion of the builder We chose to place the switches toward the front of the fuse on each side 3 Mark location for...

Page 74: ...tery nylon tie mounting hole on side of the engine box Note The mounting location of the ignition battery is left to the builder We mount the battery to the engine box side for ease of installation an...

Page 75: ...ubber as shown 10 Secure the battery connectors with safety wire string tape or other method Ensure the con nectors will not come apart from vibration or light tension 11 Mount the ignition module and...

Page 76: ...omers wanting to install canister or full length pipe mufflers This also allows all customers access to this area if needed 13 Apply epoxy to outside edges of mounting tray as shown 14 Install the rad...

Page 77: ...receiver antenna wire to the radio mounting tray and to the end of the antenna guide tube as shown This will prevent the antenna wire from vibrating back out 19 Attach all servos battery regulator an...

Page 78: ...do not over tighten and crack the fuse or wing root wood 3 Gather the 4 4 40 stab mounting bolts and 4 6 small rubber backed washers 4 Slide the stab tubes in the fuse stab tube sleeves short tube fr...

Page 79: ...bolts and 4 6 small rubber backed washers Note It is highly recommended 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...

Page 80: ...hobby knife plastic squeegee or credit card Windex or Application fluid like Rapid Tac Also a solution of 1 drop of dish detergent to a cup of water sprayed on the model will as sist in proper positio...

Page 81: ...e Transfer tape will be reused DO NOT throw away any transfer tape until decal placement is complete Decals supplied with the kit may vary from the photos below Decal application steps will be similar...

Page 82: ...ansfer tape to top of decal 9 Peel backing from decal 10 Spray model surface with application fluid Windex or soapy water solution 11 Spray back side of decal with application fluid Windex or soapy wa...

Page 83: ...card Spread decal smooth and remove all excess application fluid Let decal set until dry enough to be able to remove transfer tape with out removing decal Do not leave until completely dry or transfer...

Page 84: ...yle in small steps especially when shifting the CG to ward the tail Move the battery or add small stick on weights to the nose or tail as necessary Note If additional nose weight is necessary we recom...

Page 85: ...dder throw measured in inches from the rudder boost tab 4 Use the supplied flight control deflection me ter to measure the throws in degrees It is recommended you level the model as shown 5 Elevator t...

Page 86: ...18 up 1 1 2 or 14 down 2 1 2 or 20 down For 3D flying use the following throws 3D Rate Aileron 4 or 35 up 4 or 35 down Rudder 4 left 4 right Full rudder deflection is typically recommended for all out...

Page 87: ...olts hatch bolts servo screws control horn bolts wheel collars and clevis keepers are tight and secure Use Loctite were necessary Covering Check all seems and overlaps are se cure and have not lifted...

Page 88: ...is a list of some of the more popular aerobatic and 3D maneuvers you can try Loops and rolls Knife edge flight Stall turns Snap rolls 2 4 and 8 point rolls Slow rolls Spins upright and inverted Flat...

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