Hangar 9 Beast 100, Assembly Manual

Page 1: ...Wingspan 89 0 in 2 260mm Overall Length 87 in 2210mm with spinner Wing Area 2 490 sq in 161 sq dm Flying Weight 26 28 lb 12 13 kg Engine Size DA 100L Assembly manual Beast 100 Specifications ...

Page 2: ...vator Hinging 20 Cabane and Mid Wing Section Installation 22 Stab Flying Wire Installation 24 Tail Gear Steering Installation 26 Rudder Servo and Pull Pull Installation 28 Cowl Installation 30 DA 100L Engine and Throttle Installation 32 Fuel Tank Installation 37 Wing Servo and Control Horn Installation 39 Elevator Servo and Control Horn Installation 45 Battery Installation 47 Regulators and Receiv...

Page 3: ... Questions Assistance and Repairs 64 Inspection or Repairs 64 Warranty Inspection and Repairs 64 Non Warranty Repairs 65 Safety Precautions and Warnings 66 Instructions for Disposal of WEEE by Users in the European Union 67 2010 Official AMA National Model Aircraft Safety Code 68 ...

Page 4: ...HANU874 Gold HANU879 True Red HANU866 Before Starting Assembly Before beginning the assembly of the Beast 100 remove each part from its bag for inspection Closely inspect the fuselage wing panels rudder and stabilizer for damage If you find any damaged or missing parts contact the place of purchase Go over the covering using a heat gun or sealing iron It is best to use a heat gun to take away any ...

Page 5: ... the rudder that should use greater than 400 oz in 2 2000mAh or larger Li Po for receiver A minimum of 4000mAh is required when using super high torque servos 1350mAh or larger for ignition 4 8 or 6 0V The elevator installation requires Two servos and mixing through the radio Or Two servos and a JR MatchBox JPA0900 The ailerons installation require Four servos and mixing through the radio Or Four ...

Page 6: ...100cc reproduction for Hangar 9 He did so with the full cooperation of Mr Kimball as well as Bryan Jensen the Beast s pilot and owner and Mirco Pecorari who designed the full scale plane s trim scheme At the heart of the model s design is a rigid lightweight airframe that features thinner wings for better top speed and agility Beast 100 is one of the few truly scale but high performance giant scal...

Page 7: ...anium carbon fiber and some lightweight components Power of the 10 000 cc 9 cylinder engine was increased to 410 hp with modifications including high compression pistons fuel injection and advanced micro polishing of internal parts Increased maneuverability was found by wingspan and tip modifications aileron design changes improvements to the tail and CG The Beast weighs 1420 pounds with 1850 poun...

Page 8: ...s on each side and help remove any dirt in the hinges Note the rod is 1mm in diameter as seen in the picture below Step 2 Iron the edges then line up the hinges on the rudder and vertical fin Lubricate the rod with a low viscosity lubricant and push it through the hinges A drill would make this easier If binding back out and slowly push the rod through Putting too much pressure when binding would ...

Page 9: ... DO NOT force it in as you may break the fuselage opening Remove some covering on the conservative side until the vertical fin fits in the fuselage You can use pictures in Step 2 as reference Step 2 Remove the vertical fin and covering 1 8 inch inside the lines you marked Make sure not to scar the vertical fin Use a new blade and change as needed Then go over the edges with a heating iron If you s...

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Page 11: ...11 Step 3 Install the rudder control horn by passing the bolt through the rudder Use a drill on a slow speed for ease of installation It would be best to have the bolt centered on the rudder ...

Page 12: ...n them on both sides Install the control horn so the distance between the hinge line and pivot point of the horn measures 1 1 4 inch Test this by installing the arm if one control horn is off you won t have a straight shot at 1 1 4 inch hole of the arm ...

Page 13: ... minute epoxy or wood glue Wipe out the excess with alcohol swabs In case of using wood glue make sure to allow 24 hours for wood glue to cure The advantage of using wood glue is that you can easily clean the excess glue with water Step 6 Bend the rudder hinge rod 90 degrees toward the aft of the rudder and put clear tape on it ...

Page 14: ...2 wrench and crescent wrench Required Tools and Adhesives Threadlock Hex wrench 050 inch 3 32 inch Step 1 Install the shaft on the gear Step 2 The landing gear should be installed such that it is swept forward Install the wheel collar Use threadlock on the setscrew It is best to file the axle where the setscrew sits Follow the measurement shown for the wheel to be centered in the pant Landing Gear...

Page 15: ...tep Leave a small gap between the wheel and collar to avoid braking The wheel should turn freely Tighten the nut on the axle using a 12 and a crescent wrench Step 4 Install the wheel pants and secure them using the screws provided Use threadlock on the screws ...

Page 16: ...is completely centered and square If you feel the need to make measurements 5 times or more please do so Once the stab is glued modifications would be extremely difficult Step 1 Three accurate measurements are required to ensure the stab is placed correctly 1 The distance from the tip of the stab to the fuselage should be equal on both sides 2 The distance from the tip of the stab to behind the tu...

Page 17: ... to ensure correct measurements of the plane The above numbers are given as an estimate Step 2 Once measurements are taken and you feel comfortable with them mark the stab with a marker or pen Remove the stabs and remove the covering 1 8 inch inside your markings Go over the covering and edges using a heating iron It is very important you do not scar the stab while removing the covering Make sure ...

Page 18: ...ue on the left and right side of the stab and allow time for the balsa to absorb the CA Next flip the plane to knife edge and repeat the procedure all around the stab top and bottom Use a CA extension nozzle and apply some CA from the elevator opening in the fuselage over the stab and braces Watch for running CA If you move the plane before the CA is set the CA will run onto the covering 30 minute...

Page 19: ...19 19 Step 4 To ensure your stab is properly glued apply extra CA medium by extending your hand inside the fuselage and applying some CA over the horizontal bracing and stab ...

Page 20: ...elevator half is not hinged on the stab side so you are able to glue the stab in the fuse Go over the edges with a heating iron Then apply some petroleum jelly to the pins Avoid getting oil on the hinge itself Wipe with alcohol if that happens Step 2 Using 30 minute epoxy glue all the way in and around the pocket walls of the pockets in the stab Then apply some to the hinge itself ...

Page 21: ... too much of a gap between the two Use the other side of the elevator gap as reference Move the elevator through its full up and down deflection to ensure there is no binding Wipe excess glue Secure the elevator with masking tape and wait until the epoxy cures ...

Page 22: ... the slot use a hobby knife and remove balsa as necessary Apply a drop of threadlock to the screws and bolt the cabane to the frame that has blind nuts Note that there are slots to guide your ball driver Step 2 Go over the mid wing section with a heating iron before installation Install the mid wing section on the cabane The mid wing section attaches to the cabane via 2 6 32 inch screws on each si...

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Page 24: ...s to the vertical fin and horizontal stab as pictured Do not tighten down completely If the holes are too tight for the screw to pass through drill the holes carefully using a 1 8 inch drill bit Do not put excessive pressure on the stab while drilling Once the plate and screw are installed rotate the brass plate over the hinge line or edge of the stab to be able to bend the side the wire passes th...

Page 25: ...through the crimp to loop it Crimp the non adjustable side Repeat the same steps for the adjustable side but pull on it so there is no slack and then crimp Adjust once all crimping is finished Pictures below show the correct installation of the nut clevis and fuel tubing ...

Page 26: ... bend on the other side It is best to attach the ball link to the tiller arm of the gear and Z bend end to the T plate Step 2 Mark where the plate will be attached to the bottom of rudder Approximately 2 to 3 inches away from the hinge line Do not attach the plate too far as it will result in poor steering Using a pin wise and 1 16 inch bit make two pilot holes Screw the T plate to the bottom rudd...

Page 27: ...and cut the rod to the appropriate length and Z Bend the top of the rod to be inserted to the plate Now proceed with final installation on the tiller arm Apply threadlock to the nut make any necessary adjustment to the length and tighten the nut ...

Page 28: ...of torque The rudder tray can accommodate up to two servos Use a JR 8711 or 2 digital servos with equal or greater torque combined and a JR MatchBox Step 1 Install the rudder servo so the output shaft is toward the aft of the fuselage Install the arm and ball links Pass the cables through the tubes already mounted in the aft section of the fuselage Cross the cables Crimp the servo side first Rudde...

Page 29: ...er side before crimping Adjust the tension by opening the Phillips head screw in the horn tighten as necessary then use threadlock and reassemble the horn Note that control horn assembly of the rudder was done in the rudder hinging section ...

Page 30: ...ers to the bottom half of the fuselage Use threadlock on the screws but do not tighten yet Line up the bottom half of the cowl and bolt the cowl to the brackets using the included 1 2 inch 4 40 screws and washers Once everything is lined up tighten the L brackets screws to the fuselage Step 2 Attach the top support tabs such that they are located at the radius of the top half of the fuselage Use t...

Page 31: ...31 Step 3 Attach the top half cowl to check the connections Use 1 4 inch 4 40 screws and 4 washers for mid section attachments ...

Page 32: ...e kit to mount the engine but go over the standoffs with thin CA first Then mount the engine temporarily to mark the hole for your throttle rod Mount the throttle servo so the output shaft is towards the aft of the aircraft Drill through the marked hole Goal is to have a straight shot at the servo arm It has to pass through the tri stock and the balsa sheeting Approximate measurement is shown in t...

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Page 34: ...eader 3 Push the Teflon coupler on the canister inlet and slide the clamp over it 4 Push the Teflon coupler over the header until there is 1 8 to 1 4 inch gap between the header and canister Since this might be a little hard to do use a heat gun and glove to move the coupler over the header easier 5 Slide the other clamp so it is in front of the bump towards the front of the plane If you install t...

Page 35: ...35 Disclaimer Teflon is a trademark or registered trademark of E I DuPont de Nemours and Co Corporation Wilmington Delaware ...

Page 36: ...he cowl for DA100L stock muffler installation Attach the template to the bottom cowl through the two bottom bracket screw holes The template should lay tight on the bottom cowl Mark the center of the holes through the template onto the cowl Start with a small circle and adjust as needed for a perfect fit Note This only works with the DA 100L and the 1 inch standoffs provided in the kit You will ne...

Page 37: ...sure the connections are solid before final installation Note The lines can get stiff if the plane sits for some time with no fuel in the tank after use Please make sure to check your lines often Step 2 Reassemble the tank Make sure the cap is secure but avoid over tightening Cut some 1 4 inch foam the size of the bottom of the tank Use double sided tape between the tank and foam or wrap masking t...

Page 38: ...side of the Velcro to the tank tray in the fuselage This prevents the tank from fore aft movement Velcro is a registered mark of Velcro Industries B V Netherlands Step 4 Use the aluminum T fueler for the carb connection Tie wrap the connections to avoid any air leaks ...

Page 39: ...kage as in the pictures Apply threadlock to the nut and tighten until it bites the wood but do not over tighten The length of the titanium rod exposed from the ball link to the control horn should measure 22mm Make sure to equally thread the titanium rod in the ball link and the control horn Step 2 Attach a 6 inch extension for top wing or a 12 inch for the bottom wing Use dental floss to secure t...

Page 40: ...d the leading edge of the wing Use 1 16 inch drill bit to drill pilot holes for servo screws then go over the holes with thin CA Wait until it cures before inserting the servo in the bay and securing it You can use a long rod to pull the servo extension to the wing root ...

Page 41: ...should measure 22mm These measurements should be the same for all 4 wings Attach the 1 5 inch arm to the ball link and complete the assembly Step 5 Make 3 more identical length control horn ball link setups and complete the other 3 wings in the same exact way Remember top wings use 6 inch extensions where bottom wings use 12 inch extensions ...

Page 42: ...in and where it would line up with the extension exit from the wing root The cut can be as big as 30x20mm so there is no problem with catching the extension 2 Plug the wing and mark it through the fuselage slot 3 Remove the marked balsa sheeting and pull the plug Note When plugging the wing pull the extension from inside the fuse to avoid damaging the extension by jamming it ...

Page 43: ...teps below 1 Insert the sleeve and check the length If it is longer than it needs to be make one side flush with the side of the bottom fuse and mark the other side to cut using a hobby knife 2 Insert the sleeve making sure it is flush on both sides and has thin CA over the edges The thin CA will soak in Do not use CA accelerator Repeat the process two times and allow time for it to dry Do not bui...

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Page 45: ...e is a chance one side would have only a few threads and pull out unexpectedly in the air Attach the servo arm at 1 5 inch hole to the ball link Step 2 Elevator control horn installation is similar to the wings with a few considerations Insert the bolt through the elevator do not tighten the nut but turn the nut up the bolt Hold the control horn at the tip of the bolt and turn the bolt to grip the...

Page 46: ...loss and the masking method described in the wing section Turn on power to the servo with the sub trim at 0 Try to put the arm on the output shaft so the servo arm is directed slightly to the front of the plane or at 90 degrees With this method max up down deflection should be 43 45 degrees equally Note Do not lengthen the linkage any longer than 60mm as it may not be safe It is OK to carry some s...

Page 47: ...ides Masking tape Medium CA Note Do not glue your battery tray in if the installed engine is not the DA 100L so the model can be balanced by relocating batteries Step 1 Prepare the tray completely before gluing it in place Wrap masking tape to the bottom of each battery Then CA Velcro to the masking tape on the batteries and also the tray i e soft part of Velcro to the batteries and mating part to...

Page 48: ...epoxy and brush it up on the tray Apply a small amount to the fuselage frame and place the tray in the fuselage Add some weight until the epoxy cures Note In the picture above a crescent wrench that has some weight has been placed on top of the batteries with two small clamps Make sure you do not move the fuselage which can drop the weight and damage the fuselage ...

Page 49: ...ht plywood Use 1 16 inch drill bit to mark the screw locations and apply a drop of thin CA to the holes for strength Then glue the light plywood to the fuselage balsa floor Complete the installation by screwing the regulators to the fuselage floor Step 2 Switches will be installed at the side of fuselage right behind the turtle deck Mount the cover of the switch over the fuse where it needs to be ...

Page 50: ...bit of thin CA to the screws before completing the installation If the steps are followed properly as described there is no need to back the screws with a sheet of light plywood Step 4 Follow the steps below to prepare the receiver for mounting 1 Apply masking tape to the bottom of the receiver 2 Glue using CA 1 4 inch foam to masking tape 3 Glue using CA medium Velcro soft part to foam ...

Page 51: ...red the same way except they do not need foam The following pictures show preparation and mounting of satellite receivers Note It is still necessary to perform a healthy range check and make any adjustment needed to the location of satellite receivers for best results A Spektrum Flight Log SPM9540 can be very helpful for this process ...

Page 52: ... or CA but the advantage of hot glue is it won t damage the extension coating and is easy to remove In case of using CA it would be best to pass your extensions through nylon tubing or heat shrink Top wing extensions can be secured to the struts using black electrical tape or by cutting strips of black UltraCote making a loop and ironing them to the struts ...

Page 53: ... inch Du Bro foam Step 1 Mark the switch location on the side of bottom of the fuse below the engine box Remove the plywood and make the pilot holes for screws using a pin wise and 1 16 inch drill bit Complete the installation Step 2 Prepare the ignition module by following the same method for receiver preparation installation Use 1 4 inch split flex guard and tie wraps to protect the spark plug w...

Page 54: ...re the ignition switch wires to the side of the engine box Step 4 Mount the appropriate battery for your ignition module next to the ignition in an available slot It is best to mount the battery closer to where the switch is mounted ...

Page 55: ...ls to dry and adhesive to set It is important to take all the wrinkles in the covering out and would be best to apply the decals after the plane has been taken to a flying field a couple of times and all the wrinkles have been removed The following pictures are the schematic of where the stickers belong on the full size model ...

Page 56: ... damage Plane Assembly 1 Start by Bottom wing assembly Each bottom wing panel is attached to the fuselage with two 1 4 20 plastic bolts Do not forget the CF anti rotation pin 2 Attaching the top wings Each wing panel is attached to mid wing section with 2 6 32 bolts and washers Use a short 1 5 2 inches long 7 16 inch hex driver for ease of use 3 Interplane struts attach top and bottom wings togeth...

Page 57: ...hrow deg Expo Throw deg Expo Throw deg Expo 1 23 55 15 35 45 70 2 25 60 10 30 22 25 35 3 25 60 10 30 45 65 4 45 75 45 70 45 65 Explanation Flight Mode 1 Set this flight mode for takeoff and landings as the precision rate may not have enough elevator for adverse condition slow speed landings Flight Mode 2 This flight mode is for precision flying including snaps Flight Mode 3 This flight mode is als...

Page 58: ...wn transmitter This should provide modelers a good reference point Rudder to Elevator Curve Mix Point 2 1 L 3 4 5 H R Rudd 0 2 5 L Rudd 0 2 4 5 means up elevator Each point represents 1 3 of full deflection i e point 2 is first 1 3 of stick deflection and L is full right rudder Point 3 is stick at center The photograph below is a screenshot of the 12X radio programmed with the information from the...

Page 59: ...ttom Wing Aux2 Define the mix below and assign it to a switch The example switch below is Rudder D R and crow is mixed with throttle As throttle decreases deflection increases and at full throttle ailerons will be back to normal Please check www hangar 9 com for Quique s personal program for the Beast The program can be downloaded by JR 12X owners ...

Page 60: ...ow 1 Eliminate regulators by using JR 8911HV servos and 8917HV for throttle The speed and torque of JR 8911HV servos are superior to the JR 8711 At the same time the 8911HV offers new SuperSteel gears to take the extra abuse 2 Get 50 to 55 degrees of elevator deflection by replacing the 2 5 inch titanium pro link included in the kit with the 3 inch Hangar 9 pro link HAN3553 The extra 10 degrees in...

Page 61: ...ane struts in order from left to right Top wing attachment Top wing 6 32 screw joint Bottom wing attaching to fuselage Bottom wing extension in the fuse Left interplane strut assembled Final Pictures of Plane Assembly and Setup ...

Page 62: ...62 Top wings extension routing Bottom wing attachment 12X setup no MatchBox Regulators location MatchBox setup one on each side of receiver Engine and ignition setup ...

Page 63: ...ive In the event of a defect these are the Purchaser s exclusive remedies Horizon reserves the right to inspect any and all equipment involved in a warranty claim Repair or replacement decisions are at the sole discretion of Horizon This warranty does not cover cosmetic damage or damage due to acts of God accident misuse abuse negligence commercial use or modification of or to any part of the Prod...

Page 64: ...this Product needs to be inspected or repaired please call for a Return Merchandise Authorization RMA Pack the Product securely using a shipping carton Please note that original boxes may be included but are not designed to withstand the rigors of shipping without additional protection Ship via a carrier that provides tracking and insurance for lost or damaged parcels as Horizon is not responsible...

Page 65: ...tion date Any repair left unpaid or unclaimed after 90 days will be considered abandoned and will be disposed of accordingly Please note non warranty repair is only available on electronics and model engines United States Electronics and engines requiring inspection or repair should be shipped to the following address Horizon Service Center 4105 Fieldstone Road Champaign Illinois 61822 USA All oth...

Page 66: ...bject to interference from many sources outside your control This interference can cause momentary loss of control so it is advisable to always keep a safe distance in all directions around your model as this margin will help to avoid collisions or injury Always operate your model in an open area away from cars traffic or people Avoid operating your model in the street where injury or damage can o...

Page 67: ...ycling of waste electrical and electronic equipment The separate collection and recycling of your waste equipment at the time of disposal will help to conserve natural resources and ensure that it is recycled in a manner that protects human health and the environment For more information about where you can drop off your waste equipment for recycling please contact your local city office your hous...

Page 68: ...with metal blade propellers or with gaseous boosts other than air nor will I operate model aircraft with fuels containing tetranitromethane or hydrazine 8 I will not operate model aircraft carrying pyrotechnic devices which explode burn or propel a projectile of any kind Exceptions include Free Flight fuses or devices that burn producing smoke and are securely attached to the model aircraft during...

Page 69: ... site a day use agreement between sites or testing which determines that no interference exists A frequency management agreement may exist between two or more AMA chartered clubs AMA clubs and individual AMA members or individual AMA members Frequency management agreements including an interference test report if the agreement indicates no interference exists will be signed by all parties and copi...

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