PURSUIT T-34C TURBO MENTOR, User Manual

Page 1: ...emplate 192 Center of Gravity Diagram 194 Laser Cut Parts Diagram 196 Inventory of Laser Cut Plywood 197 Inventory of Polycarbonate Skins 198 Inventory of EPP Components 198 Inventory of Loose Wood 199 Inventory of Hardware 199 Introduction Scale Pursuit Models would like to thank you for purchasing our T 34C Turbo Mentor kit and congratulates you for selecting one of the most durable and best loo...

Page 2: ...tool like Dremel No 565 Small and big cutter bits for dremel tool Nos 111 114 115 and 561 Long X acto blades X acto No 26 6 32 tap Light weight wall spackle available at home improvement stores Contour gauge Forstner Bits Scotch Brite pads Waxed Paper Sharpened brass tube for drilling tunnels in the foam airframe 1 2 dia Large C clamps for securing the wing spar sleeves Engine Selection Several en...

Page 3: ...door sequencer for the nose wheel doors Robart or Sierra Precision are good sources for the required air support accessories www robart com or www sierragiant com You will need 4 main tires we recommend the Robart Tuff Treads and a 3 nose wheel tire You may want to consider using pneumatic brakes Robart Part No 140 and 13845A0 as this can provide extra insurance against taxi and landing accidents ...

Page 4: ...readed music wire for control linkages 24 oz Du Bro fuel tank Fuel line 1 2A control horns 4 40 threaded ball link sets main gear attachments 2 56 threaded ball link sets gear door attachments and misc linkages T nuts for mounting your engine size dependent on your engine bolts Micro drill bits 040 for small screw pilot holes Servo wire extensions 6 9 Channel radio 4 spinner Electro Dynamics sells...

Page 5: ...go to http www sheffieldplastics com web_do cs BRO002 pdf Applying paint to the skins will protect the polycarbonate from fuel residue so only run an installed engine on a model with primer or paint As with most plastics polycarbonate could tear if a crack is present so radius corners of cut lines where possible We form the skins using both male and female vacuum form molds therefore some skins ma...

Page 6: ...ly in appearance You could choose to laminate all the pieces primarily Sheet C on page 197 before getting into the assembly process so that these parts are ready for installation In the back of this manual is diagram of the laser cut part sheets and a reference list of these parts The parts that require lamination are also identified Before assembly ensure that all the pieces are accounted for Add...

Page 7: ...e extend the instrument panel and cockpit back surfaces to the fuse top 2 Your fuse should be marked as shown above With a new X acto blade cut along the lines Cutting EPP with a dull blade does not work well so make sure the blade is sharp 3 Next cut the cockpits false floor supports as shown below Note the bench where the scale side instruments go retain this bench Getting a knife down into the ...

Page 8: ...there also Note With the fuse halves taped together check the fit of your selected fuel tank into the provided cavity and modify the cavity as needed Your firewall opening may also need to be modified to fit certain fuel tanks you can do that later 6 Adding a drain will help get any leaked fuel out of the fuel tank cavity and alert you that something is leaking so you can fix it To do this heat a ...

Page 9: ...er In the photo below we inserted a 1 8 brass tube into a soldering iron you want the tube or wire to be less than 1 4 as the foam will melt easily The rear rail support is the first of the laminated 1 8 plywood pieces you will be working with If you have not already done so laminate two pieces together to form a piece thick Tip Inserting a 1 8 dia music wire into a scrap wood block provides a sta...

Page 10: ...cess surrounding the steering servo cut out in the left fuse wheel well Test the fit of the 1 8 ply servo plate Once satisfied with the fit trace an outline of two 1 x3 8 x3 4 basswood blocks as shown below The blocks should protrude slightly into the cavity These blocks will anchor the servo plate screws Use a dremel tool to remove the foam within the drawn boundary of the blocks so that the top ...

Page 11: ...addle This is one of three locations where you can choose to place your battery to obtain proper CG see page 184 It is easier to enlarge the battery cavity if needed now rather than after the fuse is glued together To use the supplied glue you will need a caulk gun like this They are available at hardware stores for just a few dollars In preparation for gluing the fuse halves together we recommend...

Page 12: ... if you need more elsewhere on the fuse centerline To seal the end of the adhesive dispenser when not in use you can use some non hardening clay found at craft stores and push a good size ball of it over the tip or cover the tip with plastic wrap and tape 11 Insert the two air tanks into the left half of the fuse airline end first so the air lines exit out the left side Now position the right side...

Page 13: ...to accomplish this task and it should only take a few minutes 12 Assemble the ply tail assembly pieces together using CA being careful to keep the assembly square You can temporarily place the assembly on the fuse to check its alignment Once the assembly is glued together place 30 minute epoxy on the fuse surfaces that will mate with the tail assembly Use masking tape to securely position the asse...

Page 14: ...e within the hole These short sleeves can extend a bit toward the fuse centerline 3 Using a work surface that is flat and level level the fuse from forward to back and from left to right using the cockpit area as your level reference If you opened up the cockpits use a plank of wood to span the cockpits If you left the cockpit s false floor you can use that surface Place wood blocks under the rear...

Page 15: ...rial under the spar than over the spar The ply cap gets glued to the stab after the gluing process described in Step 10 6 A small tip of the stab s LE near the root will need to be removed to fit inside the tail assembly 7 Install the stabs and use the ply templates to support them The inner support should be placed near the root and the outer support is placed about mid span Add spacers under the...

Page 16: ...ther so their trailing edges remain aligned If after your adjustments there is a gap between the stab cap and the tail assembly this can be filled with balsa later You can temporarily insert a wedge screw driver shown on the next page in the gap to maintain the adjustment during gluing Now that you know your adjustments if any you can properly align the stabs You should make some final checks befo...

Page 17: ...lock Don t worry about cleaning up every last bit of glue that runs out of the channels as you can remove it later If after the expanding glue cures there are any areas that need more glue you can add some epoxy to those areas 11 With the stabs still in position use a dremel tool or sanding block to remove any excess glue that is above the channels Later you will add some filler so don t worry abo...

Page 18: ...p and the tail assembly Glue the balsa blocks in place you can trim these pieces later 15 Remove the stabs from the tail assembly Sand the spar at the drill hole locations so that the spar can pass through the tail assembly easily You can now add some CA to the bottom stab cap joint 16 Remove the tape from the bottom of the stab Draw a one inch square around the drilled hole locations on the botto...

Page 19: ...art Point Hinges you will be doing this task for all other hinge locations too Start by marking the hinge locations on the stab s TE The scale placement of the hinges are at approximately 4 7 5 and 14 from the root Next center a one inch square balsa block at the hinge location on the stab s upper surface then trace its outline on the stab Use an X acto knife to cut out the foam Using CA glue the ...

Page 20: ...too critical After the next step you can test the fit of the molded tips over the foam and further sand the foam for its best fit With that said it is better to leave the tips more blunt now than too tapered It is usually fine if there is a little air space between the foam and plastic but you should strive for the foam to fill the molded piece 19 Cut the outer edge of the elevator s counter balan...

Page 21: ... epoxy within 2 from the root you will be adding a ply doubler there later Add epoxy to the sub LE and then place the elevator over the sub LE as shown in the picture below and let it cure this way You can add a piece of tape to hold down the root end but don t apply tape to the rest of the elevator like you did over the stab s TE as this could easily warp the elevator Just make sure the elevator ...

Page 22: ... to extend the diagonal line of the CBT onto the elevator and place a mark on the elevator s sub LE Position the balsa LE with its end located 2 in from the elevators root Mark a line on the LE at the mark you made near the tip and then cut the LE at this line 5 Glue on the balsa LE to the ply sub LE ...

Page 23: ... behind the stab and draw a line representing the hinge line locations Remove the balsa LE on both sides of this hinge line Make sure you do not cut into the ply sub LE Extend the hinge line onto the sub LE Carefully drill a 3 16 hinge hole at the center of the sub LE at the hinge line A Robart Hinge Point Drill Jig is helpful for this task You want to drill just though the balsa block slightly in...

Page 24: ...serted align the hinge so it points 90 degrees from the LE centerline This ensures the hinges are properly aligned 8 Once the elevator s hinges have cured align the elevator against the stab and mark where the hinge holes need to be along the stab s TE centerline Drill 3 16 hinge holes at your marks Do not glue in the hinges into the stab yet you will wait until after the parts are skinned for tha...

Page 25: ...t the LE of the CBT follows the stab tip outline curvature In the picture above you can see that the CBT is a little behind the stabs tip In this case you should add an additional balsa spacer between the CBT and the elevator to get the CBT s LE aligned with the stab s tip Use CA to secure the CBT to the elevator making sure that it is properly positioned relative to the stab Once the CBT is cured...

Page 26: ...es These pieces are the elevator control arm sleeves 13 On only the right elevator mark the centerline of the exposed sub LE near the root Then draw two reference lines 1 8 from the centerline Do nothing to the left elevator until step 17 14 Apply CA along the centerline and center the tube between the reference lines with its two holes position toward the tip end as shown Drill a 3 32 hole center...

Page 27: ...derneath both elevators TE so that they are both on the same horizontal plane as shown below Place weights on the elevators to keep them against the object wood block shown above Note where the left control arm sleeve will contact the left elevator and apply CA between the sleeve and the elevator then press the sleeve against the elevator while making sure both elevators are still on the same plan...

Page 28: ...rs You can find light weight spackle in most hardware stores only a small amount is needed during the assembly Also fill the area over the ply plate on the bottom of the stab but leave an area around the hole free from filler for the bolt Skinning the Elevator 1 Trim the top and bottom elevator skins The bottoms have a bulge near the root s TE Cut the LE of the skins so it includes the LE radius A...

Page 29: ...tail minded builders these hinge cut outs can be made to look more realistic or scale by an optional step adding an overlapping panel which we will explain later on page 34 So for now make the opening in the skin just big enough that the hinge can move freely The cut outs in the photo above are larger than scale see full scale photo below 7 Sand lightly the underneath surface of the top and bottom...

Page 30: ...mine the size of the trim tab See page 64 for an illustration of this technique 8 With the bottom skin positioned over the elevator note and then mark the area on the elevator where the TE bulge occurs In this area you will not be applying any adhesive Now get your paper towels ready You will be gluing first the bottom then the top skin 9 Apply adhesive to the bottom of the elevator in a pattern s...

Page 31: ...eded the tip may require this The LE of the skin at the tip can be glued to the elevator with CA to help this area lay flat 11 To help retain the elevator in position its TE against the crease during the next step apply masking tape to the elevator s top surface TE extending onto the TE of the skin 12 Use CA to glue down the skin s LE radius to the balsa LE Hold the skin down while the CA cures gl...

Page 32: ...r to do this now compared to after it has cured 16 For this step gather some hardwood sticks or similar and several clamps Apply slow cure CA to the mating area of the top and bottom skins TE and tip A long applicator tip is helpful for this task Immediately clamp the TE around its tip and with the sticks along its TE While it cures try not to introduce any flex at the TE Repeat the skinning proce...

Page 33: ... have this detail To recreate this look use some scrap polycarbonate 010 thick and cut out panels in a shape to match the full scale panels Refer to the CD photos for reference These panels are on the top and bottom surfaces of the elevator Next position the panel in place on the elevator In the next photo the rivets are highlighted for reference Trace the panel s outline on the elevator then ligh...

Page 34: ...n at the tip that the CBT skin overlaps as the CBT will need to get glued to it later The edge of the CBT that parallels the stab s tip should be trimmed with a slight overhang you will be adding a cap to the CBT later and then trimming this edge flush with the cap 2 After trimming reposition the CBT skin on the elevator and outline its edges on the elevator s top and bottom skins Sand the elevato...

Page 35: ...p and bottom then apply a clamp to the edge Your fingers can apply more force at the clamp if needed to get the CBT skin to pinch tightly against the elevator s tip 4 Apply CA to the CBT s TE that overlaps the elevator s skin Again make sure you do not apply too much CA near the edges 5 Lastly the CBT will be glued to the elevator s foam CBT at the inside edges 6 To cap the CBT trace its outline o...

Page 36: ...with the cap 7 Perform the same capping procedure on the root end of the elevator Cut out the area of the cap over the control arm sleeve Trim any overhang of the elevator skins flush with the cap Skinning the Stab 1 Sand the dried light weight spackle to fair into the stab top and bottom 2 Test fit the stab tip skin over the end of the stab You can rough trim the aft end of the tip skin as shown ...

Page 37: ...ve while you re cutting as the plastic is a slippery surface 4 Once the two top skins are separated you can use scissors to trim back the skins LE To do this first lay the skin on its corresponding stab Position it with the last row of rivets on the stab s wood TE To help position the skins you can highlight the last row of rivets we use a sharpie to dot some of the rivets Draw a line on the skin ...

Page 38: ...op stab surface in the pattern shown below 9 Spread adhesive to an even level with a putty knife The next photo shows that after spreading some excess adhesive can be scraped off you can use this excess when you do the bottom side 10 Position the top skin on the stab with its last row of rivets on the wood TE Begin to rub down the skin thus removing the trapped air underneath 11 After you rub the ...

Page 39: ... skin of the stabs and let the adhesive cure for 24 hours Since the stab s bottom skins are a little shorter than the top skins it may be necessary to position the bottom skin such that the rivet column close to the tip will get covered up by the stab s tip skin The fact that some rivet detail is covered up by other skins is something that can occur on some of the model s skins These details if de...

Page 40: ...te with the LE skin Sand the entire inside of the LE skin 18 Optional apply a small bead of adhesive to the LE of the stab Carefully place the LE skin over the bead and press it down close to the stab Adding the adhesive as noted above and shown below increases the resilience of the LE however it is not critical for adhering the LE skin as the CA at its edges is more than adequate therefore this i...

Page 41: ... TE to accommodate the elevator Check the gap between the stab tip and the elevator s CBT make adjustments to the stab tip skin as needed to achieve a uniform gap and free movement of the elevator Once satisfied with the position of the tip skin apply CA to just the tip of the stab as shown Where the tip skin overlaps the other skins use an applicator tip to work CA under the tip skin Again make s...

Page 42: ...to the foam parts Cut the foam parts along this line 2 Draw a centerline on the tip edge of the foam parts Sand a slight radius to the centerline the TE of the rudder does not need a radius The line on the side of the fin below denotes roughly where the taper begins about from the top To test your sanded edge cover the foam parts with the rudder tip skin as shown to determine if more sanding is ne...

Page 43: ...this mark make a mark 1 3 16 above it perpendicular to the root edge Lastly make a mark on the rudder s TE 2 7 8 from the root measure along the TE Now connect the marks as shown This is the bottom edge of the rudder Cut the rudder along this line 5 You will now be adding the balsa hinge support blocks as you did with the stab elevator The hinge location are roughly 4 and 6 measured from the from ...

Page 44: ...der perpendicular from its LE and trim the rudder along this line 7 Make a mark in the rudder where the CBT s lower edge will join it shown here on the balsa block Next transfer the upper cut edge of the middle strip onto the thick balsa LE 8 With the trimmed upper edge of the balsa LE positioned against the mark made near the top of the rudder mark where the bottom edge of the balsa LE will be tr...

Page 45: ...es connecting the edges of the radii will help you to shape the LE Sand the LE to shape 11 Epoxy the LE to the rudder aligning their centerlines 12 Trace the rudder s bottom edge onto scrap 1 8 ply Draw additional parallel lines 1 16 inside those lines except at the LE radius Cut the ply along these inside lines and along the LE radius This ply plate will add rigidity to the rudder s control arm b...

Page 46: ...les through the hardwood block and through the ply plate as shown Apply thin CA into each of the holes then insert a round toothpick deep enough to pass through the ply plate Cut off the toothpicks flush with the rudder s bottom 16 Cut off 1 from the LE of the portion of the rudder you trimmed previously and use CA to attach this portion to the rudder as shown Draw a line even with the bottom of t...

Page 47: ...hin these boxes so that the fin can be positioned while these spars are inserted into the tail assembly Test the fin s fit again making sure it makes contact with the bottom of the tail assembly Also note that the fin s LE should be offset slightly to the left as shown 19 Glue a block of balsa measuring wide by 1 tall by 1 7 8 long into the back of the tail assembly as shown Skinning the Fin The f...

Page 48: ...cut the excess material where it begins to deviate from the contour of the fin 3 To help position the skin on the fin draw the following reference lines on the fin 1 a line forward of the fin s TE 2 a line perpendicular to the TE where the CBT cut begins 3 a line 5 8 below the line you just made and 4 Insert the fin into the tail assembly and mark a line where the fin meets the fuse and tail assem...

Page 49: ...e pattern shown and then spread evenly Compared to the previous skin applications the fin benefits from slightly more adhesive around the corrugations to help hold down the skins Try not to get adhesive in the fin spar slot 8 Wipe the air from underneath the corrugation areas towards the TE Afterwards ensure the skin is properly positioned and then tape its edges 9 Apply the fin s other skin in a ...

Page 50: ...rea is covered later by the dorsal fin Once the LE is cured if applicable you can apply CA to the edges as you did with the stab 13 Place the fin tip skin in position to test its fit Trim the LE or side skins as needed to get the tip skin to sit flush against the top of the fin Tape the tip skin down and draw a trim line perpendicular to the side skins TE at the point where the tip and the side sk...

Page 51: ...t the edge congratulations you just made a scale effect without trying See the full scale fin tip in the photo below You will glue the fin to the fuse after the fuse TE and tail cone are mounted Fuselage TE 1 Cut the fuselage TE piece on the right side of the photo as shown Use CA to glue the two halves of the fuse TE together 2 Tape the fuse TE against the fin post aligning its sides and bottom w...

Page 52: ...atter is available at most hobby shops What ever rods you choose make the rudder push rod 36 1 2 long and the elevator push rod 37 long clevis pin to clevis pin These lengths should still allow a 4 40 clevis at each end to be threaded in or out to make fine adjustments 6 To make some of the needed cavities to the inside of the fuse TE you will need to use the rudder torque rod Do not worry about b...

Page 53: ...e bracket onto the elevator control arm bolt 9 First install the left stabilizer with elevator temporarily attached then insert the control arm into the left elevator and then install the right stab elevator Remember the short end of the control arm gets inserted into the right elevator Even though the elevator hinges are not yet glued in you will still be able to test the push rod function and id...

Page 54: ...2 hole in the center of each ply plate With the tip of a pencil mark the holes location onto the floor of the cavities 13 Using a sharpened 9 32 brass tube drill a tunnel through the fuse TE at the hole locations You could also burn the tunnel with a hot piece of music wire or poke a long tipped soldering iron through the fuse TE to do this task 14 Screw 4 button head screws into the ply plates wi...

Page 55: ...ruler transfer the location of the straps onto the fuse TE and remove foam from those locations yours may be located differently from that shown below Test fit the fuse TE Ensure that it can mount flush against the fin post and does not impede the operation of the linkages When removing the fuse TE only back out the screws enough to separate it from the fin post this will leave the screw in place ...

Page 56: ...l as the entire curved top Note how the skin is positioned to achieve full coverage You will trim the excess length after some sections are glued 20 To glue the skin first apply CA to one of the vertical sides position the skin against it and hold until cured Next place the smaller spacer piece at the aft edge of the top curve DO NOT glue Apply CA to the forward area of the top curve and drape the...

Page 57: ...k a line at a consistent height The height is adjustable and the block accommodates a pen 2 Trim the tail cone along these lines Some finish trimming and sanding will be done later so the cut lines need not be perfect Trim off the ends at the scribe lines again the cuts need not be perfect 3 To make some initial cuts to the tail cone first tape the two halves together matching the centerlines as c...

Page 58: ...p skin of the TE at this time Push the tail cone over the TE as far as it will go Look at the tail cone from the side and make sure its bottom edge is resting against the top of the aft bottom skin also make sure the aft bottom skin is firmly held against the fuse bottom Check that the tail cone s centerline is roughly in line with the fuse centerline Mark a line all the way around the tail cone f...

Page 59: ... observe that the centerlines are flat and make contact with each other evenly 11 To join the two halves you will use a piece of scrap polycarbonate Using a flat portion of the excess material you trimmed from the tail cone flashing will work fine Make two joiner strips about wide by the length of the tail cone Remove the film from it and rough up one side with sandpaper 12 Use CA to attach one ha...

Page 60: ...curvature 16 Clamp the ends and apply CA to the strip Using a small applicator tip helps If you do a small part at a time the aligning process will be a bit easier Remove the clamps and apply CA there 17 The full scale tail cone has a notched TE so to replicate this draw and trim the notch as shown The top of the notch is roughly 5 7 8 from the tail cone s top forward edge 18 The tail cone will at...

Page 61: ...ar and 1 8 anti rotation rod for this next step To test fit the fin now with skins into the tail assembly carefully guide the fin down the fin post keeping it between the fin skins aft edge overlaps As it approaches the bottom you will probably notice some of the side skins will need to be trimmed to clear the tail assembly pieces Areas at the lower aft corners and around the fin spar will likely ...

Page 62: ...s TE crease 4 Tape a rudder skin to the rudder in the location that seems appropriate and note the location of key corrugations as a reference For example in the photo below the second to the bottom corrugation is located directly above the rudder s ply plate When aligning the rudder skin make sure the rudder s TE is aligned with the skin s TE crease 5 With the skin s placement references noted re...

Page 63: ...e strips in place setting them back slightly from the slot edges Cut out a piece of scrap 010 polycarbonate wide enough to span across the strips and long enough to cover the entire slot Remember to remove the film from the strip Apply CA to the tops of the styrene strips and place the polycarbonate strip on top 8 Position the skin over the rudder and outline where the slot plastic contacts the fo...

Page 64: ... apply a bead of CA along the crease where the foam touches it This will help hold the skin in position 12 Apply adhesive align and rub down the other rudder skin When finished apply a bead of CA between the left and right skins TE Use clamps until cured 13 Position the rudder onto its foam saddle You can use the foam middle strip piece to fill the forward area of the saddle or use something else ...

Page 65: ...wn a spacer about 040 over the stab root Glue balsa blocks to the outside of the ply side wall with their bottom against the spacer do not glue balsa to the spacer this will allow the stab to be installed without interference from the balsa 3 Remove the stab and sand the blocks so that they extend the fuselage curvature at the fin spar bulkhead back to the fin post at which point the curvature is ...

Page 66: ... cut back to its TE Also trim the excess skin at the tip even with the foam You will be making more trim cuts later as you position the rudder s CBT skin 3 Note where the balsa blocks are located behind the rounded LE and drill your 3 16 hinge holes into the rudder s LE 4 Using a file notch the LE around the hinge holes to a depth of about 3 16 5 Temporarily insert hinges into the rudder and tape ...

Page 67: ...in post s rudder push rod cut out and then mark on the rod where the bend that enters the rudder needs to be 8 Cut the rod s outer sleeve just short of the mark Important install the sleeve onto the rod before you bend it 9 Make a 90 degree bend so that the rod looks like this Once the bend is made cut the end that will get inserted into the rudder to a length of about 1 long 10 Make a small chann...

Page 68: ...2 Rough trim the rudder s LE skin as shown below and remove the side skins film 13 Tape the LE skin so that it is firmly against the balsa LE The top of the LE should be slightly above the top of the balsa LE and should be plenty of excess at the bottom 14 As seen in the full size rudder picture the LE skin terminates just in front of the corrugations Draw a line denoting this edge Also note where...

Page 69: ...edge to press the edges down 18 Using a dremel with a small router bit remove the LE material that covers the hinge holes Make sure you provide enough movement for the hinges You can also look to the full size rudder for how these cutouts look Also remove material over the torque rod hole and channel 19 Install the rudder torque rod and its brackets onto the fin post Temporarily fit the rudder wit...

Page 70: ... skin There is a small angle at its TE see Page 63 Next draw a line parallel to the fin tip skin s angle about 1 16 from it Draw these finish trim lines on each side then remove the skin and trim it 23 Hold the trimmed skin in place and trace its lower edge onto the rudder Remove the film from the under side of the skin if any and use sand paper to rough up the inside Do the same for the area of t...

Page 71: ... into the skin Reinstall the rudder and check the CBT clearance with the fin by moving the rudder back and forth Trim sand as needed Fitting the Cowl to the Fuse 1 First you will trim the aft edge of the cowl It is helpful to mark the cut line with a pen before starting to cut just follow the molded aft line Also ensure that the nose gear doors are outlined per the diagram below The cowl has some ...

Page 72: ...engine from the back of its mount if any to its propeller washer This manual will document the installation of the Revolution 50 gas engine so your engine specifications may differ The Revolution 50 engine is 8 3 8 from the back of its mount to the prop washer The fuselage s firewall location is cut specifically to accommodate this rather long engine dimension Shorter engines mounts will require s...

Page 73: ...nd up right but do not set the fuse on its fin this could cause damage One way to accomplish this task is to set the wing saddle s LE on a shelf that is high enough to keep the fin about a foot off the floor If you don t have such a shelf you can make one by screwing a short 2 x4 stud horizontally to a door or to a wall at the appropriate height If desired you could later use this 2x4 shelf to ser...

Page 74: ...ore durable model When impact forces act on the cowl the magnets will let go whereas a more traditional screw fastener will rip out and or cause the cowl to rip at the screw hole Using magnets will reduce your repair work after a crash we know this from experience 1 Mark the panel lines on the cowl that separate the top from the bottom half Apply several layers of masking tape to protect the cowl ...

Page 75: ...centerline with the fuse centerline and the aft edge on the line you drew around the fuse Tape the cowls together Work a pencil between the halves and draw a line denoting the cowl mate line then remove the cowls 3 Mark three circles on the fuse as shown this is where you will locate magnets to hold down the top cowl 4 Use a dremel tool to route a depression for the magnet The depression needs to ...

Page 76: ...racted to each other Apply a piece wax paper over the fuse magnets and then place a magnet sanded side facing up over each fuse magnet this ensures you will get the polarity right You will be applying CA over these magnets and then positioning the upper cowl 9 Turn the fuse on its side magnets facing up and apply a generous amount of thick CA on the exposed magnets sides and on top of them 10 Plac...

Page 77: ...ote that the magnets are located off from center Using a forstner bit the diameter of the magnet will make a nice flat bottom recess Make sure the magnets have the correct polarity to join together then CA in the magnets Make two pairs as these will be attached to each side of the front cowl 17 Make a template of the cowls curvature near the front centered at the break line Using a contour gauge m...

Page 78: ...wl Mark and sand the blocks to fit the inside curvature of the rear edge of the front cowl Note that each side has a different contour When making the right side magnet pair locate the magnet in the block close to the cowl about 1 16 this is so that the block can later be sanded to clear a muffler if needed without affecting the magnet 22 Using CA glue on the top block to the inside of the top cow...

Page 79: ...ed piano hinges to the length of the doors Rough up the flange of each hinge where it will contact the door and drill the existing holes larger to 3 32 The larger holes on the inside flange will except 1 screws and the holes on the outer flange will allow for a more secure glue bond to the inside of the door 26 Attach the doors lower edges to the fuse magnets and position the hinges in place Firml...

Page 80: ...st the hinge and its flange until the CA cures Run an X acto blade between the door and the hinge to cut and remove the masking tape Repeat Step 27 for the other side 29 Once both doors are glued to the hinge flange you can apply a set of magnets to the inside of the doors to hold them together when opened fully The strip between the doors over the flanges can be made from 020 polycarbonate or G 1...

Page 81: ... route a channel the depth of the tube you will use Make the channel deeper near the wing saddle so the tube is below the saddle Later you will route a cavity for the receiver in this area of the saddle 3 Install the tube into the channel no glue is needed if it is a tight fit You can add some foam to the channel near the saddle to help retain the tube and reinforce this area 4 Next you will be ad...

Page 82: ...nug it is in the proper place Mark then cut the skin s LE at the wing saddle This edge will get overlapped by the belly pan skin Draw lines on the fuse marking the trimmed skin s outline this helps in locating where to spread the adhesive 8 Remove the skin s protective film from its mating surface Apply adhesive as shown then spread evenly out to the fuse corners Once you apply the skin and rub it...

Page 83: ...1 16 in from the edge of the rivets 5 Rough cut the left side skin so that you maximize the useable material at the top rear and front Leave the area that extends over the wing saddle as it is easier to trim it after it is glued and cured There is a row of rivets near the bottom aft of the wing saddle area trim that area 1 8 below the rivets This edge will overlap onto the bottom skin s sides so m...

Page 84: ... have its leading edge trimmed back to make room for the hinge Use the photos below to help guide your cuts Below is a photo of a full size baggage door for reference 9 Reposition the skin on the fuse make sure to use the molded hatch references and slip the hinge flange under the side skin Place the door skin inside its opening while aligning its edges and the hinge Mark on the balsa frame the lo...

Page 85: ...a realistic joint just follow the next few steps 14 Notice that the cowl might fit snuggly against the fuse in one area and lift slightly in another as shown above You will be modifying the height of the side skin to meet the cowl To do this first slide a scrap piece of 010 polycarbonate about 3 4 wide under the cowls It should be long enough to extend from the top fuse center line to a few inches...

Page 86: ...irly thick 030 belly pan adjacent to the bottom cowl 16 Peel back the film from the underside of the side skin s LE Rough up the underside of the LE about 3 4 with sandpaper 17 Position the side skin on the fuse making sure to properly align it Tape its edges so it does not move Make sure the LE is properly aligned with the edges of the cowls Lift up the LE so you can apply CA to the spacers then ...

Page 87: ...ly adhesive there Do apply some adhesive near the door s hinge flange as this will help the skin lay flat over that area Apply some adhesive to the underside of the side skin as shown below so that you can work some adhesive into the gaps between the spacer steps Additionally apply some adhesive to the underside of the side skin where the molded hatch details are since these are raised details the...

Page 88: ... like the T 34C 22 Use an applicator tip to apply CA under the skin onto the balsa door frame and hold down the skin until cured Also apply CA to the bottom rear of the side skin were it overlaps the bottom skin 23 Once cured you can trim the skin at the wing saddle but first draw a line aft of the saddle s LE you want the skin to overhang so that when you install the ply plate it will have a skin...

Page 89: ...masking tape over the door hinge to prevent CA from seeping into the hinge Placing a scrap piece of foam in the opening will allow you to press the hinge fully against the balsa support when gluing 27 Apply a bead of CA to the support where the outer edge of the flange will be Then position the support in place and hold until cured 28 Once hinged you may need to further sand the door for it to fol...

Page 90: ...ins first This is because the LE of the aft side skins need to align with the LE of the turtle deck skin To start you first need to rough trim the fuse top skin This is the large skin that covers the top of the fuse from the cowl to the turtle deck area Rough trim the top skin by maximizing the useable area Again what that means is to trim at the mold bend where the fuse contours begin Laying the ...

Page 91: ...p skin You will have to trim the turtle deck skin a bit more around the fin for it to be positioned correctly Tape in place 6 The turtle deck skin needs to be trimmed over the stabilizer area Installing the stabs will help you draw cut lines at the stabs top surfaces and LE You want the skins to be close to the stab but not interfere will the installation of the stab You could leave these edges a ...

Page 92: ...e fuse TE will be secured with a screw Spread adhesive evenly do not apply adhesive to the adjacent skins 10 Position the aft side skin in place aligning it with the tick marks Rub down and let cure Apply CA along the LE and bottom edges Right Side Skin and Aft Skin The procedure for the right side skin is the same as you did on the left However some of the positioning references are different In ...

Page 93: ...re gauge There is a pdf file on the CD named pressure gauge Print it on glossy paper The photo below is what you will be replicating 3 Position the side skin on the fuse aligning it with the references Tape it in place Draw a circle on the fuse the same diameter as the ring of rivets the circle template shown below is under the skin The shown circle represents a window diameter this will be the si...

Page 94: ...e molded hatches as you did on the left side Apply adhesive to the right side of the fuse as shown below Keep the adhesive away from the pressure gauge recess Spread evenly then apply the skin and rub down Use CA to glue down the edges if needed Right Aft Side Skin 1 At this time before the right side skin has cured you can temporarily place the top skin and turtle deck in place to determine the r...

Page 95: ... s side edges along the cockpits extend slightly beyond the fuse These side areas do not need adhesive since the top edge next to the cockpit openings will be glued and later you will CA the side s lower edge It is OK to leave an air pocket under this part of the top skin The area behind the cowl will need a good amount of adhesive to fill the gaps Note in the photo below that no glue was added un...

Page 96: ...nate any waves in the edge Use CA accelerator to speed the cure time if desired Turtle Deck Skin 1 Position the turtle deck skin in place and tape it down Temporarily install the stabilizers To trim the lower edge of the turtle deck you first need to finish trim the molded strakes that extend forward from the stabilizers 2 Draw cut lines as shown in the photo above you want to leave a small flat e...

Page 97: ...ith its TE centered on the LE of the stabilizer Draw a line on the turtle deck skin denoting the top edge of the strakes Finish trim the turtle deck s lower edges at least below the marked line make sure the lower edge does not project beyond the lower edge of the strakes 6 Peal up the last few inches of the top skin s film Rough up the top and turtle deck skins with sand paper where they will con...

Page 98: ...fuse 2 Rough up the skins with sand paper where they mate with each other and where the ventral fins will attach to the fuse curved upper surface Outlining the creased edge of the fin depression on the aft bottom and ventral fins will help you align the skins prior to gluing The reason you have yet to trim the aft bottom skin is that it is semi rigid as one piece and will help keep the ventral fin...

Page 99: ...ether 5 Once cured flip the fuse over and draw a finish trim line along the ventral fins upper edge Make sure there is sufficient material to attach to the fuse 6 Remove the aft bottom skin from the fuse Mark finish trim lines on the rest of the ventral fin about 1 8 away from the crease 7 Mark a finish trim line along the LE of the aft bottom skin Below this line is set back from the LE of the ve...

Page 100: ...ough up part of the fuse that you shouldn t you can apply masking tape adjacent to the marked line or just use a Scotch Brite pad to rough up the area all skins get buffed in this manner prior to painting 2 To ensure your stabilizers can be easily removed you will need to remove a portion of the stabilizers LE at the root Hold the strake in position and note where it contacts the stabilizer s LE F...

Page 101: ...ou can apply CA accelerator if desired After this first application of CA is done you can apply CA in longer sections 6 or so and then repeat the edge pressure technique 5 Once the top edge is completed flip the fuse over so glue does not seep down the fuse sides and repeat the process on the strake s lower edge When gluing down the aft few inches make a final check that the strake is centered on ...

Page 102: ...e TE of the fin skins Trimming the cockpits 1 Draw trim lines around the openings of each cockpit You want have some of the top skin over hang the sides of the cockpits about 1 8 2 Using a cut off wheel to rough trim the top skin near the cut lines will make finish trimming along the cut lines with scissors easier Cowl Details Louvers 1 Draw alignment lines on the louvers by using a straight edge ...

Page 103: ...ou will trace the outer edge of the louvers over the cowl s clam shell doors so remove them from the fuse Use the molded recess on the cowl as a positioning guide only In the picture below the molded recess the inner rectangle is drawn for reference See photos of the full size to determine final placement Draw a bottom edge on the cowl parallel to the bottom of the door and then trace the louver s...

Page 104: ...e inside of the stack works well Alternatively you can get a metal exhaust stack at a hardware store look for a 1 5 dia wall tube in the plumbing section You can also purchase an optional pre cut metal exhaust stack from us for 12 each There are a few critical alignments to make before you bolt it on To give you an idea of what you re re creating here is a picture of the full size stack from the b...

Page 105: ...t side goes up ever so slightly Here is a full size perspective 2 Sand the inside portion of the stacks where the ribs will be located as shown then CA the radius side of the ribs against the stack 3 Begin to test your alignments Final adjustments will require slight sanding of the ribs where they contact the cowl One adjustment includes sanding the ribs at a slight angle so they mate flush agains...

Page 106: ...inate two 1 8 ply pieces to make the mounting plates 2 x 3 4 Trace the hole locations and then drill two 9 64 holes in the ply Sand one surface of the ply as shown so it can mate flush with the inside of the cowl 7 Push two 6 32 bolts 1 long through the holes and secure with nuts Evaluate your results and make adjustments as needed If you find that there are gaps between the ribs and the cowl afte...

Page 107: ...sells a hex head wrench that is handy to secure these small bolts Part No WR0 Canopy 1 Your canopy has a pre drawn trim line Trim the canopy along this line Sand the edges as necessary so that the canopy sits flush against the fuse The front windscreen portion of the canopy rests against the front part of the raised dash area of the top skin With the canopy s lower edges against the fuse the aft e...

Page 108: ...hat line and then begin to bend the tape forward above the 1 mark as you approach the top Follow that strip with one 3 8 wide placed slightly in front of it as shown above Below is the look that you are replicating The windscreen s bent frame angle is often missed by Mentor models and 3 views 5 Draw the outline of the frame areas around where the two left side canopy handles go draw the radii at a...

Page 109: ... at the middle section only Draw vertical lines from the bottom edge to the line you just drew at the LE of the rear canopy s frame and at the front canopy s crease line Cut away the area that is hatched in the photo above 10 Hold the recess piece against the canopy with its dashed line aft edges of recess aligned with the LE of the rear canopy frame Trace the shape of the radii the aft end of the...

Page 110: ...is later covered by the glare shield so it will not be seen Make three hardwood blocks with slightly angled front sides so they can be epoxied to the fuse and top skin inside of the raised area Use a screw driver to place the epoxy against the front of the raised area and on the foam then position the blocks inside with needle nose pliers Since the front windscreen s bottom edge gradually moves aw...

Page 111: ...so that the ply sits flush with the skin CA the ply in place 5 Attach the canopy at the front and tape down the rear edge firmly against the fuse then drill a hole for the screw in the center of the block 6 Next you will add blocks for four more screws to secure the middle of the canopy First trace the edge of the canopy as shown below Note the masking tape applied to the fuse top skin The above p...

Page 112: ...stall 1 screws After these four screws are installed your canopy should be very secure on the fuse 10 With the canopy on trace the edge of the windscreen back to the front canopy frame and trace the middle canopy section back to the front frame of the rear canopy These reference lines will help you center the glare shields Remove the canopy The glare shields have a crease line molded near the bott...

Page 113: ...llows for the protruding air line of the larger top air tank only to make a bend without being pinched 1 Arrange your switch es and fill valve s on the plate and secure them You will need to remove some foam where the switches and fill valves are located in order to have the plate sit far enough into the opening To route your switch wiring sharpen a brass tube and turn a tunnel from the baggage do...

Page 114: ...structed the sleeve will get permanently glued into the wing The sleeve is constructed around the 3 8 ply spar to ensure a perfect fit Gather the components of the sleeve and the spar and some clamps 1 Draw a line on the 3 8 thick spar at its midline both sides On one side of the spar tape a top and a bottom basswood stick as shown below You can extend the root end of the basswood slightly as you ...

Page 115: ...f the sleeves Cut off the excess top and bottom caps at the tip end The top and bottom of the sleeves should be sanded to remove any excess glue Base on which side of the spar the sleeve was made mark the spar and sleeve as either left or right front or back Wing Ribs Two ply ribs will be installed at the wing panel breaks These will stiffen the wing and support the retract rails Ply doublers will...

Page 116: ...b where the retract rail rests 4 Assemble the top half inner and outer wing saddles by taping them together Place the wing top side down onto the saddle and again test fit the ribs between the wing s inner middle and outer panels Temporarily insert the spar sleeve to register the ribs You will note that the ribs may extend aft of the wing Mark a line where the TE of the wing is on the rib and cut ...

Page 117: ... This provides three hinge locations for the flap and three for the aileron For the flaps we will illustrate the use of Robart point hinges and hinge pockets hinged below the flap This arrangement will provide a fowler flap like movement similar to the full size T 34C the flap moves aft as it is lowered There are fowler flap hinges on the market and these could be used as well with some considerat...

Page 118: ...0 minute epoxy to the balsa TE and set it against the wing s TE Apply weights to the wing and then use weights to apply pressure against the balsa TE You can use clamps too but only apply a slight pressure Make sure the balsa TE is down against the saddle at the root and tip ends There is a portion of the wing near the middle that the TE will not met the saddle that is OK 6 Once cured remove the w...

Page 119: ...nding polyurethane glue Gorilla Glue for example to glue the sleeve to the wing This will allow the glue to fill any small gaps in the spar slot It can be hard to predict the amount of glue expansion so it makes sense to keep the glue away from the centerline you can insert glue there after the initial cure We put a little tape along the spar sleeve joint to make sure no glue seeps in You will be ...

Page 120: ...ill holes for the wing hold down bolts and the plate will help to distribute the pressure across the wing Remove the wing hold down plate 7 To stiffen the wing further around the wing hold down plate mix some 30 minute epoxy and brush it into the cavity at those areas that the square sections of fiberglass will cover As shown below note that the fiberglass pieces do not extend all the way to the c...

Page 121: ... the two wood pieces 11 Use a 8 x screw to attach the plate Marking the orientation of the plate can help the installation Wing to Fuse Joint 1 Find the 1 long 1 square balsa blocks and mark their center then use a Forstner bit to drill a 3 8 hole about 1 into the block We recommend you use a drill press to ensure a straight hole 2 Position the blocks onto the wing s 1 8 ply LE as shown below and ...

Page 122: ...e wing s LE Immediately remove the dowel without shifting the block Do the same for the other side 7 Position the LEs in place on the fuse using the reference marks you made and then butt the wing next to the blocks Mark on the wing where foam will need to be cut away as shown Use a sharp knife to cut out the foam With the wing s LE against the saddle LE test fit the wing and the cut outs around t...

Page 123: ...of the wing s LE needs to be slightly offset from the LE to achieve equal distances from the wing tip to tail you can add some wood to that side between the LEs The wings LE skin applied later will cover the 1 8 ply LE and any wood spacers if any 14 Use a portion of the foam piece that you cut from the wing to fill in the space above and below the balsa block Use epoxy to glue them in Installing W...

Page 124: ...ill need to route or burn the cavities to receive the stanchions A dremel tool will work but we prefer to heat up a brass tube about 1 8 diameter with a butane torch These cavities are 2 3 8 deep at the rear and about 2 1 8 at the front Again marking the tube at the maximum depth makes this easy to achieve Use good ventilation if you burn out the cavities Make the cavities slightly wider than the ...

Page 125: ...at is 1 8 wider on each side and allows for about 1 8 in front and behind the stanchion area Route this area with a dremel tool to a depth of about at the front and about at the back 8 Test fit the wing to ensure your top wing cavities are deep enough to allow the wing to sit flush against the saddle Pass the wing bolts through again and screw them into the blind nuts If the bolts do not thread ea...

Page 126: ... more time Ensuring the bolt alignment is perfect now makes for a much more enjoyable wing mounting experience later Remove the wing while the glue cures Wing Control Surfaces 1 Find the pre cut EPP wing TE for the inboard wing panels and the EPP strip that goes in front of it These will be marked as shown below to help orient the pieces right bottom side has one mark left has two Tape the strip a...

Page 127: ...the belly pan you can simply cut away this portion and later sand this area if needed to get the belly pan to lay flat Flap Mounting 1 Epoxy the short TE piece to the longer TE piece The middle strip is not required 2 To cut the flap from the remainder of the TE place a mark on its LE 19 from the root Tape the TE to the balsa TE of the wing From that mark draw a line aft to the TE parallel to the ...

Page 128: ...re that the flap s top surface is facing up and the balsa s bottom edge is against the table Apply tape to hold it in place add some weights to hold it down and ensure the TE is flush against a straight edge 6 Position the x 1 x 48 balsa against the 1 8 thick balsa you just glued and mark the length of the flap on it then cut to size Similarly to the last step glue the thick balsa to the 1 8 balsa...

Page 129: ...ainst the TE of the wing Position the point hinges so they are perpendicular to the wing s TE and over the flap s balsa blocks Mark on each flap block both sides of the hinge near the LE of the block as shown In a similar fashion as you did with the hinge holes in the wing use the drill guide to make progressive holes into the flap s blocks The holes should begin just behind the flaps 1 8 balsa In...

Page 130: ...rvo to 3 8 x basswood using the hardware that came with your servo Note that you will need to cut a notch in one side to clear the servo wires 12 Position the servo on the ply plate and ensure that it is positioned so the servo arm is perpendicular to the TE of the wing Drill a 1 8 hole through the basswood servo mount and through the ply plate Remove the servo from the wing and enlarge the holes ...

Page 131: ...ned below and in comparison to the other flap servo shown above this orientation can use a standard Y harness to connect the flaps to a single channel on the receiver If the flap servos point in opposite directions then you would need a reverse direction Y harness If you were to use fowler hinges this would be the case as you want the flap horn to be as close to the center of the flap as possible ...

Page 132: ...ks on the aileron mark lines on either side of the push rod and mark where the servo plate should be glued Glue in the servo plate where marked Note The 3 8 gap is not the finished gap between the aileron and flap as the skins will overlap these surfaces Also in the photo below the servo arm is pointing up this is to facilitate the alignment process later you will install the arm pointing towards ...

Page 133: ... skin at the wing s tip edge This dashed line represents a guide for your contouring of the foam to match the skin Next cut the navigation light notches and cut the TE aileron along the solid thin line location Glue the TE piece centered on the wing s balsa TE 1 8 outboard of the thin line denoted on the wing this is so you have a small overlap of the skin Cut the tip end of this fixed TE even wit...

Page 134: ...ts toward the bottom Work the epoxy into the foam well so it penetrates deep into the foam You can optionally insert round tooth picks into the aileron through some of the horn s holes which should be filled with epoxy too Sand these down when cured 11 Make a paper conduit about dia for the aileron servo wire to pass through into the flap servo cavity Glue paper in place then cut some scrap EPP yo...

Page 135: ...ls where the inboard edge of the retract s flange is located It may be necessary for fit and alignment purposes to make shallow relief notches in the rails to accommodate the retract s fasteners these are the existing bolts on the retract s vertical side plates If necessary mark the location of these bolts heads on the rails with the inboard edge of the retract aligned at the lines you made You ma...

Page 136: ... alignment If the retract s side plate fasteners hit the rails and prevent proper alignment then you know that a shallow relief notch is needed Make any needed relief notches before you glue in the rails it s easier that way 4 Once you know that your retracts can be positioned correctly you can use 30 minute epoxy to glue in your rails To help keep the glue from dripping into the wheel well place ...

Page 137: ...g line between the inner outer doors yet 2 Outline the raised areas of the outside doors with a pen as shown below and draw a centerline along the raised ridge In this photo the raised areas are protruding down toward the table these are the right side doors The area below the dashed line will be the inner door and the area above the dashed line is the outer door attached to the strut To draw this...

Page 138: ...the oleo scissors center pin Also the LE of the doors should be aligned near the wheel well opening When you think the doors are properly placed use masking tape to hold down the front and rear pieces in their corresponding positions adjacent to the doors Remove the outside doors and test the movement of the gear leg tire to ensure it has sufficient clearance from the taped down front and rear pie...

Page 139: ... the holes in the hinge s holes only to 1 16 9 Align the outside doors skins still taped together within the area defined by the front and rear plastic pieces that you taped to the wing earlier You can fine tune the gaps between pieces later Note where to drill pilot holes on the surface of the outer door just those shown in the photo below Before drilling placing scrap foam under the hinges not s...

Page 140: ...d of the front piece is over the metal retract flange use a small pair of magnets to secure that end 3 16 dia rare earth magnets work well For the rear piece use three small pieces of 1 8 ply to secure the screws Route a recess for the ply and use CA to secure the ply pieces Position the rear piece with the desired gap from the doors and then drill holes for the mounting screws as shown below 12 N...

Page 141: ...can pivot Trim the bolt beyond the secured nut so it will not extend more than from the back of the plate Secure one screw not longer than not provided through the slot at the upper end of the plate and into the block If you find you need more foam removed route more away 16 Using a suitable control horn we use the small Robart horns attach the cylinder s ball socket onto a ball that is screwed on...

Page 142: ...remove the outside doors from the wing It is helpful to mark which hinge goes where as you should now remove the hardware from the doors If you have not yet done so cut the inside door skins into its inner outer parts With the inside skin for the inner door clamped in place on the outside door mark where the hinges are located on the inside skin Trim away this area of the inside skin Note below ho...

Page 143: ...o about half its normal length Trim away some of the 4 40 rod s threads so that the installed length is about an inch as shown above 24 Modify a 1 2A nylon control horn as shown to receive the 4 40 rod Trim away the remaining small holes 25 You will be temporarily gluing the horn to the inside skin of the outer door while you determine its correct placement To do this first attach the horn to the ...

Page 144: ...ation for skinning the bottom wing you can test how the doors hinged edges might clear the soon to be installed skin To do this position a strip of scrap plastic adjacent to the door s edge at the gap distance you think is appropriate Extend the door and determine if there is any interference If so you can sand back the door s edge moving it further from the hinge line allows for more lift of its ...

Page 145: ...erlap the skin as is shown later for the rear piece Draw cut lines where the skin should be trimmed at the root around the wing mounting plate and front cavity Draw a cut line on the skin s LE about back from the wing s LE Note below how the rear gear piece is removed and the skin cut line will be partially underneath that rear piece an overlapping joint There are two cut lines to draw for the ski...

Page 146: ...the skin s edges This allows you to later insert a spacer underneath the skin to get its height right where you want it This can occur after the adhesive has cured and you can CA the skins to spacers and the spacers to the foam 7 With a paper towel rub the skin in long strokes to remove the trapped air underneath Once the skin is rubbed down check its alignment with the reference marks you made at...

Page 147: ...ng block to remove the foam When finished apply epoxy to the recess and position the ply in place and add weights until cured 4 Rough trim the top wing skin maximizing the useable material To help position the skin on the wing first make the following marks the aft most rivet line near the root and tip and the crease line at the LE break Position the skin at the LE break then its highlighted rivet...

Page 148: ...y ample CA to the piece and position onto the underside of the wing skin Press the piece firmly on a flat surface while the CA cures This will firm up the area and minimize the likelihood of surface waves 7 The top wing skin will require a small extension at its tip end First trim the tip skin near where you rough trimmed it with a straight edge Cut a piece of scrap 010 polycarbonate as long as th...

Page 149: ... a table both sides and then tape the straightedge for the straightest possible cut 3 Peal back the wing s protective film from the LE top and bottom to the molded spar detail Tape the trimmed skin in place making sure it is firmly against the wing some edges might lift up off the wing that s OK Trace the LE s aft edge on the wing skins top and bottom and remove the LE skin Lightly sand the wing s...

Page 150: ...s 2 The fixed foam TE may need some additional foam to better match the tip skin Add scrap foam as needed then cut off with a long sharp blade 3 If you are using navigation lights wire them together and test their operation Secure the lights to the wing tip skin For the strobe light you can use some scrap plastic to make a support for the bulb then use screws to fasten it to the wing tip skin this...

Page 151: ...in s TE jog Do not trim flap skin yet You may want to re cut the wing skin s jog to better match the angle of the flap s tip end finish trim line Tape the top flap skin in place along the flap s TE Draw a line where the skin will be cut later even with the wing skin s jog and mark a line on the flap under the outer most corrugation as a reference Remove the flap with its skin 3 Mark the flap where...

Page 152: ...sition the top skin in place ensuring the TE crease is at the flap s TE the outer most corrugation is over the reference line you drew and the corrugations are over their respective balsa cavities Rub down the skin and then ensure the flap is aligned Flip the flap over and use CA to tack down the foam TE to the underside of the top flap skin Do not get CA onto the flat TE part of the skin this get...

Page 153: ...is again for the area outboard of the horn 11 Trim the bottom flap skin back so that it extends about 1 8 forward of the corrugations Apply CA to the LE of the bottom flap skin and attach it to the balsa LE working over the radius slightly Remove the film from the top and bottom flap skins 12 Rough trim the flap LE skin and position it over the flap s LE so that there is ample material overhanging...

Page 154: ...he flap to the wing You will need to trim the excess skin at the root in order to install the flap Trim a little bit at a time until there is sufficient gap Once the flap is installed into the wing confirm the trim line at the flap s tip even with the jog at the wing s TE then trim 18 Next apply the tip end cap to the flap If desired you can add lightening holes for a scale appearance Holes can be...

Page 155: ... of the wing skin The overlapping panel on the aileron is 010 polycarbonate Note the hinge cut out is enlarged to match the overlapping panel s inside edges 20 With the flap temporarily installed note how the flap is positioned relative to the wing Is there a large gap between the flap and the overhang If so adjust the point hinges within the hinge pockets to get the flap s upper surface close to ...

Page 156: ...u can still tell if there will be interference 23 With the flap hinges secured and the aileron hinges inserted in the wing but not glued to the wing you can trim the TE of these control surfaces Tape the aileron to the wing so that its LE is against the wing s TE or just slightly aft from it Use a long straight edge to draw a cut line The flat portion of the TE should be about 1 8 wide Remove the ...

Page 157: ...nform the lens to the tip skin 3 Reposition the lens after trimming and tape it tightly against the wing tip so that its contour best fits the tip Draw finish trim lines one even with the inboard edge of the wing tip skin and the other perpendicular to it just behind where the tip skin is notched for the lights Trim along these lines 4 Tape the lens tightly in place Drill pilot holes for 1 screws ...

Page 158: ...eld will tend to get bumped often therefore you should apply a reasonable amount of thick CA at the joint With that in mind applying packing tape adjacent to the flange will prevent glue seepage on to the wing skin The full size T 34C shield has two small holes at the rear You can drill these now or after painting if desired Wing Wiring and Plumbing 1 Join the wing halves together Use 5 minute epo...

Page 159: ...ain the wiring tubing 6 Guide servo extensions and air line tubing through the channel and into the wheel well Attach a 24 extension to the aileron servo lead and a 12 extension to the flap lead You will need to tee air lines for the two air cylinders on the main gear retracts Removing the inner door cylinder plate will allow you to tuck the wires and tubing behind it You can insert a round toothp...

Page 160: ...the larger channels to keep the wires down see below It can be lifted and re glued if needed Also route channels for wires and tubing coming from the fuse These are as follows Retract air line and brake line disconnects at bottom of photo above Aileron s extension s Flap s extension s opt Y harness Retract extension Y harness w brakes Brake extension optional Making a harness taping the extensions...

Page 161: ...r elevator and rudder servo leads and all extensions that go to the wing to the receiver Belly Pan 1 Attach the wing to the fuse attach wiring and hand tighten the wing bolts Rough trim the belly pan essentially removing the vertical flashing Lay the belly pan onto the wing Center the pan and press the portion of the pan that curves at the wing s LE firmly against the wing Tape in place 2 The bell...

Page 162: ... against the wing s LE Mark a trim line extending forward from the wing LE as shown below Draw a trim line at the TE about 1 behind the wing saddle Cut along these finish trim lines Leave the pan s LE untrimmed 4 Mark on the fuse and wing the locations for the magnets that will retain the belly pan Alternatively you could use screws instead of magnets however the magnets are by far more user frien...

Page 163: ...ed side down into the cavity The CA should surround the magnet but not flow onto the top of the magnet Move it to the cavity s center with a piece of wood then use accelerator to cure the CA Repeat for all magnets in the fuse and wing 7 Place waxed paper over the fuse wing magnets Note how a magnet will be attracted to one of the fuse or wing magnets and then sand its face up side for a better bon...

Page 164: ...d as shown below Trace the plate s outline on the firewall 2 Remove the firewall and align then clamp the plate to the firewall Drill holes for the mounting bolts through the plate and firewall 3 Attach the floating anchor nuts to the backside of the firewall putting a bolt through the hole and screwed into the anchor nut will help align it Drill pilot holes for the screws we recommend 2 servo scr...

Page 165: ... down until the tire sits just below the cavity walls There will be a slight angle to the rails as shown below After adjusting the height of the retract if there is any portion of the rear rail supports that extend above the fuse trim these areas away You will also need to remove some of the engine plate to allow the retract s down lock link to extend Test the retract s movement to ensure there is...

Page 166: ...ch the cowl or balsa blocks note how the rear balsa block required modification for clearance the upper cowl s block may need to be trimmed as well d Trace the engine mount s outline once you are satisfied with the engine s orientation The cowl s large air intake will provide enough cooling air even if the cylinder head is not perfectly in the middle of the intake 9 Because there are many engine o...

Page 167: ...ome time to work the glue deep into the foam such that little epoxy is present on the surface Then apply another thin layer of epoxy to the surface Make sure to keep epoxy away from the anchor nut cavities Place the firewall on the fuse and install the upper ply keys to properly align the firewall do not glue in the keys yet Use tape to press the firewall firmly against the fuse 13 Once the firewa...

Page 168: ... steering arm to the servo arm and make a 4 40 rod with a clevis and Z bend as shown above it is important to have the rod installed on the servo with this offset to avoid interference with the retract Use a long servo arm to have the linkage deep in the wheel well In order for the steering linkage to be straight you may need to make a notch in the left side s rear support as shown below Test the ...

Page 169: ...upport Position the front support a little lower than you did on the right side use CA to attach it Make a hole sufficient to pass a screw driver through to access the carb adjustment screws then glue on the balsa triangular stock Test that your screwdriver will access the adjustment screws 19 Drill holes for the retract s mounting screws Make sure the retracted wheel is 5 8 away from the back of ...

Page 170: ... 23 Mount the throttle servo as shown in a position near the rear inside corner Make a 4 40 rod of sufficient length to attach the servo arm to the carb s throttle arm For the choke extend a tunnel in a similar way but you may also need to extend a tunnel from the left bay to join the tunnel coming from the fuel tank cavity you can make the tunnels by a curved heated rod as well The choke s 4 40 l...

Page 171: ... key and cut to receive the switch Remove foam where needed to clear the switch and wires The location of the ignition battery will be some where in the left bay but its final location should be determined during final balancing so you will leave the battery s connection for later 26 You can optionally remove some of the left equipment bay and firewall key to allow for air to more freely flow out ...

Page 172: ...forcements should not require notches If the cowl s position is not consistent adjacent to the doors then adding an additional set of magnets near the doors will make the installation of the cowl more consistent see photo later on this page 3 Use 1 8 ply to make the hinge reinforcement plates as shown route recesses for them then CA in place The left rear ply plate is extended forward because ther...

Page 173: ...etter engine cooling roughly 1 25 x 1 75 Cut out the air exit hole in the cowl We recommend making it larger than scale size for better engine cooling Trace the outline onto the fuse 6 Route foam away from the opening and make another opening above the steering servo plate to make an air passage outlined in black You can add plastic to the visible areas of the cavity for aesthetics later 7 To prov...

Page 174: ...nose gear fork during its movement then tack glue with CA Test the servo s motion When satisfied use screws or bolts to attach the control horn to the door 10 For the right side door make a cavity for the servo into the rear wall of the wheel well and recess cavities for two hardwood screw blocks as shown The servo should be about 1 below the opening Make a 1 8 ply plate roughly 1 5 x2 5 and cut i...

Page 175: ...tensions go into another tunnel leading into the receiver cavity in the wing saddle The tunnel is best made with a short heated piece of music wire The wiring can be secured to the cockpit floors or covered up with the optional cockpit kit pieces We recommend that you avoid making trenches for these wires in the cockpit floor due to its minimal thickness from the wing saddle 13 Now is a good time ...

Page 176: ...pe onto a piece of 1 32 030 brass or similar metal 16 Bend the metal piece as shown note how it curves to match the inside of the cowl Finish the piece by rounding and drilling the tabs for a 2 56 bolt Also drill holes in the base to help adhesion Use CA and a clamp over waxed paper to secure the upper piece to the cowl 17 Align the door onto the cowl to ensure your slots for the door hinge pieces...

Page 177: ...e fold line you drew and adjust the base angle as needed so it mates flush with the inside door surface 19 Insert the hinges and clamp the ends to the tabs so they are centered at the tab s bolt holes Flip the cowl over so you can add CA under the hinge base Press the base against the door while ensuring the forward extensions are still centered with the tab holes 20 Once cured mark the hinges for...

Page 178: ...stops shown above to the inside of the cowl will help set the door s closed position When satisfied with the horn s position drill it for 1 screws Important Reminder Once the door is attached to the strut you cannot remove the lower cowl without first disconnecting the door linkage Engine Ducting The key to adequate engine cooling is maximizing the effectiveness of the incoming air and providing s...

Page 179: ... material We like to use thin G 10 phenolic Glue the floor in place 4 From balsa sheet make a left and right side wall to the duct that will guide air from the inlet past the cylinder head There should be about a 1 8 gap at the closest point to the engine CA the bottom of the side pieces to the floor or cowl The right side piece requires a notch to clear the muffler Also pay attention to how the c...

Page 180: ... out s perimeter as shown tape in place Install the cowl to determine if the skin requires slight adjustments Make any adjustments necessary to achieve proper alignment 9 Mark the skin so its LE is trimmed at the firewall Also mark a line around the perimeter of the skin on the foam so you can reposition it correctly Trim the LE and then glue the skin in place using CA or epoxy Make sure the LE is...

Page 181: ...ine plate Make a hole in the engine plate where needed sanding its edges smooth Connect the fuel lines to the engine For the Revolution 50 the best location to exit the fuel lines is at the upper right corner In the photo below the brass tubing was bent in this direction Here you can see the three fuel lines vent line black carburetor line with filter and the fill empty line Adding Details At this...

Page 182: ...th Below are pieces to the tail skid Draw their shape from reference photos We used thick gauge plastic 040 060 Since this unit is functional you should build it durable Make two while you re at is so you can have a spare if needed CA the pieces together then screw the unit down into the ply base do not glue it The dashed lines on the support pieces below are fold lines Below are molded pieces for...

Page 183: ...p www houstonhobbies com tips pai nting latex spraying latex pdf http www warbirdcolors com about_wa rbirdcolors html http www nelsonhobby com paint html To prep your model for paint make sure all protective film is removed and then rub down the skins with a Scotch Brite pad This process removes the gloss finish of the polycarbonate and aids paint adhesion We recommend that you test your primer an...

Page 184: ...indicator in Appendix C to the wing at the specified distance from the LE at the LE break Invert the model and place on your CG stand Your CG device should be suitable for a 30 lb model To adjust the CG shift the receiver and or ignition battery location s as needed to achieve the desired balancing point With the RX battery in the wing saddle first try to locate the ignition battery to achieve the...

Page 185: ...e runway and then slowly reduce the throttle to control the model s decent you should be about 15 feet high at the beginning of the runway Throttle should be at idle or a few clicks above it as the model gets close to the ground Settle the model onto the runway with a slight flair landing on the mains first Ideally the model should touch down as a result of a stall a few inches above the ground Re...

Page 186: ... incident while extreme proves the airframe can flex a great deal under impact forces and receive little or no damage Despite the extreme flex of the wings and aft fuselage seen below at the moment of maximum deflection there was no damage to these areas and only the small stress cracks as noted above How about major damage Yea we did that too On another occasion after our model veered off the run...

Page 187: ...ge the cockpit cross section is about one inch thick some reinforcement is beneficial Highlighted below in black are the breaks and the two horizontal lines are locations for plywood longerons to span the fractures We epoxied the plywood into routed slots Align a replacement skin so that you can determine where to trim it Once the skin is trimmed you can follow the procedure for skinning the airfr...

Page 188: ...t 303 953 2925 For a limited time we are offering free replacement skins for anyone that provides us with a digital video of their T 34C crash and a photo report on the repair process Give us a call or email us for details info scalepursuit com Feedback We are eager to continually improve our products and believe that our customers can provide us with valuable insight and feedback We encourage you...

Page 189: ...190 This template and those that follow are also located on the CD in the Document folder and are printable Stabilizer Elevator Template ...

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Page 196: ...b Doubler Tip End Forward Piece Right 24 Rib Doubler Tip End Rear Piece Left 25 Rib Doubler Tip End Rear Piece Right 26 Wing Inner Rib Left 27 Wing Inner Rib Right 28 Cowl s Clam Shell Door Plate 29 Inner Gear Door Air Cylinder Plates 30 Spacer for 29 make two spacers 31 Aileron Control Horns 32 Flap Control Horns 33 3 8 x3 8 Plates for Tail Cone three pieces 34 5 8 x5 8 Plates for Fuse TE 35 Wing...

Page 197: ...in Outer 27 Dorsal Fin 28 Cowl Louvers 29 Exhaust Shields 30 Canopy PETG Plastic 31 Canopy Recess 32 Front Glare Shield 33 Rear Glare Shield 34 Left Wing Tip 35 Right Wing Tip 36 Left Gear Door Inner 37 Right Gear Door Inner 38 Left Gear Door Outer 39 Right Gear Door Outer 40 Left Wing Bottom 41 Right Wing Bottom 42 Left Wing Top 43 Right Wing Top 44 Left Wing LE 45 Right Wing LE 46 Left Flap Aile...

Page 198: ...ate 1 Round toothpicks for rudder 4 3 8 Harwood Dowel 8 long for wing fuse joint Inventory of Hardware Robart Point Hinges 21 Robart Hinge Pockets 12 Disc Magnets 46 PL Polyurethane Sealant to attach skins 6 Rudder Torque Rod 1 sleeve 1 and straps 2 Offset Hinges for gear doors 12 Elevator Horn 1 Piano Hinges 2 Exhaust Stacks 2 x 12 Aluminum stabilizer spar 1 and phenolic sleeves 2 Music Wire for ...