AirfoilZ NX Profile Series Assembly Manual - V2

NX Profile Series
Assembly Manual
Designed by Jim Vigani
Version 2.0 – 10/12/09
EXTRA 300NX
EDGE 540NX
YAK 54NX
KATANA NX
A Tech Hobbies,LLC Company
532 North Avenue
Dunellen, New Jersey 08812
Ph: (732)424-6400
Website: www.airfoilz.com
e-mail: info@airfoilz.com
© Copyright 2009 all rights reserved
Limited Warranty
AirfoilZ takes pride in the care and attention given to the manufacture of the components in this
kit. The company warrants replacement of any materials found to be defective for their intended
use prior to their use in the construction of the model, provided the purchaser requests such
replacement within a one year period from the date of purchase, and the part is returned, if so
requested by the Company. No other warranty, expressed or implied, is made by the company
with respect to this kit. The purchaser assumes full responsibility for the risk and all liability for
personal or property damage or injury resulting from the purchaser’s use of the components of
this kit whether assembled or not.
The Company reserves the right to provide a full refund to the purchaser if the model does not
perform as advertised. Any refund is at the sole discretion of the Company.
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Introduction:
Thank you for choosing one of the AirfoilZ NX Profile Series airplanes. We have taken great care to
provide a design and kit components that, when properly assembled, will give you a high quality
model with outstanding performance. While the assembly is not complicated, the quality and
ultimate performance of your model will depend on the care you take while building. Please read
these instructions carefully and be sure that you understand them before you start. Take
care to assemble the components as shown and in proper alignment.
Please note that the material used for some of the parts shown may be
different in from those provided in the kit. The installation of these parts
is unaffected by the material change.
Warning
This radio-controlled model is not a toy and, if operated inappropriately can cause serious
bodily injury and property damage. It is the buyer’s responsibility to assemble the kit correctly
and properly install the motor, radio and all other equipment. The model must always be flown in
accordance with the safety standards of the Academy of Model Aeronautics (AMA).
This model is designed for high performance. While it is reasonably simple to assemble, it is not
intended for the novice flier. Do not attempt to learn to fly with this model! If you are an
inexperienced modeler, we recommend that you get the assistance of an experienced modeler to
help you with the assembly and initial flights. There are many local clubs that can offer help with
assembly and flight instruction. Information on local clubs can be found through the Academy of
Model Aeronautics. The AMA has over 2500 chartered clubs throughout the country. Information
on the AMA can be found at www.modelaircraft.org.
We do not recommend the use of hot glue for mounting components such as servos, control horns,
receivers or speed controls.
Recommended Power System:
This plane has been designed to use a 175 to 250 watt power system. Recommended motors
include the Common Sense E5 –L -13, Hacker A20-20L, Scorpion 2215-18, or AXI 2217-16. The
prototype was flown with the Common Sense E5-L-13. a 25-amp Pheonix ESC, and a 1500 mAh,
3S Li-poly battery with a APC 10x5Epropeller. Other power systems with similar capabilities can be
used. Performance will vary depending on the specific power system selected. For information on
alternate power systems please visit http://3dxhobbies.com or your local hobby shop.
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Kit Contents:
Before you start the assembly of this model, check to make sure that there are no missing parts and
that none of the parts have been damaged during shipment. If you have any questions with the
assembly or flying of this model, please contact us and we will be happy to assist you. If you need
replacement parts please provide the model name. The parts included in the kit are shown on the
Part Sheet included with the kit.
Other items you may need that are not included with your kit:
Building Supplies:
In addition to the kit contents, we recommend having the following building supplies on hand to
complete the kit assembly in accordance with this manual.
Foam safe (odorless) CA
Foam safe CA “Kicker”
Gorilla glue
5, 15, and 30 minute epoxy
Double back tape or spray adhesive
Low tack masking tape (blue painter’s tape)
Sanding block with 100 grit sandpaper
Sanding stick or emery board (150 grit)
Soldering iron and resin core solder
1
/32 inch and 1/16 inch diameter drill bits
Exacto knife with #11 blade
Utility knife
Small square
36 inch ruler
Needle nose pliers
3
/8 inch diameter brass tubing
Diagonal cutting pliers
Power and Control Equipment:
The following items are needed to provide power and control function to your model.
Brushless outrunner motor with radial mount
4 motor mounting screws
Brushless motor speed control
4 micro servos (Hitec HS-55 or equivalent)
3S Li-poly battery pack
LI-poly battery charger
4 or 6 channel micro receiver
Y harness if a 4 channel receiver is used
3 to 6 channel transmitter
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Making a Sanding Block:
The leading edges of the elevator, the rudder, and both ailerons need to be beveled prior to
installing the hinges. This is best performed by the use of a 2-inch wide by 12 inch long, 100 or 120
grit sanding block or sanding bar. In addition, other areas of the airframe need to be sanded as
shown in this manual to complete the assembly and enhance appearance. If you do not have a
suitable sanding block, one can be easily made by securing a piece of 100 grit sand paper to a 2
inch x 12 inch x ¾ inch wooden block. The sandpaper can be secured to the block using either
double backed tape or spray adhesive. Make sure that the block is flat! A styrofoam block is
great for general sanding of the fuselage and non-beveled edges of the control surfaces.
Figure: 2
Figure: 1
Figure: 3
General Comments on Assembly:
While not difficult to assemble, the AirfoilZ NX Profile Series kits are intended for persons with some
building experience. As such, the instructions are presented as a simple sequence that, when
followed, will help ensure that the airframe turns out straight and light. Improperly aligned surfaces
and unnecessary weight will only hinder its performance. Apply glue and epoxy in a thin uniform
coat, using only enough to achieve a strong bond. Excess glue or epoxy will only add unnecessary
weight and will not increase the strength of your model. Trial fit all components to ensure fit and
alignment before applying any glue or epoxy. Keeping joints tight fitting will minimize the amount of
glue required and will ensure a strong bond. Use a light touch while sanding. Foam cuts very
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quickly and excess pressure can limit your ability to accurately shape the foam. Take extra care not
to over sand. Avoid scratching the surface of the Depron foam.
Graphics:
The AirfoilZ NX Profile Series kits come with printed vinyl graphics. Extra care in cutting out and
applying the vinyl panels will result in a professional look for your plane. Some people prefer to
lightly mist the surface with “Frebreze” before applying the vinyl. This allows the vinyl to be
repositioned while applying them.
Fuselage Assembly:
The fuselage assembly on the AirfoilZ NX Profile Series kits consists of two routed depron skins,
laminated over a carbon tube and a balsa spar.
Right Fuselage Skin with Spars and Landing Gear Mount
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Fuselage Assembly - Exploded
Fuselage Assembly
Follow the steps in the order outlined below to ensure accurate alignment of the
components.
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Step 1
Glue the two 1/8”x 1/2”x
24” balsa spars together
to form a single spar
measuring 1/4"x 1/2"x
24”. Check that the spar
edges are straight.
If
slightly bent, lightly
sand the edges as
required to eliminate the
bend.
Step 2
Test fit the carbon tube
and balsa spar in their
respective groves.
Test fit the other skin
over the spars and
check that both skins
touch without any gaps.
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Step 3
Glue the fuselage spars
and skins together
using 30 minute epoxy
or a very thin layer of
Gorilla glue. NOTE:
Place the glued
assembly on a flat
building surface and
weigh down to ensure
the assembly dries flat
and true.
Step 4
Using the fuselage
cutout as a guide, glue
the stack of landing
gear mount plates
together with CA to form
the landing gear block.
If necessary, sand the
block to the thickness of
the fuselage. Do not
glue the blocks to the
fuselage.
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Step 5
Glue one of the plastic
landing gear mount
doublers to the side of
the fuselage with foamsafe CA. Epoxy the
landing gear block and
other plastic landing
gear mount doubler in
place with 5 minute
epoxy. Tip: Sand the
surface of the plastic
landing gear mount
doublers that mate to
the fuselage for better
bonding of the glue.
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Step 6
Glue the plastic nose
doublers in place with
foam-safe CA making
sure to align the edges
of the doubler with the
opening in the fuselage.
Tip: Sand the surface of
the
plastic
nose
doublers that mates to
the fuselage for better
bonding of the epoxy.
Step 7
Test fit the ply motor
mount in the fuselage
opening.
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Cut the balsa tri-stock
motor mount supports
to the proper length and
check their fit behind
the
motor
mount.
Epoxy the motor mount
and balsa tri-stock rear
supports
in
place
making sure that the
motor mount is square
to the fuselage.
Tip:
lightly sand the plastic
doubler for a better
bonding of the epoxy.
If you would like to finish the edges of the fuselage, do that after the motor mount and the
landing gear mount have been installed. Use your sanding block to smooth and either
bevel or round the edges approximately 1/8 inch. Sand the edges of the motor mount and
motor mount supports smooth using the sanding stick or emery board.
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Wing Assembly and Installation
Assembling the Spar:
Step 8
Glue the spar web to the
center of the bottom spar
cap with thin CA being
sure to keep the spar web
perpendicular to the spar
cap.
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Step 9
Repeat for the top spar
cap forming the “I beam”
Tip:
When
shape.
completed, lightly sand
the spar edges to help it
slide into the wing.
Wing Assembly:
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Step 10
Using the distance from
the table below, place a
mark spar location mark
behind the leading edge
at each wing tip. Place
another mark behind the
leading edge at each
wing root.
Model:
Extra 300NX
Edge 540NX
Yak 54NX
Katana NX
Tip Distance:
2 1/8”
2”
2 1/8”
2 1/8”
Wing Root Distance:
3 1/8”
2”
3 1/8”
3 1/8”
Step 11
Glue the 3 mm foam wing
alignment tabs in place
on the left wing using
foam safe CA staying
sufficiently away from the
spar location mark to
allow room for the spar.
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Step 12
Mark the center of the
spar and test fit it in the
wings. Glue the spar into
place with Gorilla Glue or
15-minute epoxy. Align
the spar with the spar
location marks on the
wing panels.
Step 13
Repeat for the other wing
making sure to align the
root sections at the
center seam. Apply the
epoxy to the center seam
after sliding the second
wing on the spar, just
before the two wings are
pushed together.
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Step 14
Push the wing center
joint together making
sure the wing root airfoil
profile of both wings
match at the center.
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Step 15
Carefully sand the wing
tip profile and spar end to
remove any irregularities.
Glue the wing tip caps
onto the wing using foam
safe CA and foam safe
kicker. For curved wing
tips, carefully bend the
wing tip caps around the
bend.
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Step 16
Trim and sand the wing
tip to final shape.
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Wing/Fuselage Assembly:
Step 17
Test fit the wing in the
fuselage.
DO NOT
FORCE!
If the fit is
tight, gently sand the
fuselage opening to fit.
Make sure the wing is
centered on, and square
to the fuselage. With
the
wing
properly
aligned, tack glue it in
place with medium foam
safe CA.
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Step 18
Permanently glue the
wing in place by forming
a fillet from mixture of
15 or 30-minute epoxy
and micro balloons.
for KATANA NX ONLY
KATANA ONLY
Step 18a
With the wing properly
aligned, tack glue it in
place with medium foam
safe CA.
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KATANA ONLY
Step 18b
Tack glue the aileron
fairing in place with
medium foam safe CA.
Step 18c
Permanently glue the
wing and aileron fairing
in place by forming a
fillet from mixture of 15
or 30-minute epoxy and
micro balloons.
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Tail Feather Assembly and Installation:
Installing the Elevator Joiner:
Step 19
Using the end of the
3/16” diameter carbon
elevator joiner, gently
create a shallow grove
in the elevator joiner
cutout.
Step 20
Secure
the
3/16”
diameter
carbon
elevator joiner in place
with epoxy. Tip: For a
lighter joint, a mixture of
15 minute epoxy and
micro balloons can be
used.
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Step 21
Cut out the foam bridge
behind the wood joiner,
between the elevator
halves.
Installing the Horizontal Stabilizer Spar:
Step 22
Glue the ¼”x¼” balsa
horizontal
stabilizer
spar to the rear of the
horizontal stabilizer
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Step 23
Using the sanding block,
bevel the leading edge of
the elevator as shown to
allow for movement of the
elevator when hinged.
Step 24
Temporarily secure the
elevator to the stabilizer
with tape. Mark the
position of the elevator
hinges with strips of 3/8”
wide painter’s tape. Use
3 hinges on each side of
the elevator.
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Step 25
Cut the tape along the
hinge line and remove
the elevator.
Step 26
Using your Exacto
knife, carefully cut a
slit
along
the
centerline of both the
stabilizer and elevator
at each hinge location.
Test fit the hinges into
the slits. NOTE: Do
not glue the hinges in
place at this time.
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Step 27
Glue the vertical Stab
to the horizontal stab
making sure the parts
are square.
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Step 28
Trim the rear of the
horizontal stab slot in
the fuselage.
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Step 28
Test fit the horizontal
and vertical stabilizer
assembly in the
fuselage and check
that it fits square to
the fuselage and wing.
Glue the stabilizer in
place with medium
foam safe CA.
Step 29
Install the elevator and
epoxy the hinges in
place.
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Rudder Installation:
Step 30
Glue the rudder post in
position using foam
safe CA.
Sand the
rudder post flush with
the top of the vertical
stabilizer and with the
bottom of the fuselage.
Trim the back of the
fuselage at an angle to
match the rudder post
using your Exacto knife.
This allows clearance
for the rudder control
horn.
Step 31
Bevel the leading edge
of the rudder and install
using the same method
as with the other control
surfaces. Use 3 hinges.
Remember
to
leave
1
approximately
/32”
clearance between the
top of the vertical
stabilizer
and
the
rudder.
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Aileron Installation:
Step 32
Using the sanding block,
bevel the leading edge of
the ailerons as shown to
allow for movement of
the ailerons when hinged.
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Step 33
Temporarily secure the
ailerons to the wing with
tape. Mark the position
of the aileron hinges with
3
strips
of
/8”
wide
painter’s tape.
Use 4
hinges for each aileron.
Note: To minimize aileron
flexing,
position
the
centerline of the second
hinge approximately 5½“
from the side of the
fuselage,
near
the
location
where
the
aileron control horn will
be located.
Step 34
Cut the tape along the
hinge line and remove
the ailerons. Using your
Exacto knife, carefully
cut a slit along the
centerline of both the
aileron and the wing
trailing edge at each
hinge location and glue
the hinges in place
NOTE: that the wing has
a glue seam along the
centerline of the trailing
edge. Make all the slits in
the wing trailing edge as
close as possible to the
centerline, directly above
the glue seam!
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Aileron Servo Mount Installation:
Step 35
Mark the wing servo
locations on the bottom
surface of the wings. The
recommend
servo
location using Hitec HS55 or HS 65 servos is
shown. Cut the hole in
the wing skin for the
servo using your Exacto
knife. Cut the servo lead
exit hole location being
careful to avoid cutting
into the wing spar.
Step 36
Test fit the servos in the
holes. Mark the location
of the servo mounts and
remove the servos. Glue
the servo mounts in
place with foam safe CA.
Drill a 1/32 inch diameter
pilot hole in the servo
mounts at each servo
mounting lug location.
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Typical Control Horn Installation:
Step 37
Sand the edges of the
plastic
control horn
parts to remove the
edge caused by the
laser cutting. Test fit the
pieces together
Step 38
Mark the location of the
control horns on the
control surface and cut
a slit in the control
surface with an Exacto
knife to accept the
control horn mounting
tab.
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Step 39
Glue the control horns
in place with medium
foam safe CA or Epoxy.
Landing Gear Installation:
Step 40
Solder a #2 washer on
the landing gear. as an
inner wheel retainer Tip:
Drill a 3/32” hole in a
scrap block of wood to
use as an alignment
tool. Lightly sand the
axel and washer to
ensure good bonding of
the solder.
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Step 41
Place a scrap piece of
thin
plywood
or
cardboard
over
the
wheel as a spacer and
slide a #2 washer on the
axel. Solder in place.
Use only enough heat to
ensure good solder
flow. Excess heat may
melt the wheel hub.
Completed wheel
installation
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Step 42
Fit the landing gear
wires into the slots in
the landing gear mount
and secure in place with
a small electrical tie. Fit
the tie into the grove on
the bottom of the
landing gear mount.
Tip: Round the corners
of the slots so that the
wires fit flush to the
mount surface.
Note: Trim the wire
extension that fits into
the
fuselage
as
necessary
to
avoid
interference.
Step 43
Bend the tail wire to
final shape and glue
between the two tail
wire mounts.
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Step 44
Glue
the
tail skid
assembly in the slot
provided at the rear of
the fuselage.
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Motor, ESC, Servo, Receiver and Battery installation:
Aileron Servo Installation:
Step 45
Secure the wing servos
in place with the servo
mounting
screws
provided
with
the
servos.
Route
the
aileron
servo
leads
through the interior of
the wing, and out
through the exit hole.
Do not over-tighten the
screws as you may strip
the screw holes.
Step 46
Cut a section of carbon
fiber tube to length and
insert the threaded rods
into each end. Prior to
insertion, it is best to
rough sand the smooth
end of the rods for
better
adhesion.
Secure with thin CA or
JB Weld. Heat shrink a
section of heat shrink
tubing onto the end of
the carbon fiber tube.
Wick thin CA into the
joint between the heat
shrink and the rod.
Install the clevis on the
threaded rod leaving
room for adjustment,
and attach to the servo
arm.
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Elevator and Rudder Servo Installation:
Step 47
Securely glue the
elevator and rudder
servo mounts in place
with medium foam
safe CA.
Step 48
Insert the threaded
rod into the end of the
carbon fiber tube and
glue with thin CA or
JB Weld.
Heat
shrink a section of
heat shrink tubing
onto the end of the
carbon fiber tube.
Wick thin CA into the
joint between the heat
shrink and the rod.
Install the clevis on
the
threaded
rod
leaving
room
for
adjustment,
and
attach
to
the
appropriate
servo
arm.
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Step 49
Install the elevator
and rudder push rod
securing at both ends
with
the
nylon
clevises
provided.
Bend the rod ends as
appropriate
to
maintain torsion free
geometry.
Motor, ESC, Receiver and Battery installation
Step 50
Mount the motor using #2
wood
screws
and
washers. Check to make
sure the motor turns
freely and there is no
interference between the
rotating
motor
components
and
the
fuselage.
Tip: Right
thrust adjustments can be
made by placing #2
washers under the left
legs of the motor mount.
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Step 51
Mount the ESC and
receiver with Velcro on
the left side of the
fuselage as shown.
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Step 52
Mount the battery with
Velcro strips on the right
the fuselage as shown.
Use
a
Velcro
strap
through the slots in the
lower crutch to secure the
battery in place.
Pre-flight checklist
Balancing:
We recommend that you perform initial flights with the CG 3½ to 4 inches behind the leading edge at
the wing root. Adjust the CG to get the flight characteristics that suit your taste.
Electrical Components:
Check that all electrical components are securely attached and the all plugs are fully seated.
Secured any extra length on servo leads neatly within the fuselage or the wing. Avoid loose or
dangling wires. For 72 MHz systems, we recommend the use of a micro antenna such as the Azarr,
or the Berg Peel & Stick Antenna.
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Controls:
Check that all the control surfaces move in the correct direction. For 3D flying adjust the servos and
pushrod locations to give 450 of control surface travel. If you radio has a dual rate function set the
low rates to suit your taste. We recommend 30-40% expo to start.
Prior to each day’s flying, always perform range check of your equipment in accordance with
the manufactures instructions.
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