F LY R C M A G A Z I N E AEROWORKS Ultimate Biplane 27% Aerobatic Biplane, 100% Fun! SPECS PLANE: 27% Ultimate Biplane MANUFACTURER: Aeroworks DISTRIBUTOR: Aeroworks TYPE: 3D Sport or IMAC Biplane FOR: Advanced pilots by Tyler Renkert eroworks started out 12 years ago as just a small two-man company with large ideas. They now manufacture, design and import large volumes of planes, setting the pace for the competition. (See sidebar.) The Aeroworks Ultimate comes with all the hardware required for a basic build. They offer a hardware package that contains all the additional items to finish the ship. The package includes an Ohio Superstar tail wheel, pull-pull system from Du-Bro, Kavan wheels, Du-Bro axles and pushrods, Du-Bro pinned hinges, and Nelson control A 100 FLY RC MAGAZINE WINGSPAN: 63 in. (top); 63 in. (bottom) horns. I found these components to a best of breed solution for completing the Ultimate. The pilot must choose a radio, gas engine, onboard batteries for servos and ignition, and a 24-ounce fuel tank. The wings are mounted to the airframe with wing tubes. The roots of the wing and horizontal stabilizer have brass pins that lock into brass tubes that are pre-installed in the belly and tail of the ship. These provide a secure mounting point as well as a surface that will not wear out over time when the wings are removed: a very clever setup. WING AREA: 1,420 sq. in. WEIGHT: 234 oz. WING LOADING: 23.7 oz./sq. ft. LENGTH: 63 in. PHOTOS BY WALTER SIDAS 3D SPORT/IMAC BIPLANE FLIGHT REPORT RADIO: 4 channels required; flown with Hitec Eclipse 7 transmitter, Hitec HPD-07RH 7-channel Q-PCM receiver, 7 Hitec 5645 digital servos, 1 Hitec 425 servo for throttle ENGINE RANGE: 1.8 to 2.1 glow; 3.2 to 4.2 gas PROPELLER/SPINNER: Mejzlik 22x8 propeller, Tru-Turn 3 1/2 spinner TOP RPM: 6,850 FUEL: 100LL Avgas ONBOARD BATTERY: 2 Duralite 2000mAh Li-Ion receiver packs, 2 Duralite voltage regulators with failsafe switches for servos, (1) 2000mAh Li-Ion pack for ignition PRICE: $549.00 COMPONENTS NEEDED TO COMPLETE: Gas engine, propeller, spinner, radio, (8) 70 oz. or greater servos, (6) 24 in. extensions SUMMARY The Aeroworks 27% Ultimate Biplane is a scaled down version of the 2002 TOC winner flown by Chip Hyde. This new addition to the Aeroworks line is one of the nicest quality ARFs I have ever seen. The removable wings and stabilizer allow this 27% bird to fit perfectly and travel in the back of my four-door VW Jetta. The most impressive part of this plane is that it weighs less than 15 pounds, ready to fly. The Ultimate has a wing loading of only 23 oz./sq. ft. Factor in its 1,420-inch wing area and a fire breathing 2-stroke 52cc gasoline engine and you have the recipe for true extreme flight with unlimited vertical. The Ultimate’s box should boast the disclaimer: “THIS IS NOT A TOY!” The Ultimate is very easy to build and easy to fly—a truly impressive, robust platform for experienced pilots to hone their flying skills or enter any IMAC event or competition and compete to win! JANUARY 2005 101 AEROWORKS 27% ULTIMATE BIPLANE ENGINE Aeroworks recommends a 50cc gas engine. (I had a 50cc engine in my first Mini Bike!) The detailed instruction manual from Aeroworks features a Brison 3.2 ci engine (52cc). The large engine box accommodates this class of engine very easily with plenty of room under the cowl to fit the Pitts style muffler. (See sidebar.) SERVOS The hand polished Brison 3.2 mounts very easily to the stock engine box. I opted to use Hitec 5645MG digital servos, which produce 168 ounces of torque at 6V. This bird requires one servo per aileron (4), two for the elevator and one for the rudder. The throttle servo does not need to be high torque, but it does need to be reliable. I chose a Hitec 425 to control the carburetor butterfly. I believe you can never have too much power when it comes to servos. (See sidebar.) The Du-Bro heavy-duty servo arms direct the torque from the servos to the control surfaces. RADIO My Eclipse 7 was up for the challenge to channel these powerful servos. I used the HPD-07RH 7-channel Q-PCM receiver so I could use the QPCM mode for ultra secure radio connection. This receiver also provides two channels, so my redundant Duralite battery packs plug right in. Since I needed to control two elevator servos, I set up one of the custom mix features. I used channel 2 for elevator and then I programmed channel 7 to be the slave to 2. This allows both servos to work in unison for pinpoint control. I also used flaperons to control all four ailerons. The left and right side servos each met a separate Y harness: the left group was plugged into channel 6 while the right side was plugged into channel 1. This allows me to dial in precise throw for each set of ailerons and set the deflection so that the ship will axial roll as if on a wire. BATTERIES Left: The Hitec 5645MG is coupled to the Nelson control horn for precise, no slop control. Right: The huge fuselage provides ample room for the redundant Duralite battery system. The Hitec servo rests in the center with the Du-Bro pull-pull system controlling the huge rudder. I chose to use the redundant Duralite battery system to power the servos and the ignition. This large ship will demand a lot from the servos and I wanted to make sure there was plenty of power to spare. I used two 2000mAh Li-Ion cells with switched regulators to dial the 7.4V down to a usable 6V for the servos. Lightning response and extra torque is provided by the 6V current. The redundant power supply will assure that there is always power to the servos if one pack fails. The ignition for the Brison engine is hooked into a 2000mAh Li-Ion battery and a non-switched regulator. (See sidebar.) SMOKE SYSTEM Sullivan products have a great product—the Skywriter. This direct drive system uses a microprocessor so you can set the amount of smoke oil that is released into the muffler. I had to use a 16-ounce tank with the Sullivan aluminum stopper and special tubing that The Sullivan Sky Writer is mounted to the engine box with servo screws for a clean install. 102 FLY RC MAGAZINE AEROWORKS 27% ULTIMATE BIPLANE can be used in gasoline applications. The plumbing was easy to set up, and the pump can be screwed into the fuselage or just ziptied in place. Great gobs of smoke! TIPS FOR SUCCESS Building this ship is very easy due to the well laid out instructions and pictures of the components. The Ultimate is 90% finished when she arrives: you only have to hinge the control surfaces, install the control horns, wing tube and radio, and glue the rudder in place. I took my time and the ship was ready after 16 hours of work. HARDWARE AND ACCESSORIES When you purchase this ship, you should also get the accessory package from Aeroworks. The components work perfectly and there is no need to re-engineer anything. I think the nicest part of the hardware is the Nelson control horns. When installed, they become part of the airplane as if they were built up with the kit. I found them to be very easy to adjust and rock solid. Reluctant to use them, I contacted Aeroworks about the CA hinges. They recommend I use them. Aeroworks has used CA style hinges in their ARFs and kits for many years and have had great success with them. Even Chip Hyde's 42% TOC Winning Ultimate Biplane used CA style hinges. Having experience with the Du-Bro pinned hinges, I prefer to use them. I will use epoxy to glue them in place. HINGING ENGINE BOX The Ultimate comes with CA hinges resting in the precut slots of the control surfaces. Epoxy, Epoxy, Epoxy. Do not be shy: coat the box with 30-minute Z-Poxy and make Flight Review and 3D by Dave Baron SMOKE ON! AIRBORNE The Brison engine had been run at the factory and adjusted, so all I had to do was mount the Mejzlik 22x8 propeller. I wanted to use a carbon fiber blade from Mejzlik to squeeze every ounce of energy from the Brison powerplant. I set the throws per the instruction manual and found the performance best in 3D mode—40-45% deflection. Use your dual rates to shift on the fly, from normal mode to 3D (behind the power curve mode). The Ultimate needs only 1/3 throttle to be airborne in about 20 feet to begin its climb out. The first order of business, after a quick trim, was to roll inverted on a 45 degree upline (per Chip Hyde’s instructions in the manual) to check the CG. It should only require a small amount of down elevator to maintain the line; we were perfect! I found the rolls to be axial and precise and the tracking was perfect. This ship will groove. Since this was my first biplane, I thought it would be a different flight experience than my single wing ships, and it was...better! The wing area is massive and following the plane through its maneuvers was very easy. The bright yellow looks awesome in the sky! The loops were very easy and precise inside and out. They were any size we wanted as the plane is capable of pure vertical climb outs or lazy slow flight, your choice. I asked Fly RC Chief Test Pilot Dave Baron to wring the ship out. 104 FLY RC MAGAZINE TAKEOFFS—Bipes like this one have a higher center of gravity than a similar sized monoplane. Nothing makes this stand out more than at takeoff and landing! Any time you induce motion, but are not yet flying, hold some backpressure on the stick to keep the tail down on the ground. The most important reason is that with a blast of power, the tail rises before the rudder has authority in yaw. The result is the loss of tracking and the dreaded ground loop (and the missing covering under the wing tips to remind you of your mistake!). There is so much power with this model that it is in the air just after it moves. It all happens quickly, but you still need to be on your toes, and ready to compensate for torque and “P” factor with a little right rudder to keep it on proper runway heading. FLIGHT—This ship is true, and it is a tribute to Aeroworks’ experience in building TOC winning designs. It points really well, (the ability to go a straight line when you let go of the sticks at any attitude,) and yet has a wing loading that gives you performance with no surprises. I especially like the inherent drag of a biplane design. When you throttle back, the airspeed begins to fall immediately. This makes many maneuvers better, and landing approaches much more comfortable. AEROBATICS—Tumbles and snaps are just plain fun with a biplane. Its compact shape makes for outrageous acceleration in tumbles. I like to think of it like being a kid on a rope swing, accelerating the rotation by pulling your legs in under your torso, and seemingly doubling the rate of rotation. Bipes just start out life with their legs tucked in! The Ultimate knife-edged especially well. I think that there is something about the pressure balance on the fuselage, with a wing on top and bottom, that allows knife edge to require only a bit of rudder and very little coupling. Hovering was solid, and if there were more time on the engine, we would have gone for the classic “Tail Touching Shot.” LANDING—Due to the drag discussed earlier, you enjoy the ability to truly let power control altitude. Let altitude bleed off at low throttle, and then adjust the throttle to arrest the descent, and provide the necessary air flow for deep long flares. Landings are the best when power is held in until touchdown, and then cut after you are firmly down. If you have ever been to an air show and watched the full-scale super bipes land, it is always with power! AEROWORKS 27% ULTIMATE BIPLANE HITEC FACTS: DURALITE FACTS: Hitec’s line of servos is very diverse, ranging from park flyer to giant scale. The digital 5645MGs are the latest generation from Hitec. They are programmable and utilize Hitec’s unbreakable gear train. The dual ball bearings coupled with a 3-pole ferrite motor create a powerful, smooth, and reliable servo. The torque is rated at 143 ounces at 4.8V and 168 ounces at 6V. Speed is .23 and .18 respectively. The 5645s are a great choice in the Aeroworks 27% Ultimate Biplane. Duralite Batteries has been an innovator in light, high-energy battery systems for RC applications since 1998. With planes and helicopters getting larger and more complex, and the new digital servo technologies demanding more and more current, it only stands to reason that the Lithium power systems are a great alternative. Lithiums are lighter and have a higher energy density than the older technologies. Duralite produces complete systems for the hobbyist. During the development of new products, team pilots do the initial testing. This process is invaluable and leads to constant product improvement and development. Although this is costly and time consuming, it results in higher product satisfaction and reliability. I used a dual battery system in the Aeroworks Ultimate. A 2-cell 2000mAh Li-Ion battery and voltage regulator are plugged into the receiver. A second identical system is plugged into a separate channel to offer a backup in case one battery should have a malfunction. The voltage regulators are integrated into the failsafe switch harness that reduces the voltage from 7.4V to 6V. The ignition is powered by a non-switched regulator connected to a single 2000mAh Li-Ion battery. Before each flight, I use a Duralite load tester on the cells. The load tester places a one-amp load on the cells and gives you a true reading of their voltage under load. The Duralite system gives you that power you require for your digital servos while adding minimal weight to your ship. AEROWORKS FACTS: Aeroworks was started 12 years ago by two avid RC modelers looking for a better quality and performance product than was available. Rocco and Kevin, owners of Aeroworks, designed their own version of what an aerobatic plane should be. Competing and winning with their designs soon drew attention to their planes. Pilots looking for that same winning performance began placing orders and, before long, Aeroworks was born. Aeroworks is the only manufacturer to have won the Tournament of Champions four years in a row. Their ships have competed and won in every class of high-level competition flown today. At the last TOC in 2002, Aeroworks was the first manufacturer to introduce an ARF able to compete at such a high level competition. Chip Hyde flew the Aeroworks 42% Ultimate to first place, proving that ARF aircraft not only are competitive and well built, but here to stay. BRISON FACTS: The Brison engine line has been around for over 15 years and is manufactured in Texas. Gary Allison has created an impressive line of engines that caters to the large-scale market. I chose the 3.2ci (52cc) gas engine for the Aeroworks Ultimate Biplane strictly because of his reputation in the marketplace. The Brison 3.2 is different from other engines in many ways. The cylinder has a Nikasil professional grade liner inside. Nikasil is used by Porsche and Husquevarna in their engines as well. This liner lets oil adhere better to the cylinder walls for improved lubrication and less oil consumption. Brison recommends a 100-1 mixture as opposed to 50-1 for most other similar engines. The crankcase is 6061-T6 aluminum bar stock that is beautifully hand polished to a mirror finish. The crankshaft is machined from 4140 steel that is heat treated to allow more flexibility than a forged crankshaft could offer. Gary is so confident in his engine that he offers a crash warranty on the crankshaft! In addition, the head has a 1000-hour life expectancy. The ignition is from C+H ignition products. This CDI (capacity discharge ignition) is very reliable and lightweight; no magneto or flywheel is required! This adds to the engine’s fantastic power to weight ratio. There’s even a throttle-coupled spark advance that allows this engine to idle down to a whisper. Speaking of whispers, the Pitts-style muffler from Bisson is IMAC legal, coming in at 96 dB. Look to Brison for your next large project and you will have one less component to worry about in your airplane. ship actually flies stronger with a forward CG, and the limits are very broad so it is easy to work with. competition. This ship changes the rules. Now you can jump into scale flight and not break the bank; no trailer required! = Links CONCLUSION sure those joints are secure. This is not a glow plane! There are serious forces at work here and you must make sure that box is solid. This box is very sound and comes with triangle stock to sure up the joint, but you must build it correctly to avoid potential problems. CG The CG is very important and it should be perfect if you follow the instructions. The 106 FLY RC MAGAZINE I am thrilled with my Ultimate! It was quick to build, awesome to fly, and it looks tremendous. This has been my favorite project so far. It definitely attracts attention at the field with its bright colors and the cool factor a biplane brings with it. The Ultimate is ready for competition if I so choose, or it’s ready to go skywriting at the local field and just have a ball. This ship is one that will be in my hangar for many years to come. I would especially recommend the Aeroworks Ultimate to any pilot out there who has seen a large scale ship and thought it was only for extreme pilots and Aeroworks, www.aero-works.net, (303) 366-4205. Brison R/C Engines, www.brisonaircraft.com, (972) 241-9152. Duralite Batteries, www.duralitebatteries.com, (877) 744-3685. Hitec RCD USA, Inc., www.hitecrcd.com, (858) 748-6948. Mejzlik propellers, distributed by Desert Aircraft, www.desertaircraft.com, (520) 722-0607. Sullivan Products, www.sullivanproducts.com, (410) 732-3500. Tru-Turn, www.tru-turn.com, (281) 479-9600. ZAP and Z-Poxy are manufactured by Pacer Technology, www.zapglue.com. For more information, please see our source guide on pg. 177.
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