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EDGE-2 Xtreme Building Instructions

Revised 01/23/2003

FUSELAGE

1. Cut out the 1/8"x 19" slot for carbon fiber tube.

2. Glue in the 18" Carbon fiber tube. Position to back of slot for 1" motor clearance. Tip: Its easier to attach wing, stab, and motor mount if you do not apply glue in these areas.

3. Cut 5/16" x 3 1/8" slot for motor mount. Also cut clearance slots for motor

4. Glue in the motor mount. See Note 1 

5. Cut out the Rudder. See Note 2.

6.  Hinge the Rudder. See Note 3.

7.  Cut 1/8" x 8" slot for wing.

8.  Cut 1/8" x 2 1/8" slot for horizontal stab. Also cut out the small clearance area above the back of the stab.

WING

1.  Cut out the 1/8"x 18" slot for carbon fiber tube, remove material.

2.  Glue in the 18" Carbon fiber tube.

3.  Cut out the ailerons. See Note 2.

4.  Hinge the ailerons. See Note 3.

HORIZONTAL STAB

1.  Cut out elevators. See Note 2. 

2. Mark and fit the elevator wire to the elevators. See Note 4 . Check that both elevators are level with each other, adjust as required.

4.  Glue the elevator wire to one elevator only for now.

ASSEMBLY

1.   Slide wing into fuse cutout.

2.  Line up and glue wing to fuselage.

3.  Slide horizontal stab into fuse cutout.

4.  Line up and glue horizontal stab to fuselage.

5.  Snake elevator with elevator wire into fuse stab cutout, glue elevator wire to other elevator.

6.  Hinge elevator assembly to horizontal stab. See Note 3.

7.  Install motor. Note: It is always a good idea attach the motor to the mount with a small screw.

8. Install radio equipment. Adjust location to allow balancing at the carbon fiber tube for normal flying, up to 1" behind for Xtreme.

Typical Control System Set-up

Ailerons                        EZ connectors on servo control arm, .032" wire with Z-Bends at control horn.

Rudder and Elevator            Quick links on servo control arm, .032" wire with Z-Bends at control horn.

Additional Items Needed

1.     Control Horns   2 pkg.   Dubro # 848  Micro Control horns   2/Pkg, 

Or make your own from 1/32plywood

2.     EZ Connectors   1 pkg.  Dubro #845   Mini EZ Connector   2/Pkg

3.      Quick link    1 pkg         Dubro #849    Micro EZ link    4/Pkg 

4.      Control Rods  .032" wire, make Z-bends at control horns, use EZ connector on ailerons

5.      Velcro Industrial Strength

6.      Double sided tape

Notes:

1.   MOTOR MOUNT   The motor mount has been sized to fit either the IPS single or dual motors. Due to tolerances, motor fit will vary.  Sand as required to fit.

2.   CONTROL CLEARANCE: Angle your xacto knife at the hinge line both ways to cut out a wedge of material.

3.  HINGES: Box tape works well. Use the full 2 width of the tape on the non-beveled side of the hinge.

4.   ELEVATOR WIRE INSTALLATION: The elevator wire is shaped like a U. Temporarily tape the elevators to the stab. Position the elevator wire in place and mark the location for the " legs on the back edge of the elevators. Using a small nail or drill bit ,1/16", carefully push or drill a hole about " deep into the elevators. With your xacto knife, cut a small slot for the wire from the hole to the edge of the elevator.

5.    RADIO LOCATION: The prototype used GWS equipment attached to the profile fuselage, 3-servos; Aileron above the wing, elevator, and rudder between the wing and stab, all tack-glued. The receiver and speed controller were mounted with double sided tape. The battery was attached with Velcro between the motor and wing.

6.   MOTOR: The prototype used GPS motors, either IPS Single - D on 3-cell LI-PO or IPS Dual -B on 2-cell LI-PO. Note a slightly larger motor clearance will be required for the IPS Dual. For ultra-Extreme use Dual - B ON 3-CELL!!!

7.   WEIGHT: The prototype airframe weighed 1.5 oz, flying weight with GWS equipment, Single D, and 3 cell 700ma LI-PO, was 5.6 oz.

8.   ADHESIVES: Foam safe CA was used on the prototypes. Epoxy is ok, but a little messy and heavy. Regular CA will melt the foam.

Foamy T-Bird Building Instructions

Revised 12/10/2006

FUSELAGE PREP

Top Fuse

1.                  Cut out the opening for the fan.

Bottom Fuse

2.                  Using medium, Foam safe CA, start about an inch or so from the front of the fuse and glue the flat carbon fiber stiffener to the bottom of the fuse. Note: It works a little better if you glue the front 1 or 2 inches of CF to the

                     curved forward section of the fuse first. Let the glue set a bit, then glue the rest of the CF to the bottom of the fuselage. The CF greatly strengthens the fuselage as well as provides a tough skid for landings.

3.                  Cut out the opening for the fan.

Horizontal Fuselage/ Stab/ elevator

4.                  Cut the five (5) slots out of the Horizontal Fuselage.

5.                  Cut out the opening for the fan.

6.                  Cut out the elevator. See Note 1.

7.                  Hinge the elevator. See Note 2.

WING PREP

8.                  Cut out the .125"x 26" slot for carbon fiber tube, remove material.

9.                  Glue in the .125" OD x 26" Carbon fiber tube.

10.              Cut out the ailerons. See Note 1.

11.              Hinge the ailerons. See Note 2.

ASSEMBLY

12.              Glue wing to bottom of Horizontal Fuselage. The wing is located between the 2nd and 4th slots in the fuse.

13.              Using the Fan cut out in the Horizontal fuse as a guide, cut out the opening in the wing for the fan.

14.              Line up and glue Top Fuselage half to Horizontal Fuselage. Trial fit pieces together before gluing, adjust as required. See Note 3.

15.              Install the ducted fan into the opening in the fuse and wing.

16.              Glue the fan to the Horizontal and Top fuse.

17.              Line up and glue Bottom Fuselage half to the Horizontal Fuselage. Trial fit pieces together before gluing, adjust as required. See Note 3.

18.              Glue the 3/8" x 8 " triangle balsa stock tail stiffener to the fuselage. This piece is to be glued to the joint between the Bottom fuse and the bottom of the Horizontal Fuselage on the right side, flush with the wing.

19.              Install radio equipment. Adjust location to allow balancing " in front of the carbon fiber tube.

Typical Control System Set-up

Ailerons                        EZ connectors on servo control arm, .060" CF Rod push rods with .032" wire on ends, Z-Bends at control horn.

Elevator                        EZ connector on servo control arm, .060" CF Rod push rods with .032" wire on ends, Z-Bends at control horn.

Additional Items Needed

1.      Control Horns      2 pkg.        Dubro # 848       Micro Control horns      2/Pkg, 

          Or make your own from 1/32plywood

2.      EZ Connectors      2 pkg.        Dubro #845      Mini EZ Connector      2/Pkg

3.      Control Rods                      .032" wire, .060"  CF Rod

4.      Velcro Industrial Strength

5.      Double sided tape

Notes:

1.                  CONTROL CLEARANCE: Angle your xacto knife at the hinge line both ways to cut out a wedge of material.

2.                  HINGES: Box tape works well. Use the full 2 "width of the tape on the non-beveled side of the hinge.

3.                  FUSELAGE DUCTED FAN PREP. - It is important to have the fan cutout on the Top and Bottom Fuselage halves flush with the fan cutout on the Horizontal fuselage for attachment of the fan.

                                                                                     If required, trim the locating tabs on the Top and Bottom fuse to suit.

4.                  RADIO LOCATION: The prototype used GWS equipment attached to the fuselage and wing, 2-servos; Aileron and elevator mounted in the horizontal fuse, all tack-glued. The receiver and speed controller were mounted

                                                            with double sided tape. The battery was attached with Velcro on the forward Bottom Fuse.

5.                  FAN: GWS EDF-40

6.                  MOTOR: Fieago Brushless DF motor with Phoenix 10 brushless Speed Control.

7.                  WEIGHT: The prototype flying weight with GWS equipment, EDF-40, brushless Fieago, and 3 cell 700ma LI-PO, was 6.0 oz.

8.                  ADHESIVES: Foam safe CA was used on the prototype. Epoxy is ok, but a little messy and heavy.  Regular CA will melt the foam.

EDGE-X Building Instructions

Revised 02/28/2003

FUSELAGE PREP

Top Fuse

1.      No Prep Required

Bottom Fuse

2.      Cut 5/16" x 2 7/8" slot for motor mount as marked on the Bottom Fuselage.

3.      Glue in the motor mount. The mount is about 1/16" wider than the foam. Glue the mount flush with the right side of the Fuselage. I use a flat building board with a little wax paper between the fuse and the board. The right side needs to be flat as you will install a doubler to strengthen the engine mount later. On the left side, you can put in a nice fillet of glue around the motor mount. See Note 1

Fuselage/Horizontal Stab Clutch

4.      Cut slots (3) out of Fuselage crutch.

5.      Draw a line through the center of the crutch top and bottom for reference line up of the Top and Bottom Fuse halves.

WING

1.         Glue the wing halves together. Leave the box tape on the bottom for strength.

2.         Cut out the .156"x 29" slot for carbon fiber tube, remove material.

3.         Glue in the .156" OD x 29" Carbon fiber tube. Note: The tube is slightly larger in diameter than is the thickness of the wing. Glue in the tube flush with the Top of the wing and let the excess stick out the bottom. This will allow a strong joint to the Fuselage crutch later.

6.         Cut out the ailerons. See note 2

6.         Hinge the ailerons. See Note 3.

8.         Rough up the box tape on the bottom of the wing joint with 220 sandpaper.

ELEVATORS

1.         Cut out elevators. See note 2

2.         Mark and fit the elevator wire to the elevators. See Note 4. Check that both elevators are level with each other, adjust as required.

3.         Glue the elevator wire to both elevators

ASSEMBLY

1.                  Hinge elevator assembly to horizontal stab. See Note 3.

2.                  Lay Fuselage/Horizontal Stab clutch on flat building board, with wax paper under it.

3.                  Line up and glue Top Fuselage half to crutch. Trial fit pieces together before gluing, adjust as required.

4.                  Glue wing to bottom of crutch. The wing is located between the first two (2) slots in the crutch.

5.                  Line up and glue Bottom Fuselage half to crutch. Trial fit pieces together before gluing, adjust as required.

6.                  Glue Fuselage doubler to right side of Fuselage over the motor mount flush with bottom of crutch and leading edge of wing.

7.                  Glue the 3/8" x 9" triangle balsa stock tail stiffener to the fuselage. This piece is to be glued to the joint between the Bottom fuse and the bottom of the crutch on the right side, flush with the back of the wing.

8.                  True up the vertical stab hinge line on the top and bottom fuselage halves with a straight edge.

9.                  Hinge the Rudder. See Note 2 and Note 3.

10.              Install motor. Note: It is always a good idea attach the motor to the mount with a small screw.

11.              Install radio equipment. Adjust location to allow balancing at the front carbon fiber tube for normal flying, up to 1" behind for Xtreme.

Typical Control System Set-up

Ailerons                                   EZ connectors on servo control arm, .060" CF Rod push rods with .032" wire on ends, Z-Bends at control horn.

Rudder and Elevator                 EZ connectors on servo control arm, .070" CF Rod push rods with .032" wire on ends, Z-Bends at control horn.

Additional Items Needed

1.      Control Horns      2 pkg.        Dubro # 848       Micro Control horns      2/Pkg, 

Or make your own from 1/32plywood

2.      EZ Connectors      2 pkg.        Dubro #845      Mini EZ Connector      2/Pkg

3.      Control Rods                           .032" wire, .060" and .070" CF Rod

4.      Velcro                                     Industrial Strength

5.      Double sided tape

Notes:

1.                  MOTOR MOUNT The motor mount has been sized to fit IPS dual motors. Due to tolerances, motor fit will vary.  Sand as required to fit.

2.                  CONTROL CLEARANCE: Angle your xacto knife at the hinge line both ways to cut out a wedge of material.

3.                  HINGES: Box tape works well. Use the full 2 width of the tape on the non-beveled side of the hinge. Note: You may wish to hinge the surfaces after coloring for a better look.

4.                  ELEVATOR WIRE INSTALLATION The elevator wire is shaped like a U. Temporarily tape the elevators to the stab. Position the elevator wire in place and mark the location for the " legs on the back edge of the elevators. Using a small nail or drill bit ,1/16", carefully push or drill a hole about " deep into the elevators. With your xacto knife, cut a small slot for the wire from the hole to the edge of the elevator.

5.                  RADIO LOCATION: The prototype used GWS equipment attached to the profile fuselage and wing, 3-servos; Aileron above the wing, elevator, and rudder below the wing, all tack-glued. The receiver and speed controller were mounted with double sided tape. The battery was attached with Velcro between the motor and wing.

6.                  MOTOR: IPS Dual - B on 3-cell LI-PO.

7.                  WEIGHT: The prototype airframe weighed 2.6 oz, flying weight with GWS equipment, Dual B, and 3 cell 700ma LI-PO, was 7.2 oz.

8.                  ADHESIVES: Foam safe CA was used on the prototype. Epoxy is ok, but a little messy and heavy.  Regular CA will melt the foam.

WILDCAT Building Instructions

Revised 01/23/2003

FUSELAGE

1.                  Cut out the 1/8"x 19" slot for carbon fiber tube.

2.                  Glue in the 18" Carbon fiber tube. Position to back of slot for 1" motor clearance. Tip: Its easier to attach wing, stab, and motor mount if you do not apply glue in these areas.

3.                  Cut 5/16" x 3" slot for motor mount. Also cut clearance slots for motor

4.                  Glue in the motor mount. See Note 1 

5.                  Cut out the Rudder. See Note 2.

6.                  Hinge the Rudder. See Note 3.

7.                  Cut 1/8" x 8" slot for wing.

8.                  Cut 1/8" x 3 3/8" slot for horizontal stab. Also cut out the small clearance area above the back of the stab.

WING

1.         Cut out the 1/8"x 18" slot for carbon fiber tube, remove material.

2.         Glue in the 18" Carbon fiber tube.

3.         Cut out the ailerons. See Note 2.

4.         Hinge the ailerons. See Note 3.

HORIZONTAL STAB

1.         Cut out elevators. See Note 2.

2.         Mark and fit the elevator wire to the elevators. See Note 4. Check that both elevators are level with each other, adjust as required.

3.         Glue the elevator wire to one elevator only for now.

ASSEMBLY

1.                  Slide wing into fuse cutout.

2.                  Line up and glue wing to fuselage.

3.                  Slide horizontal stab into fuse cutout.

4.                  Line up and glue horizontal stab to fuselage.

5.                  Snake elevator with elevator wire into fuse stab cutout, glue elevator wire to other elevator.

6.                  Hinge elevator assembly to horizontal stab. See Note 3.

7.                  Install motor. Note: It is always a good idea attach the motor to the mount with a small screw.

8.                  Install radio equipment. Adjust location to allow balancing at the carbon fiber tube for normal flying, up to 1" behind for Xtreme.

Typical Control System Set-up

Ailerons                        EZ connectors on servo control arm, .032" wire with Z-Bends at control horn.

Rudder and Elevator            Quick links on servo control arm, .032" wire with Z-Bends at control horn.

Additional Items Needed

1.      Control Horns      2 pkg.        Dubro # 848       Micro Control horns      2/Pkg, 

Or make your own from 1/32 plywood

2.      EZ Connectors      1 pkg.        Dubro #845       Mini EZ Connector      2/Pkg

3.      Quick link             1 pkg         Dubro #849       Micro EZ link             4/Pkg 

4.      Control Rods                          .032" wire, make Z-bends at control horns, use EZ connector on ailerons

5.      Velcro                                     Industrial Strength

6.      Double sided tape

Notes:

1.                  MOTOR MOUNT The motor mount has been sized to fit either the IPS single or dual motors. Due to tolerances, motor fit will vary.  Sand as required to fit.

2.                  CONTROL CLEARANCE: Angle your xacto knife at the hinge line both ways to cut out a wedge of material.

3.                  HINGES: Box tape works well. Use the full 2 width of the tape on the non-beveled side of the hinge.

4.                  ELEVATOR WIRE INSTALLATION The elevator wire is shaped like a U. Temporarily tape the elevators to the stab. Position the elevator wire in place and mark the location for the " legs on the back edge of the elevators. Using a small nail or drill bit ,1/16", carefully push or drill a hole about " deep into the elevators. With your xacto knife, cut a small slot for the wire from the hole to the edge of the elevator.

5.                  RADIO LOCATION: The prototype used GWS equipment attached to the profile fuselage, 3-servos; Aileron above the wing, elevator, and rudder between the wing and stab, all tack-glued. The receiver and speed controller were mounted with double sided tape. The battery was attached with Velcro between the motor and wing.

6.                  MOTOR: IPS Dual - B on 3-cell LI-PO.

7.                  WEIGHT: The prototype airframe weighed 1.5 oz, flying weight with GWS equipment, Dual B, and 2 cell 700ma LI-PO, was 5.6 oz.

8.                  ADHESIVES: Foam safe CA was used on the prototypes. Epoxy is ok, but a little messy and heavy. Regular CA will melt the foam.