FlatfoilZ EXTRA 300, STALKER, LEK-TRICK, EDGE 540 Assembly Manual

FlatfoilZ Assembly Guide

EXTRA 300, EDGE 540, LEK-TRICK & STALKER

Version 1.0

10-27-11

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Limited Warranty

FlatfoilZ 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.

Introduction:

Thank you for choosing one of the FlatfoilZ Profile Series airplanes. The assembly of all the FlatFoilZ planes is very simple and requires a minimum of building skills. This Quick Start Guide is provided for those with some building experience. The full Assembly Manual is available at 3DX Hobbies.com.

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).

Recommended Power System: The FlatFoilZ series of planes have been designed to use a 175 to 250 watt power system.

Recommended motors include the Hacker A20-20L, Scorpion 2215-18, or AXI 2217-16. The prototypes were flown with a 1350 mAh, 3S Li-poly battery and a 25 amp ESC. 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.

General Comments on Assembly:

While not difficult to assemble, the FlatFoilZ 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. All the FlatFoilZ prototype wings and fuselages were laminated using 15 minute epoxy thinned with alcohol. 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 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.

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Fuselage Assembly:

Exploded View of Typical Fuselage Assembly

Fuselage with Right Skin and Carbon Fiber Spar in Place

The fuselage assembly on the FlatfoilZ NX Profile Series kits consists of a 6 mm depron laser cut core, over which are laminated 3 mm depron skins. A 6 mm carbon tube is embedded in the 6mm core piece.

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Completed Fuselage Assembly

Follow the steps in the order outlined below to ensure accurate alignment of the components.

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Step 1

Apply thinned 15 min epoxy to one side of the 6mm fuselage core and position the core on the 3mm fuselage skin .

Step 2

Apply epoxy into the center slot in the fuselage core and insert the 6mm carbon tube spar into the slot.

NOTE: Lightly sand the surface of carbon tube for better glue adhesion.

Step 3

Apply thinned 15 min epoxy to the other side of the 6mm fuselage core and position the other 3mm fuselage skin over the core.

Step 4

Place the glued assembly on a flat building surface and weigh down to ensure the assembly dries flat and true.

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Step 5

Glue the 3mm depron nose doublers on both sides of the fuselage.

Step 6

Test fit the ply motor mount in the fuselage opening.

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Step 7

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.

If you would like to finish the edges of the fuselage, 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 a sanding stick or emery board.

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Wing Assembly and Installation

Exploded View of Typical Wing Assembly

Wing with Bottom LE Skin and Carbon Fiber Spar in Place

The fuselage assembly on the FlatfoilZ NX Profile Series kits consists of a 6 mm depron laser cut core, over which are laminated 3 mm depron leading edge skins. A 6 mm carbon tube is embedded in the 6mm core piece.

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Completed Wing Assembly

Step 8

Join the two wing cores together using 5 minute epoxy.

Wing Assembly:

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Step 9

Cut the spar slot through

the center joint.

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Step 10

Apply thinned 15 min epoxy to the bottom side of the 6mm wing core and position the core on the 3mm bottom LE skins. NOTE: Test fit the

bottom LE skins on the wing core and lightly mark where the rear edge is located on the wing core. Only apply the epoxy up to that line.

Step 11

Apply epoxy into the spar slot in the wing core and insert the 6mm carbon tube spar into the slot.

NOTE: Lightly sand the surface of carbon tube for better glue adhesion.

Step 12

Apply thinned 15 min epoxy to the top side of the 6mm wing core and position the top 3mm LE skin over the wing core.

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Step 13

Place the glued assembly on a flat building surface and weigh down to ensure the assembly dries flat and true.

Step 14

After the epoxy has

cured, sand the wing LE

round.

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Wing/Fuselage Assembly:

Step 15

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.

Permanently glue the wing in place by forming a fillet from mixture of 15 or 30-minute epoxy and micro balloons.

Step 16

Using the end of the

3/16” diameter carbon

elevator joiner, gently create a shallow grove in the elevator joiner cutout.

Tail Feather Assembly:

Installing the Elevator Joiner: (Note: Not required on the Stalker)

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Step 17

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.

Step 18

Cut out the foam bridge behind the wood joiner, between the elevator halves.

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Installing the Horizontal Stabilizer Spar: (Note: Not required on the Stalker)

Step 19

Glue the 1/8” x 1/4” balsa horizontal stabilizer spar to the rear of the horizontal stabilizer

Step 20

Test fit the horizontal stabilizer 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 21

Trim the rear of the horizontal stab slot in the fuselage. Install the elevator and apply the hinges. (Not required

on Stalker)

Note: See Control Surface Hinging section below for installing tape hinges.

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Step 22

Glue the 1/8” x 1/4” 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. (Not required

on Stalker)

Step 23

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. (Not required on

Stalker)

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Control Surface Hinging:

Step 24

Using a sanding block, bevel the edge of the both mating surfaces along the hinge line.

All the control surfaces on the prototypes were hinged with tape. Any number of schemes can be used. However, we prefer the Over/Under method outlined below.

Making Over/Under Tape Hinges:

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Step 24a

Hinges are made by overlapping 2 pieces of tape together along the hinge line. One side goes on top of one surface and the other side goes on the bottom of the mating surface.

Step 24b

Attach the 2 pieces of tape together before attaching to the surfaces.

Step 24c

Apply the hinges in groups of three along the length of the hinge line.

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Step 25

Sand the edges of the plastic control horn parts to remove the edge caused by the laser cutting. Test fit the pieces together.

Note: The control horn with the short mounting tab is for the elevator.

Step 26

Mark the location of the control horn on the control surface and cut a slit in the control surface with an Exacto knife to accept the control horn mounting tab.

Typical Control Horn Installation:

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Step 27

Glue the control horns in place with medium foam safe CA or Epoxy.

Step 28

Test fit the servos in their mounting holes. Install the plastic servo mounts using medium foam safe CA. Secure the servos in place with the servo mounting screws provided with the servos. Do not over-

tighten the screws as you may strip the screw holes.

Servo and Pushrod Installation:

Servo Installation:

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Pushrod Assembly and Installation: Note: The Stalker uses solid wire pushrods

Step 29a

Cut the pushrod wire

into 3” long sections and

form a Z bend on one end.

Step 29b

Cut a section of carbon fiber tube to length and insert the Z-bend wire into one end of the tube.

(Prior to insertion, it is best to rough sand the end of the rods for better adhesion.) Secure with

thin CA.

attached with Z bends. Support the Stalker elevator pushrod with the plastic support provided.

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Step 29c

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 tube.

Step 30

Attach the pushrod to the control horn and then attach a section of Z bent wire into the servo arm. Insert the wire into the end of the push rod and adjust its length so that the control surface is neutral when the servo is centered. Secure in place with thin CA. Heat shrink a section of heat shrink tubing onto the end of the carbon fiber tube.

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Motor, ESC, Receiver and Battery installation

Step 31

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.

Step 32

Mount the ESC and receiver with Velcro on the LEFT side of the fuselage as shown.

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Step 33

Mount the battery with Velcro strips on the RIGHT side of the fuselage as shown. A Velcro strap can be added for additional security.

Stalker

3” to 3¼”

Extra 300

3½” to 3¾”

Edge 540

3” to 3¼”

Lek-Trick

3¼” to 3½”

Pre-flight checklist

Balancing:

We recommend that you perform initial flights with the CG located behind the leading edge at the wing root as shown below. Adjust the CG to get the flight characteristics that suit your taste.

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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 taped to the wing. Avoid loose or dangling wires.

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 use approximately 50%). We recommend 30-40% expo to start.

Recommended throws on the Stalker are 3/8” for the elevator and 3/4” for the ailerons.

Prior to each day’s flying, always perform range check of your equipment in accordance with

the manufactures instructions.

FlatfoilZ EXTRA 300, STALKER, LEK-TRICK, EDGE 540 Assembly Manual

Specifications and Main Features

Frequently Asked Questions

User Manual