TufFlight Bouncer Instruction Manual

5376 Amalfi Drive, Clay, NY 13041 www.tufflight.com
The Toughest R/C Planes Ever!
Wingspan: 40" Length: 44" Flying Weight: 24 oz Motor: Himax HC3510-1100
brushless outrunner or
Radio: 4 channels Servos: 4 (HS 65 or equivalent) Wing Area: 429 sq in
Hello, and thanks for buying the Bouncer! Whether you’ve just entered the exciting world of radio control and 3D flying, or you’re a seasoned veteran, the Bouncer is the perfect combination of agility, durability, versatility and value for the school or front yard 3D flyer.
Caution: The Bouncer can be a very agile performer, and requires care in setup and operation. Please obey manufacturer’s safety rules for your motor, propeller and battery. Lithium polymer (lipo) batteries are ideal for this plane. Charge lipo batteries ONLY with a lithium capable charger according to battery instructions.
Bouncer
250 W equivalent
Excellent 3D capability
-plus-
Outstanding Durability
The CG location is 5-1/2” from the wing leading edge at the root.
(6-1/2” for expert)
While you may be tempted to fly close to yourself, please practice in a safe manner.
Please read and understand the instructions before starting to build. We recommend joining the AMA and following the AMA safety code. Call 1 (800) I- FLY-AMA for more details.
We assume no responsibility for how you use your plane. That said, let's get started!
Items Included in kit:
Foam Parts:
(1) right/left EPP wing cores in shucks (2) EPP tail feathers sheets in shucks with wings (1) EPP front fuselage piece (1) EPP rear fuselage piece
Misc:
(1) 0.030” control horn plastic sheet (1) clear mylar hinge sheet (1) 1/32” G10 sheet (1) 3/16” white plastic motor mount sheet (2) 3/32” x 1/2” fiberglass LG struts (2) 1/16” x 72” fiberglass rod (1) 1/8” x 24" fiberglass rod (1) popsicle stick (1) 0.193” x 0.023” x 18” carbon
Hardware:
(4) Dubro mini EZ connectors (2) main wheels (1) tailwheel (2) 6-32 x 3/8” nylon bolts (2) 6-32 x 1-1/4” steel bolts (6) 6-32 nuts (1) 0.039” x 18” wire (1) 1/16” x 7” wire (3) zip ties (12) O-rings #017 (1) Velcro strap
This Instruction Manual
Rev 1.6
Page 1
Items needed to complete:
Equipment:
Himax HC3510-1100 brushless outrunner
or 250 W equivalent 4 channel radio receiver 30 - 35A electronic speed control (ESC) 1200 mAH - 2200 mAH 3S Lipo battery 4 servos: Hitec 65 or equivalent
Parts:
props :
APC 11 x 3.8 Slo Flyer -or­APC 11 x 5.5 E (2) 12” servo wire extensions
connectors for ESC and battery solder (if needed for connectors) shrink tube (if needed for solder joints)
Adhesives:
Gorilla Glue (clear, dries white), small bottle
--and/or-­Quick Grip adhesive (available at Walmart and Michaels crafts) thin CA (regular, NOT foam safe) CA accelerator (kicker) masking tape 3M77 Spray adhesive
Helpful Tools:
40 grit sandpaper on block
(found at auto finishing stores and Sears) hobby knife / utility knife new single edge razor blade scrap of sheet rock as a “cutting board” soldering iron Phillips head screwdriver straight screwdrivers long nose pliers wire cutters Drill with 7/64”, 9/64”, 1/8”, 1/16” bits Dremel Tool w/ drum sander and cutoff wheel razor saw felt tip pen ruler/straight edge metal file scissors clamps plastic wrap flat building table, at least 3 ft long lightweight decorations: airbrush (recommended)
Flight Trim:
The recommended center of gravity (CG) point is 5-1/2” from the LE at the wing root with the battery in­stalled. Adjust by positioning the battery by moving the G10 plate and velcro strap on the fuselage for the new battery position.
A good test for an aerobatic CG position is to fly the plane upright and trim the elevator for level flight. Then fly inverted and see if any down elevator control is needed to maintain level flight. If the plane also flys level in­verted with very little down elevator, the CG is good for 3D. The farther back your CG moves, the more “twitchy” your elevator will get. For 3D It helps to have 40 to 50 degrees deflection on all surfaces and a rear­ward CG. 30 to 50% expo may also be helpful on all surfaces (Especially elevator). Adjust to your taste.
You may wish to check and adjust lateral balance. It should be very close to neutral if built as shown.
For hints on flying 3D maneuvers, consult our web site: http://www.tufflight.com/3d_faq.html
Notes on Crashing and Repairs:
You should be able to fix foam damage with Quick Grip for fast field repairs. Apply Quick Grip to one sur­face, join parts temporarily, pull apart to let dry for about 30 seconds (you should see “spider webs”) and then put them back together. In a few minutes the joint will be flight ready. Large damaged areas will benefit from Go­rilla glue as it foams to fill voids.
Have Fun!
Remember, weight is the enemy, so keep repairs light! If there's one thing we've learned, it's amazing how much cosmetic damage can be "ignored" when a friend shows up to fly.
We want you to have fun exploring the limits, but please do so safely.
We welcome any feedback you may have on this or other TufFlight products.
Please feel free to contact us:
take care and enjoy!
Mark & Joe
Page 2
Assemble Wings
You’ll need : Foam wing pieces, mylar hinge sheet,
medium and thin CA, kicker, hobby knife, scissors, razor blade, ruler, cutting board, scrap wood, scrap EPP / 40 grit sanding block
Step 1: Gather parts and tools. Step 6: With a new sharp hobby knife, slice
the ailerons apart on the center marks.
Step 2: Carefully separate the wing parts from the shucks as shown.
A scrap piece of EPP may also be used to “sand” off the spider webs
Step 3: Sand and peel any “spider webs” away from the foam.
Step 4: Mark the aileron piece center at one end as shown
Step 7: Ailerons should be identical
The beveled (pointed) edges face each other
Step 8: Align aileron to wing as shown
Step 9: Trim Aileron to match wing angle
with sharp hobby knife as shown
Step 5: Mark center at the other end also
Step 10: Make slicing tool from scrap wood and razor blade exactly 0.350” thick
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A ruler helps to keep the hinge/ foam joint together
Step 11: Glue razor blade to scrap wood as shown
Work carefully and press all parts to the bench when slicing
Step 12: Slice the aileron LE and wing TE with tool as shown
mylar is
0.003” thick and comes rolled in “the baggie”
Step 13: Cut two 3/4” strips of mylar for hinges
Step 16: Apply kicker to hinge.
Step 17: Trim hinge at angle as shown to aid
insertion during next step
Step 18: Slide hinged aileron into wing as shown.
Tape a credit card to the mylar strip to help feed it into the slit
Step 14: Slide mylar hinge into aileron as shown
Step 19: Flex the aileron to set the hinge gap needed to provide adequate clearance.
The hinge gap should be as small as possible while still allowing full deflection as shown
After this step, trim hinge material even with root/tip edges
Step 15: Apply thin CA to hinge on both sides Step 20: Once hinge gap ready, apply thin
CA and kicker while clamping with ruler
Page 4
Assemble Fuselage
You’ll need : Foam fuselage pieces, ruler,
white gorilla glue or quick grip glue, scrap EPP / 40 grit sanding block, sharp knife, 1/16” fiberglass rods, ruler dremel tool /cutoff wheel
Step 21: Gather parts and tools.
You’ll use the 33” pieces now. Save the longer ones for the wing later
Step 22: Cut the fiberglass rods to produce two (2) 39” and two (2) 33” pieces
Step 23: Glue front/rear fuse pieces together and tape the joint while the glue cures.
Step 26: Mark fuselage above elevator slot as shown. Repeat for other side.
Step 27: Make a slice roughly 1/8” deep with sharp knife connecting marks as shown.
Step 28: (continuation) Slice from front to rear as shown.
Step 24: Sand and/or trim with a knife the glue which squirts out of the joint
Step 25: Mark fuselage front at center of side “bulge”. Repeat for other side.
Sand/ blend the foam joint for a smooth transition as needed/ desired
Work glue into the entire slot from nose to tail.
Step 29: Apply white Gorilla Glue or Quick Grip into slot as shown.
fiberglass rod shown black in pictures-- your color may vary
Step 30: Lay fiberglass rod into groove and press down so it’s flush with surface.
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Repeat for both sides.
Insure fuselage is straight while glue cures.
(These should lie 3 - 15/16” from LE at root, 2-7/8” from LE at tip
Make 4 spanwise slices-- one on each wing surface)
Step 31: Work rod into slot. Rod will stay in place once glue starts to set.
Join Wings to Fuselage
You’ll need : Assembled Foam fuselage and wings,
white gorilla glue or quick grip glue, hobby knife, (2) 1/16” fiberglass rods, tall blocks/supports, weights, ruler, plastic wrap, medium CA, kicker old credit card
Step 32: Gather parts and tools.
measure from FRONT-- not motor cutout
Step 33: Mark fuselage 9-15/16” from nose as shown (both sides)
Step 36: Find spanwise index marks on wings and slice 1/8” deep along these lines
Step 37: Insert wings between spars guiding them into the slices to locate the wings.
use medium CA and kicker
Step 38: When satisfied with wing position, tack glue wing front to fuselage where shown.
Step 34: Slice all the way through fuselage at the marks as shown.
Step 35: Thread the 1/16” rods half way through the slices as shown.
This quickly locks wing into position for next steps
Step 39: Tack glue rear of wing similarly.
Work quickly for this and the following steps-­one wing at a time
Step 40: Apply white gorilla glue or quick grip into wing slots with an old credit card
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Note: In the following steps, the Himax motor is
shown which requires shaft reversal.
Your motor may not require this procedure.
Step 41: Work Spars into slots being careful to center them along the span (other half too)
Repeat for all wing spars
Step 42: Wipe away any glue which squirts out with acetone and paper towel.
We use two identical radio boxes
Step 43: Lay onto blocks upside down as shown. Blocks should be taller than canopy.
Step 46: Prepare your chosen motor for mounting
Make Motor Mount
You’ll need : Himax HC3510-1100 or
equivalent w/ tools, and prop mount, loc tite, 1/8”, 1/4”, 1/2” drills, saw, motor mount white plastic, scissors, paper motor mount template (“H”), scrap wood, hammer or vise, knife, 3M77
Step 47: Gather parts and tools.
Step 48: Remove hex screws as shown
Step 44: Apply white gorilla glue or quick
grip into center wing/fuse joint as shown.
Step 45: Apply weights while glue cures as shown.
Step 49: Remove collar as shown.
Take care to insure fuse is perpendicular to wing and things look symmetrical
Step 50: Remove washer and save in safe place. Separate as shown.
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Step 51: Insert motor shaft into wood block as shown
Using slow pressure with a vise is preferable if available
Step 56: Apply washer.
Step 52: Press motor shaft forward (check
next photo to know when to stop)
Step 53: Motor shaft should look like this.
Step 54: Re-assemble motor as shown.
Step 57: Install wheel collar.
Step 58: Cut out “H” motor mount from
paper template as shown.
Step 59: Apply template to white plastic sheet.
Step 55: Loc tite all screws.
Step 60: Drill 1/8” holes where shown.
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Step 61: Drill central 1/2” hole where indicated.
Step 66: Deburr corners of holes
Note wires route on left side of fuselage
(fuselage dowels won’t be installed yet at this point)
Step 62: Drill 1/4” holes where indicated at “H” corners
A band or scroll saw may also be used if available
Step 63: Saw to remove “H” insides as shown.
Step 64: Saw to remove “H” insides as shown. A band or scroll saw may also be used.
Step 67: Test fit motor to “H” mount and adjust holes if needed.
Make Tail Parts
You’ll need : Foam sheets, new sharp hobby knife,
paper templates, 3M77, carbon strip, white gorilla glue or quick grip, ruler, cutting board, mylar hinge material, clamps, assembled wing/fuselage
Step 68: Gather parts and tools.
Step 69: Remove any spider webs from
foam. Apply templates
*Note, cutouts are NOT identical
Top cutout is smaller than bottom -- label Top / bottom to avoid confusion later
Step 65: Round edges with knife or disc sander as shown
Step 70: Cut tail parts from foam sheets with sharp knife
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Step 71: Cut two elevators from the same template.
Step 76: Bevel the rudder and elevator to allow desired deflection
Step 72: Slice the elevator and horizontal stab where shown for the carbon stiffeners.
You can re-use the aileron hinge slicer if you sand it thinner to center it to the tail parts
Step 73: Make slices for 3/4” wide mylar hinges as indicated.
Step 74: Slice the rear fuselage for the 3/4” hinges also
Step 77: Cut two 9” carbon pieces.
Step 78: Glue the carbon stiffeners into the
elevator and horizontal stab as shown.
Use a technique similar to how you hinged the ailerons.
Step 79: Glue the mylar hinge into the elevator and horiz stab with thin CA.
Step 75: Glue the two elevator and stab halves together as shown.
Step 80: Center the assembled horizontal stabilizer/ elevator into the fuselage as shown
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Bouncer graphic courtesy of David Killius
Drawing A
Page 21
Step 81: Measure and align the stab to the wing to insure symmetry
Step 86: Glue Rudder to fin / fuselage with thin CA and kicker
Make Template Parts
You’ll need : paper templates, 3M77 spray adhesive,
G10 Material, clear plastic, scotch tape, scissors, hobby knife, mineral spirits, clamps, 1/8” fiberglass rod, 0.039” wire, file, white gorilla glue or quick grip, mineral spirits, pen, Dremel tool/cutoff wheel
Step 82: Mark position when satisfied
Check and adjust stab to make sure it is level with the wing.
Clamp or shim as needed
Step 83: Apply white gorilla glue or quick grip and glue stab into fuse
make lower hinge extra long (3/4” x 1­1/2”) to reinforce rudder
Step 84: Apply mylar hinges to rudder using same technique.
Step 87: Gather parts and tools.
Step 88: Apply control horn template to clear
plastic as shown
Step 89: Cut out parts with scissors.
Step 85: Carve clearance angles as needed to
clear horizontal tail parts when deflected.
Scoring and bending/snapping will free the parts more easily than cutting all the way through
Step 90: A hobby knife can be used for tight corners.
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Step 91: Locate the 0.039” wire and file one end to a sharp point as shown.
Step 96: Apply template to G10 with 3M77 as shown.
Step 92: Cut the sharpened wire to 1” as shown.
Step 93: Chuck your “home made bit” into a drill (or Dremel) and drill holes where indicated.
Step 94: Remove templates from parts. Min­eral spirits makes this easy.
Step 97: Drill holes as indicated.
Aviation shears or tin snips work well
Step 98: Cut out parts with strong scissors.
Step 99: Cut out fuse motor mount/dowel
holes paper template as shown.
Step 95: Cut template for G10 parts as shown.
Step 100: Align template to nose and mark hole locations as shown with pen.
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The Motor mount “H” plate will attach snugly behind these rods.
Be careful NOT to give UP or DOWN thrust, only right thrust
Step 101: Slice through nose to make holes for rods
You’ll need the (2) 2-3/4” rods now.
(save the other rods for later).
Step 102: Cut the 1/8” fiberglass rod to these dimensions : (1) 15”, (2) 2-3/4”, (2) 1-1/8”
All holes in G10 go closest to motor cavity
Step 103: Glue rod to G10 to fuselage as shown with white gorilla glue or quick grip
Step 106: Align rods so they give approxi­mately 2 degrees of “right thrust” as shown
Step 107: When satisfied with all angles, clamp in place while glue cures.
Badger “Createx”
paints are water based and durable
When airbrushed, they give a brilliant lightweight result
Step 108: OPTIONAL - Now is a good time for painting, or wait to the end-- your choice
Step 104: Repeat for bottom
Step 105: Glue G10 reinforcements to other
side as shown.
Install Radio Parts
You’ll need : pen, hobby knife, Dremel tool, ruler,
control horns, ez-connectors, 0.39” wire, white gorilla glue or quick grip, pliers, radio system, battery, ESC
Step 109: Gather parts and tools.
We recommend a 1200 to 2200mAH 3S lipo pack for best results.
Step 110: Obtain your battery and charge it.
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Plane RIGHT BOTTOM side shown
Don’t forget servo arms and screws!
Servo arms must point straight up with radio turned on and trims centered
Step 111: Mark receiver location on fuselage side/bottom about 1-1/2” from hinge line
Step 112: Slice hole through fuselage for receiver installation
Plug aileron servos into RX to be sure the servo locations are within reach and equidistant from center
Step 113: Mark servo locations so their wires will BOTH reach the receiver 1-1/2” from hinge
Step 116: Glue aileron servos into foam with white gorilla glue or quick grip.
slice servo cavity all the way through the fuselage
Step 117: Locate rudder servo 3-3/4” forward of hinge line as shown and slice cavity
Test fit servos into cavity, then remove for next steps
Step 118: Locate elevator servo even with stab front as shown and slice cavity similarly
A dremel tool with drum sander works well after slicing the outline
Step 114: Slice servo outlines with sharp hobby knife and clear foam to make cavity as shown
Step 115: Test fit servo and make slits in foam for wire to RX as shown.
Step 119: Extend and route servo wires to RX. Make slits and channels to hide wires
Step 120: Solder or insert extensions as desired. Forcep “pull tools” helps route wires
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Note control horn “bottom” should be flush with other side of aileron. Enlarge slice as needed.
Step 121: Pull and tuck wires in place, then glue servos into cavities.
Install servo arms so they are centered
(Transmitter trim and stick neutral with servo arms perpendicular)
Step 122: Hook up and and test your radio to insure controls move as intended.
Step 123: Install EZ connectors on all servo arms.
Step 126: Insert control horns and apply thin CA and kicker to both sides. (top too).
Step 127: Make Z bends in wire as shown. Install into aileron EZ connectors.
Step 128: Make slice for elevator control horn as shown.
Note shape of control horn-- the point at the front will inset perfectly with point of the aileron at the hinge line
Step 124: Use control horn to mark location for installation. Push rod should be straight.
Step 125: Make slice all the way through the aileron and hinge as shown.
Test fit slit in horn over carbon stiffener and adjust slit as needed for snug fit.
Step 129: Make slice and test fit elevator control horn as shown.
Step 130: Install elevator and rudder control horns and rods as you did for the ailerons.
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Trim extra push rods after all controls centered and EZ connectors adjusted.
Note the location of the corner on the spar
(repeat for both LG locations-­left/right)
Step 131: Adjust push rods to center controls as needed and tighten EZ connectors..
We feel the excellent “all terrain” landing gear adds another dimension to the Bouncer. It certainly flys very well WITH gear, however if you’d like to save some weight and time, you may omit the following section.
Step 132: Decide if you want landing gear. All LG parts together weigh about 2.5 oz
Install Landing Gear
You’ll need : pen, hobby knife, Dremel tool, ruler,
1/8” fiberglass rods, 1/16” wire, scissors, white gorilla glue or quick grip, clamps, popsicle stick, wheels, nylon screws nuts, landing gear struts, sandpaper, pliers, scrap paper, steel bolts, CA kicker, G10 parts, rubber bands/O-rings
Step 133: Gather parts and tools.
Step 136: Align the support as shown and
mark the location of the hole on the line
Remove paper in center so fuselage clears template. Align edge of paper with marks from previous step
The paper edge marks location of LG spar to be inserted into wing and through fuselage
Step 137: Make a template from scrap paper and mark wing where LG rod goes
Step 138: Cut popsicle stick in half and glue between two supports with rod as shown.
Step 134: Mark the wing bottoms 4-1/2” from each root edge as shown (left and right)
Step 135: Use a G10 LG support to mark from spar forward along these lines as shown
Sand LG strut corners round. Also sand LG support edges round where rubber band/O-ring rubs to avoid cutting.
Step 139: Drill LG struts according to tem­plate. Mount wheels with steel bolts and nuts.
Step 140: Attach struts to supports with nylon bolt and nuts. Make both assemblies.
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Step 141: With a sharp hobby knife, slice the borders for the LG supports as shown.
Careful not to poke through top surface. (glue will fill holes in following steps anyway in case you do!)
Also don’t grind away any spar material.
Step 146: Once supports and rod fit well, glue with white gorilla glue.
Step 142: Using Dremel tool with collet as depth gage, make slots in wing between slices
Test fit LG support into slot periodically to test your progress
Step 143: A Dremel tool with router attach­ment helps control the cutting.
Use a long knife or sharp file for this
Step 144: Poke hole through fuselage for LG rod as shown.
Step 147: Attach rubber bands/O rings as shown.
Refer to template pages for tailwheel bending guide.
Step 148: Make a small bend in 1/16” wire as shown.
Step 149: Make next bend to trap tailwheel and continue bending as template shows.
15” rod should go in supports and lie flush with wing surface.
Cut groove and poke/ slice hole through fuse to allow rod to lie straight (see next step)
Step 145: Test fit gear supports and 15” rod. Clear any foam which prevents full insertion.
Step 150: Make final bends and trim wire according to template.
Page 28
Slice should be next to hinge for best strength.
Step 151: Slice the rudder as shown to receive wire.
Refer to template for G10 reinforcement location
Step 152: Apply Quick grip or white Gorilla Glue and G10 supports and clamp till dry.
Final Assembly
You’ll need : pen, hobby knife, Dremel tool, ruler,
“H” motor mount, rubber bands/O rings, battery, velcro strap, Scrap wood or plastic
(ie credit card thickness,
zip ties, scrap 1/16” rod, motor, ESC
Step 153: Gather parts and tools.
Step 156: Insert round grinder into Dremel
tool.
Step 157: Make “half round” slots as shown between your marks for rods to seat.
Step 158: Mount motor to “H” mount with bolts, washers and loc tite as shown.
Step 154: Insert “H” mount as shown with bottom groove being longest
Motor thrust line should be about 1/4” above wing /fuse center
See Drawing A in center of manual
Step 155: Use center hole to orient the “H” mount and mark rod locations on “H” mount
Step 159: Insert motor assembly as shown.
Step 160: Place mount to back side of rods
and insure clearance exists for next steps.
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Step 161: Apply rubber bands (or O rings) as shown.
Step 166: Insert another zip tie around ESC rear wires as shown.
Step 162: Stretch behind “H” mount and around rod as shown.
Step 163: Mount secured as shown. Re­peat for all 4 corners of “H” mount.
Make 2 slices -­one above, one below
Step 164: Slice through fuse to poke zip tie around G10 reinforcements as shown.
Step 167: A scrap piece of 1/16” rod will prevent zip tie from pulling through hole
CG may be up to 6-1/2” from the LE for great waterfalls
Step 168: Mark CG location 5-1/2” from LE at wing root
Step 169: Place battery on wing top left side and move to balance on the marks.
Step 165: Insert zip tie around ESC wires and tighten as shown
Step 170: With battery at balance position, mark spot for battery lead to poke through
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Step 171: Make hole in wing to clear battery connector
Step 176: Glue G10 beneath velcro strap as shown.
Step 172: Mark center of battery as shown.
Step 173: Slice through fuselage above and
below battery edges as shown.
Step 174: Insert velcro strap through fuselage to hold battery.
Step 177: Route, tuck, hide remaining wires as desired.
Optional Items
You’ll need : pen, hobby knife, covering iron, mylar,
drill, scrap 1/16” rod, quick grip, clear plastic wing root joiner , airbrush, paint
Step 178: Gather parts and tools.
Locate “wing root joiner” which was made from the template when the control horns were cut from the thick clear plastic sheet
Step 179: Slice through the fuselage and both wings as shown for wing root joiner
Step 175: Cut scrap wood or plastic to act as backer support to fit between slits (height of battery).
This helps prevent the wings from separating in hard nose down crashes.
It can be installed at any time.
Step 180: Insert joiner and glue with quick grip to lock both wings together.
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A covering iron turned up to the “high” setting helps this step
Step 181: Apply quick grip to wing tip bottoms
Step 182: Apply mylar strips to avoid scuffs when taxiing “aggressively” over pavement.
This helps to give the foam a protective skin to resist tearing.
Step 183: Smear Quick Grip over any foam corners likely to contact the ground.
Step 184: Sand or melt the fuselage corners smooth and round as desired.
Badger “Createx” paints are water based and durable
Step 185: Airbrush canopy and other decorations as desired.
GO FLY !
Step 186: Install scrap 1/16” rod where shown to extend the life of rubber bands or O-rings. This prevents them from getting caught “in the scissors” if the LG struts pivot too far rearward.
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