3D AEROWORKS PR1 Guide

ASSEMBLY MANUAL
AND USER GUIDE
PR1
POND RACER
1200mm
By 3D AEROWORKS

OVERVIEW:
This replica of the Pond racer is designed for quick and easy construction and printed using
regular PLA. Designed to suit the 3548 900kv motor this model has a significant amount of
power and is happy to cruise around at 50% power on 3s. Utilizing 6 channels; Ailerons,
Elevator, Flaps, Rudder,Throttle and Landing gear, this model is sure to turn some heads at
the local flying field. Links to components used can be found on the last page of the user
guide. The modular design means it has the capability to be broken down into smaller
sections for either easy transporting or changing parts should it be required.
AIRCRAFT HISTORY:
The Pond Racer is a unique and innovative high-speed aircraft that stands out among its
contemporaries. It was designed and built by Robert J. Pond, a renowned aviation enthusiast
and president of the R.J. Pond Company, Inc. The aircraft first took to the air in 1991, and it
immediately captured the imagination of aviation enthusiasts around the world.
One of the most striking features of the Pond Racer was its sleek and streamlined design,
which gave it an unmistakable appearance in the skies. Its distinctive shape and impressive
speed capabilities made it a favorite among aviation enthusiasts and spectators alike.
The Pond Racer was flown in several air races throughout the 1990s, often competing
against other high-performance aircraft like the Mustang and the Bearcat, and it held its own
against these formidable competitors.
In addition to its racing success, the Pond Racer also played a vital role in the development
of new aviation technologies. Its innovative design and use of advanced materials helped
pave the way for future aircraft designs and engineering advancements.
Today, the Pond Racer remains an iconic aircraft in the world of aviation. Its unique design,
impressive speed capabilities, and important contributions to aviation history continue to
make it a source of inspiration and admiration for aviation enthusiasts around the world.

HELP US CONTINUE TO PRODUCE QUALITY MODELS
This model has taken many hours of hard work and testing in order to provide a nice flying
aircraft. Please do not share it. Please show your appreciation by directing interested parties
to the link below.
https://cults3d.com/en/3d-model/various/pond-racer-1200mm
GENERAL SPECIFICATIONS
WINGSPAN: 1200mm
PRINT WEIGHT: 1600g
FLYING WEIGHT: 2450g
CENTER OF GRAVITY 32mm aft of L.E at wing root. (Marked with indentation)
ELECTRICS
MOTOR: 3548 900kv
ESC: 40 amp (min for 3s)
SERVOS: standard 9g
BATTERY: 2200mah 3s 50c (175g) (or similar)
INCLUDED WITH THESE FILES
STL files for all parts
FFF factory files for Simplify 3d
GCODE files for all components
Print settings guide
Print orientation images (POI)
NOTE!
MINIMUM BUILD VOLUME: 200mm x 200mm x 200mm

Different coloured parts indicate sections which can be attached or separated from
neighboring components with the use of m2 screws or magnets.

REQUIRED TOOLS:
KNIFE
LIGHTER
SANDPAPER (MEDIUM GRIT)
PLIERS
CA GLUE + HOT GLUE
SCREW DRIVERS (PHILLIPS AND HEX)
FILE (flat)
DRILL AND BITS (1mm, 2mm)
REQUIRED COMPONENTS:
X2 3548 900kv
X2 11x10 propeller
X2 40amp esc (for 3s operations)
X2 2200mah 3s 50c LIPO OR SIMILAR
(175g)
X6 9g servo
X2 2.5kg retracts 4mm pin
X2 landing gear leg 120mm long
Hardened stainless steel rod 4mm (x2
50mm min)
1mm Piano wire
X2 1.5mm Piano wire (350mm min)
X8 10mm X 10mm X 2mm Magnet
(ROUND)
X18 16x29mm nylon hinges (OPTIONAL)
X6 m1.5 linkage stopper
M2 screws (6mm, 10mm, 14mm, 20mm)
X8 M3 screws (25mm) (for landing gear)
X3 10mm round carbon tube (500mm)
X1 3mm square carbon tube (65mm min)
X2 3mm carbon tube (200mm)
X1 25mm foam wheel (tail wheel)
Velcro
Braided fishing line (or similar)
Bamboo skewers 3mm
Small extension spring 0.3mm
X2 Extension spring 1.2x30x8mm (for grass
runways)

ASSEMBLY INSTRUCTIONS
All faces which are to be glued to other parts need to be given a light sanding (scuff the
surface) to assist with glue adhesion.
Almost all components which are to be joined will have 3mm alignment pin holes printed into
the mating faces of the parts. Cut 10mm sections of 3mm skewer and place them into the
alignment holes.
NOTE - It may be required to open up the holes a small amount if the fit is too tight. Do this
by using a 3mm drill bit. Gently spin it in reverse as you insert it into the hole. This will ensure
the bit does not tear the print.
Test fit the sections of the fuse before gluing to ensure a clean fit.

1 CENTER FUSELAGE ASSEMBLY
- Glue Center fuselage sections 1-5 of the fuse together.
- Glue the sections of the vertical stabilizer together and then to the center fuselage
section.
- Once glued, with a sharp knife, remove the false floor of the battery hatch. (see pic/
highlighted faces)
Should look like this!

2 RUDDER AND TAIL WHEEL ASSEMBLY
- Glue the sections of the Rudder together and bend up a tailwheel axle to mount into
the rudder.
- Mount the 20-25mm tail wheel and secure it in place with a m1.5 collar.
- Glue the tail wheel assembly into the Rudder using CA.(the fitment should be tight)
- Test fit nylon hinges into the Rudder and the Vertical stabilizer, then once happy with
the fitment and rotation, glue the Rudder in place with CA.
TIP: After adding the CA, use a tissue to wipe away the excess.
IMPORTANT! Only 2 drops of CA is needed for each slot for the hinges. Too much CA and
the hinge will bind and be unusable.

3 HORIZONTAL STABILIZER ASSEMBLY
- Glue the sections of the elevator together. NOTE- the elevator horn is on the top side
when fitted to the horizontal stabilizer.
- Test fit the elevators to the horizontal stabilizer using the nylon hinges, then glue them
in place.
- Cut one 110mm (front) and one 45mm (rear) section of 3mm round carbon rod. These
will be used to brace the horizontal stabilizer against the center fuselage. (indicated in
green)
- Cut one 50mm length of square carbon rod. This will be the torque tube through the
fuselage to operate the right elevator. (indicated in blue)

- Test fit the horizontal stabilizer to the center fuselage section by securing it with an
m2 x 10mm screw.
- Install the elevator and rudder servo. Use a 1.5mm push rod to connect the elevator
and rudder to their respective servo’s through the printed bowden tubes in the
fuselage.
- Remove the horizontal stabilizer for later installation.

4 CANOPY/BATTERY COVER ASSEMBLY
- Glue the respective sections of the canopy and battery bay covers together using CA.
- Glue the magnets into the canopy, battery bay covers, center fuselage and motor pod
sections.
5 MOTOR POD ASSEMBLY
- Glue sections 2-6 of the motor pod together using CA. Leave off section one until after
installing the motor.
- Glue the pod fins to the tail of the motor pods.
- Using a sharp knife, remove the false floor of the motor pod battery bay. Use a
soldering iron, remove the other faces highlighted in red.
OUTBOARD
INBOARD

6 MOTOR INSTALLATION
- Install the motor using m2 or m3 screws.
- Check the fitment and spacing of fuse 1 to the spinner backplate and add washers as
required. There should be a 1mm gap between the spinner backplate and the front of
fuse 1.
7 LANDING GEAR INSTALLATION
- Using a soldering iron, remove the indented face highlighted in red from the gear bay.
This will allow the servo wire for the retract to pass into the motor pod fuselage.
- Install the gear door blocker to the upper section of the leg using the bolt that holds
the gear spring in place on the gear leg. It should face inwards towards the center of
the model.
- For long grass, the stock spring should be exchanged for a 1.2mm x 30mm x 8mm
spring. (pictured below)

- Install the gear leg into the retract.
- Install the retract into the gear bay using m3 x 25mm screws.
- Fit a connecting wire long enough that it will reach the center fuselage section and
leave the wire in the motor pod battery bay.
8 GEAR DOOR INSTALLATION
- Use a 1mm drill bit on the gear door control arm to ensure the tension spring will be
able to be installed.
- Glue the sections of the gear doors together.
- Cut 15mm lengths of th 1mm push rod and insert them into the gear door hinge
plates.
- Test fit the Gear door to the motor pod with the hinge plates loosely fitted. The hinge
plates have small indentations indicating their position.
1 dot = front hinge plate
2 dots = middle hinge plate
3 dots = rear hinge plate
- Once happy with the fitment, glue the pins to the hinge plates with a small amount of
CA.
- Using small m2 x 6mm screws, install the gear door to the motor pod.

- Attached a small length (5mm or less) of small extension spring to a length of braided
line. This will be the tension wire which pulls the gear door closed when retracting the
gear.
- Fit the other end of the braided line to an m2 x 8mm screw and install the screw into
the gear bay. There should be a very small amount of tension on the spring when the
gear is down.
- As the gear is retracted, check the tension on the gear door. Adjust the screw to
increase or decrease the tension on the gear door.

9 CENTER WING ASSEMBLY
- Glue inner wing (1) sections of the center wings together.
- Cut an 180mm length of 10mm round carbon tube and insert it through the inner wing
sections.
- Glue inner wing (2) sections to the center wing assembly.
ASSEMBLED INNER WING SECTION

- Glue the sections of the inner flap together
- Test fit the inner flap to the inner wing section using the nylon pinned hinges. Check
that the flap does not bind with the center fuselage section or the motor pod through
its range of travel.
- Glue the inner flap sections to the inner wing assembly.
- Install the flap servo to the flap servo cover using supplied screws.
- Install the flap servo cover into the wing using m2 screws and connect up the flap
using 1mm pushrod. The servo wire should feed into the center section of the inner
wing which will later pass into the center fuselage section.
- Cut a 140mm length of 3mm square carbon tube and install it into the inner flap.

10 OUTER WING ASSEMBLY
- Glue the sections of the outer wing together using CA.
- Glue the sections of the ailerons together and fit the aileron to the outer wing section.
- Glue the aileron and outer flap to the wing using nylon hinges.
- Install the aileron servo to the servo mount plate and screw the mount plate to the
outer wing section.
- Connect the aileron servo to the aileron using 1mm pushrod. The outer flap will be
connected in the final assembly with the torque tube from the inner flap.

11 WIRING
- Wire up the esc’s so that there is a common positive and negative wire connecting the
two. This will ensure the motors spin with the same rpm and power reducing the
chances of adverse thrust.
- The wiring tunnel splits into two tunnels inside the center wing section. One forward
and one aft. The power leads for connecting the esc should be fed through the
forward tunnel and all the servo wires through the aft tunnel.

- Connect up the gear, ailerons, flaps, elevator and rudder to the receiver.