Aviation Design F-16 User manual

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F-16
for AMT Pegasus jet engine
or AMT Mercury
or Jet CAT 120
Assembly
Manual



ZI le chenet, 91490 Milly La Foret, FRANCE
Tel : [phone]
Fax : [phone]
E-mail : [email protected]
www.adjets.com
Version 01/03/2006

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INTRODUCTION
The F-16 ARF from  is designed for high thrust jet engines.
It is a scale kit, with all the panel lines engraved in the fuselage and a lot of scale details (gears, hinges,
cockpit...). It is fully molded in fiberglass, carbon and epoxy.
The flight characteristics are excellent with low and high speed capability.
The model has plug in wings, stabs and fin.
The F-16 will operate from prepared grass fields (70 meters long) or tarmac surfaces.
F-16 ARF model includes
- High quality epoxy-glass fuselage painted.
- All plywood and wood parts premounted.
- Epoxy-glass inlet fitted
- Highly detailed exhaust nozzle.
- Fully molded wings, stabs and fin and underfin painted
- Access hatch requiring no additional framework.
- ABS cockpit interior.
- Clear formed canopy.
- All hardware (ball links, bearings, screws ...)
- Instructions in English.
To complete the kit :
The following items are not included in the kit. They are available from .
Jet Engine :
1 Complete AMT Pegasus or Mercury jet engine
or 1 Jet Cat P80 or P120
Kevlar Fuel tank : ref ADJ 382
Fuel cell molded in kevlar. Capacity : 3.2 liters
Include tubing, nipples and clunks + 1 upper tank
Cockpit detail kit : ref : ADJ 355
This kit include :
1/7 full body jet pilot, 1/7 ejector seat & instrument panel.
Landing gear : ref : ADJ 360
 retractable landing gear is specially designed for the F-16.
It is made in aluminium and include also plastic parts
It includes 3 rotating retracts system, 3 oleo legs, 4 way valve, tubing, connectors, air tank, filling valve, ...
Gear doors kit : ref : ADJ 375
Include 3 air cylinders, electronic gear door cycler, 4 way valve, tubing, connectors, air tank, door hinges,
ball links

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Wheels set + brakes : ref : ADJ 370
This set include:
2 x 100 mm diameter wheels + scale cover + brakes
2 x 55 mm diameter front wheels
It includes valve, tubing, connectors, air tank, filling valve.
Variable pressure brake control valve : ref : ADT Brk
Double walded stainless steel tailpipe : ref : ADJ 390
2 wing tip missiles : ref : ADJ 385
Missile tube is in resin. All fins are in ABS
2 Underwing fuel tank : ref : ADJ 386
Fully molded , white gel-coated epoxy-glass. Rails included
2 x 2000 lbs bombs + rails : ref : ADJ 387
Fully molded , white gel-coated epoxy-glass. Rails included. Details in resin included
6 x 500 lbs bombs + rails : ref : ADJ 388
6 Vacuum bomb , rails and triple ejector molded in epoxy-glass. Details in resin included
New super scale water decals :
USAF 512 TSF version
USAF Tigermeet version
USAF 510 Buzzard 01
USAF prototype version
Norvegian air Force
More versions in near futur
-

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DISCLAIMER
 assumes no liability for the operation and use of these products.
The owner and operator of these products should have the necessary experience and exercise common
sense. Said owner and operator must have a valid Model Airplane license and insurance, as required.
CONSTRUCTION
Fuselage :
It is possible to let the fuselage in 2 parts for transportation.
If you want to dismantle it easily, cut and glue 2 mm plywood reinforcement in the front fuselage.
You'll just have to screw the 2 parts together with 4 x 3 mm diameter screws.
Don't forget to glue the 4 screws with threadlock before to fly ......
Gear doors :
Cut the front gear door according to the engraved panel
lines with fine diamond disc.
Glue the 2 door hinges with cyano (take care of the
position according to the drawing).
For this operation in order to avoid glue to “harden” the
hinges put a small drop of oil in the pivot point.
Cut the 2 main gear doors according to the
engraved panel lines.
Glue the 2 x 3 door hinges with cyano (take care
of the position according to the drawing).
For this operation in order to avoid glue to
“harden” the hinges put a small drop of oil in the
pivot point.

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Assembling the nose section on the rear fuselage :
Adjust the 2 part of the fuselage together and drill 3 x 3 mm
hole in the fuselage through C25 and C26.
Insert 3x M3 blind nuts in C25 and C26
MAIN LANDING GEAR :
Insert the 2 retracts between C8 and C9.
Fit the oleo legs in the retracts. Check that
the 2 wheels are parallel. Screw the leg in
the retracts.
Retract and extend the legs to check that the
wheels fit well in the fuselage.
Screw the landing gear on C8 / C9
You will be obliged to make 2 small holes in
the fuselage at the rear of the landing gear to
screw the retracts
Connect all the retract tubing according the
manual.

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Front landing gear :
Screw the front landing gear on C30 with 4 x d.3x10 mm
parker screws
Screw the servo on the servo fitting
Screw the servo fitting on C30
The steering servo should be a 3 kg.cm servo
Connect the servo to nose gear steering arm with 2 x M2
link and M2 threaded rod (30 mm long).
The M2 link should be connected in the arm hole closest to
the gear axis.
Retract and extend the front leg to check that the wheel perfectly rotate
during retraction.
Screw a ball link on the 1" air cylinder. Screw the air cylinder on C34.
Screw the ball of the ball link on C35
Glue C35 on the front gear door.
Connect the link to the ball link and check that the door closes perfectly : the door is open when the
cylinder is fully extended and the door is closed when the air cylinder is retracted.

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Front landing gear :
Screw C30 and the front landing gear on C33 and C31 with 4 x d3x16 mm parker screw
Front gear door :
Glue the vacuum part with CA
on the front gear door.

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Main gear doors
Screw a ball link on the 1.5" air cylinder. Screw the air cylinder on C36.
Glue C36 to the fuselage according to the drawing and pics.
Screw the ball of the ball link on C37
Glue C37 on the main gear door.
Connect the link to the ball ling and check that the door close perfectly : the door is open when the
cylinder is fully extended and the door is closed when the air cylinder is retracted.
Now, C36 and C37 must be glued with epoxy and glass fiber.
Connect all air tubing
Now connect all the landing gear tubing and the gear door tubing.

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The 2 Robart 2 way valves can be mounted on a plywood frame and glued in the front fuselage.
Wheels and brakes
Glue the 6 mm diameter screws with threadlock in the legs
Connect the system according to the manual.
Do not remove the O ring inthe brake drum
Separate rubber tires and O ring are available in spare parts.
Usually, we use the brakes on fully elevator down stick.
Fill the system with an air pump or compressor at a maximum pressure 100 Psi / 8 bars before each flight
Variable pressure brakes control valve : ref ADT brk
Connect the valve instead of the air micro switch
Usually, we use the brakes on elevator down stick. The braking effect will be proportional to the stick
travel.

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Bearings installation
You will have 2 bearings per stabs.
One bearing is fitted in the fuselage in its
location.
You can glue it or not in the fuselage.
The second one is mounted in the aluminium
bearing mount.
Just glue the bearing in the aluminium block
with threadlock.
Now fit the stab in the fuselage and of course
in the first ball bearing.
Insert the second ball bearing front the back
of the fuselage and fit it on the stab aluminium
tube.
Take care of the good side to install it. (see
drawing)
Slide C11 between C10 and the aluminium
bearing mount.
Adjust the clearance between the fuselage and
the stab in controlling the
thickness of C11.
If necessary trim it or do it a little bigger.
If the clearance is well adjusted, drill 2 x 3 mm
hole in C11 and C10 to
screw the bearing mount.
Glue C11 and screw them with 2 x 3 mm allen
screw.
Check again the clearance of the stab and the
fuselage. The stab must not
touch the fuselage when it rotate.
Do the same for the 2 stabs.
Servos installation
Important : the servo MUST be a very high
quality servo, 9 kg torque minimum, with metallic
gears.
Screw the servo on C15
Glue C15 to the fuselage according to the plan.
Now, C15 must be glued with epoxy and glass
fiber.
The servo lead must be glue to the fuselage and
protected with ceramic fiber.
The servo arm can be protected with ceramic fiber if it is made of plastic.

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Stabs installation
Important : the 2 stabs MUST be balanced
You will have to drill a hole in the stab root and glue some lest in the leading edge to balance them.
You will need approximately 35 grams of lest per stabs.
When the stabs is fitted in the 2 bearings, it must
be free in rotation : not hard point, no unbalance.
You have to glue with epoxy the 2 aluminium pin
(d; 8 mm x 20 mm long) in the stab tube to
reinforce them when you will have to drill and
tappered
Send the aluminium pin and insinde the
aluminium tube for best glue adhesion. Insert
some epoxy in the tube and fit the pin inside.
Slide the stab in the bearings and control that it is
fully fitted in them.
Slide the plastic washer on the aluminium tube in
the fuselage
Slide the aluminium control arm on the tube
Put the stab horizontal.
Put the control arm vertical.
Drill a 2.5 mm hole through the arm
and through the aluminium tube.
Tapping them with M3 screw-tap.
Connect the servo to the arm with the
large M4 ball link, M4 threaded rod
and M3 metallic link
Glue them with threadlock.
You can cut the trailing edge tip with a Dremel saw depending of the version you want to do : A or C
version The first A version have the trailing edge normal, the latest A and all the C version have the
trailing edge tip cutted.
FIN INSTALLATION :
The fin and the fin pod are molded in 2 parts with
pin alignment.
You are not obliged to glue the 2 parts together.
Drill a 2.5 mm hole through the fin tube, the 12
mm tube and C10 - C13 - C13 to secure the fin
Insert a 3 mm screw to lock the fin.

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VENTRAL FINS INSTALLATION :
You can now glue with silicone glue the ventral fins to the fuselage.
Installation of the AMT jet engine.
The AMT is just screwed with 4x 3mm diameter srews on plywood engine mount with blind nuts.
The ECU and the AMT Batterie is put in the nose close to the landing gear.
With this configuration, the Rafale don't need any ballast to balance the model. Balance the model with the
gear down and the fuel tanks empty.
Kevlar Fuel Tanks :
You will now have to install the fuel tank in the fuselage.
The kevlar fuel tank is pre build.
Connect the tubing and clunk.
Check that the clunk can move freely.
You have now to check that your fuel tanks have no leaks.
Fill them fully with kerosen and let them during 1 hour full of fuel.
Check carefully that your fuel tanks have no leaks.
Take care to not drill the fuel tanks with the screws when you assemble your model (screws
who join front and rear fuselage)
You can now fit kevlar fuel tank in the F16
Kevlar fuel tank are conformal fuel tank with a 3.2 liters capacity
It just slide on the air intake.
Connect all tubing as the following drawing.
This fuel tank is connected to a small catch tank (200 cc) to be sure that there is no bubble in the fuel line.
The tubing from the main tanks to the catch tank and to the catch tank to the fuel pump must be gasoline
tubing (no silicone tubing). Also for the air vent tube.
The catch tank is glue with double face tape.

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Filling the fuel tanks :
Connect your pump and fill the system in direction of the catch tank. It will first fill the catch tank and
after the main tanks. The main tank will be full when fuel come from the 2 air vent tube.
When tanks are full, close the filling tubing.
Do not close the air vent tube.
The system is ready for starting.
TAILPIPE EXHAUST
Fit in the fuselage the 2 plywood frames to hold the tailpipe.
Small slot in the rear frame must be up
Tailpipe will be screw on the front frame with 3 x 3 mm
diameter parker screw at 120°
Adjust the position of the front frame with the position of the
end of the engine / beginning of the exhaust tube
Slide the back of the tailpipe in the rear frame (top of the frame has a small slot)
Glue the front and back frame with silicone glue.
You can also glue the tailpipe to the rear frame with silicone glue
Exhaust nozzle
The exhaust nozzle can be screw (2 parker screws) on the fuselage
It can also be glued with silicone glue to the end of the fuselage.

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CANOPY
Fit the canopy frame on the fuselage.
Drill a 3 mm hole through the front of the canopy frames
and the fuselage
Glue the hatch latch in the fuselage.
Drill 2 holes in the frames and in the fuselage for the 2
rear pins
Glue the 2 pins in the canopy frame.
Paint now the canopy frame (inside and outside).
Adjust the canopy in the canopy frame.
The canopy must overlap the frame from few mm.
Hold the canopy in position using some tape.
Glue the canopy inside the frame with ZAP canopy glue.
Rear canopy
Adjust the rear canopy to the fuselage.
Check that there is no step with the front canopy.
Glue the canopy to the fuselage with ZAP canopy glue.
Hold the canopy in position using some tape.
Fuselage hatch
Glue 2 wood hatch pins with CA.
Glue the hatch latch and drill the corresponding hole in the fuselage.
Fuel tank :
Connect them according to the plan
Connect them to a small catch tank (200 cc) to be sure that there is no bubble in the fuel line.
All the tubing must be gasoline tubing (no silicone tubing).
Don’t forget the air vent tube.
The catch tank is glue with double face tape on the top of the air intake.

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Filling the fuel tanks :
You have to disconnect the tubing between the fuel pump and the catch tank.
Connect your pump and fill the system in direction of the tank. It will first fill the catch tank and after the
main tank. The main tank will be full when fuel come from the air vent tube.
Do not close the air vent tube after.
Connect back the pump with the catch tank. The system is ready for starting.
Rudder :
If you want to fit a rudder, we highly recommand
to cut only half the size of the real plane rudder
to minimize flutter problem.
Cut the rudder as panel line engraved (half
wingspan)
Glue in the fin and in the rudder a balsa spar (15
mm large in both side)
Put 4 large Robart hinges
Cut a hole in the rudder for the servo
Fit control horn and link. Check that there is no
play in the rudder

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Cockpit detail kit :
The first step is to assemble the ejector seat :
Cut the vacuum parts as shown
Glue with CA the 2 vacuum parts and the 2 plastic parts according to
the plan.
Drill a hole in the ejector seat head to fit the plastic horns.
Glue it with CA
Glue with CA the plastic part at the rear of the ejector seat.
The second step is to cut the pilot foot and the pilot backside.

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The third step is to fit all the part in the cockpit
Fit the ejector seat in the ABS vacuum part.
Fit the pilot and instrument panel.
You should have to heat the pilot (with a air gun
heater) to fit it in the cockpit with the good angle
and to slide the instrument panel between its legs.
If everything is OK, you have to paint all the parts
first before to glue them.
Glue the ejector seat in first.
After glue the pilot.
After glue the instrument panel.
And glue the instrument panel cover.

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3 Oleo legs :
The front oleo leg :
The front oleo leg (the Robart one) must be cutted as follow :
Use a dremel cutoff wheel and deburr the tube after cutting.
Remove the plastic washer from the strut.
Select the 3/16 adapter bushing and insert flush with the top of the tube
Secure it with threated lock.
Follow the other step of the Robart assembly manual.
The main oleo legs :
The damping is accomplished by the use of a rubber O ring in conjunction
with a special formulated lubricant.
To maintain damping the lubricant needs to be replenished regulary or when
found necessary.
Furthermore if the legs becomes contaminated with dust or grit etc then the
existing lubricant should be removed using paraffin as a solvent prior to
replacement.
To re-lubricate, remove the cap screw from the sliding bearing, withdraw the
leg and if clean smear on a thin coat of lubricant above the O ring.
Insert the leg carefully and replace the cap screw in the correct orientation.
Secure the wheel axis with threated lock.
FINISHING TIPS
Glue the 2 fairing on the nose, the 2 lights on the air intake
Fit the water decals on the plane