Aviation Design Falcon 7X User manual

AVIATION DESIGN - ZI le Chenet - 91490 MILLY LA FORET – FRANCE - Tel : int+ 33 1 64 98 93 93 - [e-mail] – www.adjets.com
1
Dassault Aviation
FALCON 7 X
for Jet CAT P160
Assembly Manual
AVIATION Design
AVIATION Design AVIATION Design
AVIATION Design
ZI le chenet, 91490 Milly La Foret, FRANCE
Tel : [phone]
Fax : [phone]
E-mail : [e-mail]
www.adjets.com
Version 01/08/2008

AVIATION DESIGN - ZI le Chenet - 91490 MILLY LA FORET – FRANCE - Tel : int+ 33 1 64 98 93 93 - [e-mail] – www.adjets.com
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INTRODUCTION
The Falcon 7X from AVIATION DESIGN is a very large model designed for a single high thrust and light
turbine.
It is fully molded in fiberglass, carbon and epoxy.
All plywood reinforcements are already glued.
The flight characteristics are excellent with very good low speed capability.
The model has plug in wings and stabs.
The Falcon 7 X will operate from prepared grass fields (250 meters long) or tarmac surfaces (150 m).
KIT FEATURES: ref ADJ 500
- High quality, white gel-coated epoxy-
glass fuselage. The fuselage is in two
parts for ease of handling and
transportation.
- Nose cone and door for radio access
molded in carbon epoxy
- 1 Epoxy-glass inlet ducting
- Fully molded epoxy carbon wings
with tube for aluminum spar and gear
support already glued.
- Fully molded epoxy carbon stabs with
tube already glued
- 2 Winglets
- 2 engine nacelles
- Carbon gear doors
- 2 carbon stab spars
- 2 aluminum wing and engine tubes
- All clear canopy CNC cut.
- Foam floor CNC cut.
- All hardware (screws, servo cover,)
- Instructions in English.
Parts required to complete the kit:
Turbine:
One Jet Cat P160 SE turbine or any light 16 kg thrust turbine.
Turbine must be as slight as possible to reduce CG problem
Kevlar Fuel tanks: ref ADJ 640 KU
Two Fuel cells molded in Kevlar with a 4.2L capacity
Includes tubing, nipples and clunks + 1 hopper tank
Can be used if you fit the interior in the fuselage. Two Fuel tanks fit under the floor
Kevlar Fuel tanks: ref ADJ 641 KU
One Fuel cell molded in Kevlar. Capacity: 4.2 liters
Includes tubing, nipples and clunks + 1 hopper tank
Can be used if you do not fit the interior in the fuselage. Fuel tank fits in the middle of the fuselage

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Landing gear: ref: ADJ 635
Aviation Design scale retractable landing gear is
specially designed for the Falcon 7X.
It is made in aluminum and steel.
It includes 3 retracts system, 3 scale oleo struts, 4 way
valve, tubing, connectors, air tank and filling valve.
Wheels set + brakes: ref: ADJ 637
This set includes:
4 x 130 mm diameter wheels + scale cover + four brakes.
CNC machined on bearings
2 x 55 mm diameter scale front wheel. CNC machined on
bearings
Includes valve, tubing, connectors, air tank, filling valve.
Gear door kit: ref: ADJ 638
Includes four air cylinders, electronic gear door cycler, 4-way valve, tubing, connectors, door hinges and
ball links.
Not included in the different package:
Self-adhesive foam tape
0.2 kg epoxy and glass fiber
ZAP CA
DISCLAIMER
AVIATION Design 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.
FIBREGLASS PREPARATION
The inside of the fuselage should be sanded with fresh #80-grit paper for best glue adhesion where
bulkheads and other attachments are fixed.
GLUING TECHNIQUES
All the plywood formers should be fitted with cyano adhesive and then glued with epoxy and glass fiber
tape. All other parts should be glued with epoxy.

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CONSTRUCTION
Stab assembly:
Elevator control surface must be installed carefully. All hinges must be glued perfectly and there must be
no play in hinges, linkage and servo
Cut the stabs according to the engraved panel lines with a Dremel saw (fine saw) or with a diamond disk
Sand the balsa inserted in the stab into ½ V shape as shown below.
Drill four x 5 mm holes in the trailing edge stab for the hinge location.
Drill each stab for the four hinges on the top surface limit
Insert and glue with epoxy the four hinges in the balsa rib. (put some grease or oil on the pin axis to avoid
gluing them)
Drill the corresponding hole in the stabs.
Insert and glue with epoxy the four hinges in the control surface. Check that the control surface can rotate
freely. All hinges must be perfectly glued.

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Cut the holes in the lower skin of the stabs according to the engraved panel lines for the servo covers
Make a 2 mm slot in the control surface for control horn.
Glue the control horn with epoxy.
Install glue and screw the servo in the servo cover.
Insert in the stab the servo extension lead
Make a hole in the stab root for the servo lead.
Connect the servo and the control horn with two x M3 links and M3
threaded rod.
Apply thread lock.
There must be no play.

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Joining the two stabs:
Check the rear fuselage for
the location for the two
stab joining carbon spars.
Drill 2 X 16 mm hole in
the rudder at the correct
location.
Fit the 2 carbon spars
through the rudder. The
Short spar is at the front,
longer at the rear. Both
must be anhedral.
Fit the two stabs on each
side.
Check that the distance
between the top of the
rudder and the tip of the
left and right stabs are
equal.
Glue with slow epoxy and
microballoon the two carbon spars in the rudder.
Put some wax in the stab tube and fit the 2 stabs on the fuselage
Check again that the distance between the top of the rudder and the tip of the left and right stabs are equal.
Hold it in location with tape.
Let it dry overnight.
Make a hole in the fin for the elevator servo lead.

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Fit the top fin pod.
The top fin pod is optional on the real airplane. The
satellite phone antenna is inside.
If you want to put this pod, just sand carefully the
fin and glue with epoxy the top pod.
Fit the rudder underfairing.
The fin fairing has been added after the first flight on the real airplane.
If you want to put this fairing, just sand carefully the fin and glue it with epoxy.

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Fit the rudder on the fin.
Cut the rudder according to the engraved panel lines with a Dremel saw (fine saw) or with a diamond disk
Sand the balsa inserted in the fin with a half round Perma Grit tool to have half round in the fin
Sand the control surface half round
Drill 3 X 5 mm holes in the trailing edge fin for the hinge locations.
Insert and glue with epoxy the three hinges in the balsa rib.
Drill the corresponding hole in the rudder.
Insert and glue with epoxy the three hinges in the control surface. Check that the control surface can rotate
freely. All hinges must be perfectly glued.
Cut the hole in the fin skin according to the engraved panel lines for the servo cover
Make a 2 mm slot in the control surface for control horn.
Glue the control horn with epoxy.
Install glue and screw the servo in the servo cover.
Insert in the rudder the servo extension lead
Connect the servo and the control horn with two x M3 links and M3 threaded rod.

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Engine hatch
Cut the engine hatch according to the engraved panel lines with a Dremel saw (fine saw) or with a
diamond disk
Cut the engine hatch in 2 half
Glue two door hinges on each side of the door
Fit engine hatch latches or screws on each side of the doors to have an easy access to the engine

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Inlet ducting:
Fit the inlet ducting in the fuselage.
Fit the plywood ring in the
fuselage and fit the fiber
ducting through the ring
Glue the fiber ducting, the
plywood ring and the fuselage
with epoxy.
Glue the fiber ring cover on
both surfaces with
microballoon

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Engine nacelle:
Check the rear of the fuselage for the location of the
two engine nacelles.
Drill a 6 mm hole in the fuselage for the nacelle pins at
the correct location.
Drill a 25 mm hole in the fuselage for the nacelle axis
at the correct location.
Insert the 25 mm diameter fiber tube in the fuselage
Put some wax on the aluminum tube.
Fit the aluminum tube through the fuselage, through the
fiber tube, and through the plywood reinforcements and
fit the two engine nacelles on each side.
Glue with slow epoxy and microballoon the fiber tube
and the two round pin reinforcement plywood pieces.
Let it dry overnight.
Glue the fan cover at the limit of the engine nacelle
Secure the engine nacelle with one x M3x16 mm screw on each side through the aluminum tube

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Wings:
Ailerons must be installed carefully. All hinges must be glued perfectly and there must be no play in
hinges, linkages and servos.
Cut the ailerons according to the engraved panel lines with a Dremel saw (fine saw) or with a diamond
disk
Sand the balsa inserted in the stab in ½ V shape
Drill three 5 mm holes for the hinges locations.
Drill each wing for the three hinges at the limit of the top surface
Insert and glue with epoxy the three hinges in the balsa rib. (put some grease or oil on the pin axis to avoid
gluing them)
Drill the corresponding hole in the ailerons.
Insert and glue with epoxy the three hinges in the control surface. Check that the control surface can rotate
freely. All hinges must be perfectly glued.
Cut the holes in the lower skin of the wings according to the engraved panel lines for the servo covers
Make a 2 mm slot in the aileron for the control horn.
Glue the control horn with epoxy.

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Install, glue and screw the servo in the servo cover.
Insert the servo extension lead in the wing.
Connect the servo and
the control horn with 2 x
M3 links and M3
threaded rod.
Apply thread lock.
There must be no play.
Flaps:
Flaps can be installed like the ailerons.
However, the flight performance does not change or improve with flaps. Flaps fully down do not do much
drag and do not improve lift. So it is possible not fit the flaps and save 2 servos and some weight.

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Front FUSELAGE
Assembling the nose gear
Cut the front gear door according to the engraved panel lines.
Put the 2 wood ribs forward for a better access from the gear door
Glue on them the 4 mm plywood reinforcement at the limit of the second rib reinforcement
Put the front gear on the wood ribs and plywood
Drill 4 x 2mm hole through the plywood and wood ribs
Screw with 4 x 3mm x 20mm parker screw the front gear on the support
Put backward the wood ribs with gear so that the plywood
reinforcement touches the plywood frame.
Put the front strut in the front gear and secure the gear screws.
Check that the front wheel retract and extend without problem.
Adjust position (forward or backward) if necessary.
Glue the two wood spars in the plywood frame.
Put the steering servo on one side on the pilot floor.
Connect servo to the steering arm.

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Battery support:
Glue the plywood battery support on the two
wood gear ribs
Glue some small plywood reinforcements (4
pieces, 1 top, 1 bottom, 1 left and 1 right) to
screw the nose on them.
Assembling the wing joining tube:
Check on the front fuselage the location for the 2-wing aluminum joining tube.
Drill 2 X 30 mm hole in the fuselage at the correct location.
Insert the 2 x 30 mm diameter fiber tube in the fuselage
The short tube in the front one, the rear tube is the long one. Mark them (front and rear)
Put some wax on the aluminum tubes.
Fit the aluminum tubes through the fuselage, through the fiber tube, and through the plywood
reinforcements and fit the two wings.
Glue with slow epoxy and microballoon the two fiber tubes and the two plywood reinforcements.
Let it dry overnight.

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Assembling the fuselage gear support:
Cut the 2 main gear door
Insert the two plywood reinforcements
Insert the 20 mm x 30 mm gear support
wood spare through the fuselage
Fit the two wings on the fuselage and check
that the gear support fit correctly in the
wing plywood support.
Glue with slow epoxy and microballoon the
gear wood support tube and the two
plywood reinforcements.
Let it dry overnight.
Main Gear
Assemble the two wings to the fuselage
Put the model inverted
Put the 2 gear on their supports
Check that the gears retract and extend without problem. Adjust position if necessary
Trim fuselage and wings so that the gears do not touch them.
Drill the 4 x 2 mm hole for the gear screws
Screw the gear with four 4x20mm parker screw

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To disassemble the model, remove only the rear screw so that the gears stay on the fuselage.
So when the model is in the normal position without wings (not inverted), it can stay on its three gears.
Main Gear door
Assemble the two wings onto the fuselage
Put the model inverted
Align the gear doors with the fuselage.
Fuselage door:
Put 3 gear door hinges in the fuselage on each side
Screw the steel ball link on the hinge
Screw the link to the 2” air cylinder
Adjust the position of the air cylinder and screw it on the plywood frame to have gear door closed when
cylinder is closed.
Check that it opens and closes without problem

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Wing door:
Attach the gear door to the aluminum gear supports with flat hinges
Connect the gear door to the strut with plastic ball link and adjust the length so that the door closes when
the gear retracts
Check that it opens and closes without problem
Front gear door:
Cut the front gear door in 3 parts according to the photos
Put 2 gear door hinges on each front gear door

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Drill a 2 mm hole in the front door hinge and screw the ball link on the hinge
Screw the ball link plastic end to the 1” air cylinder
Extend the air cylinder
Screw the air cylinder with the parker screw to have gear door closed when cylinder is closed
Check that it opens and closes without problem
Put 2 flat hinges on the rear front gear door
Attach the gear door to the front oleo strut so that the door is closed when gear is retracted
Landing Gear and door tubing:
Fit the wheels and brakes on the gears.
You have now to connect all the gear, door and brake tubing.

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Kevlar Fuel Tanks:
The Kevlar fuel tanks are 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 kerosene and let them during 1 hour full of
fuel.
Check carefully that your fuel tanks have no leaks.
You will now have to install the fuel tanks in the front section
of the fuselage before proceeding with the assembly.
There are now two possibilities:
- If you fit the cockpit interior with floor, you will have to use
the two Kevlar tanks fitted under the two mains wing tubes.
- If you do not fit a cockpit interior, it is simpler to use one single large Kevlar fuel tank fitted on the top
of the two mains wing tubes
Glue the first plywood fuel tank mounting on the front
fiber tube
Glue the second plywood fuel tank mounting on the back
of the rear fiber tube
Fit the Kevlar fuel tank on the mounting and hold it with
rubber or plastic T rap