Aviation Design Rafale C User manual

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for single BF 300 turbine
or 2 x Jet Cat P 160 SX
Assembly
Manual
AVIATION Design
AVIATION Design AVIATION Design
AVIATION Design
ZI le chenet, 91490 Milly La Foret, FRANCE
Tel : [phone]
Fax : [phone]
e-mail : [email protected]
www.adjets.com
Version 15-07-2013

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INTRODUCTION
The Rafale
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Rafale is a famous French delta fighter built by Dassault Aviation.
You love very big models, you love fighter, you love agile and aerobatic jets, you love power :
The 1/5 Rafal
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Rafale
ee
e is for you.
The Rafale
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Rafale model is really incredible in flight. It is a very big models, very aerobatic with good
roll rate and incredible high angle of attack possibility. Flight is very realistic and impressive with
big turbine sound and afterburner lights.
The Rafale
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Rafale from AVIATION DESIGN is fully CAD designed. All the plug parts were CNC
machined.. It is a scale model, with all the panel lines and rivets engraved in the fuselage.
It contains many scale details, (gears, hinges, cockpit...). It is available in single seat version or in
twin seat version.
The Rafale
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Rafale is designed for either a single high thrust (30 kg) jet engine or twin standard turbine
(2x16 kg). It incorporates special inlets and ducting for both version.
Of course the Rafale
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Rafale is fully molded in composite, and pre assembled : model is painted in mold,
all bulkeads are glued, all control surfaces are hinged. No important gluing are required.
The special landing gear was designed for strong operation (grass airfield). It is CNC machined,
will aluminum gear box and steel oleo legs. The full airframe is carbon reinforced with strong
plywood gear support to accept without trouble ‘’bad landing’’.
We also designed a specific front landing gear for the Navy version. This front gear is fully CNC
machined with special cinematic for scale operation. The front fuselage structure is also specific
for Navy version (only single seat)
The model has plug in wings and fin for transportation
The Rafale
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Rafale has a removable nose cone and a large canopy for an easy access to radio.
The large fuselage hatch gives also an excellent access to the turbine, fuel system and tailpipe.
KIT FEATURES :
•High quality, grey gel-coated epoxy-glass fuselage. All the panel lines are engraved. The
fuselage is in 2 parts for an easier building.
•All the plywood formers and the necessary wood are already glued in fuselage.
•Nose cone in fiber.
•2 Exhaust nozzles in fiber.
•Canopy frame in 2 parts in fiber for Rafale C single seater version or Rafale B twin seater
version.
•Access hatch requiring no framework for single seat version or twin seat version.
•2 Epoxy-glass inlets. Ductings are designed and specific for single turbine or twin turbine
•2 Wings molded in epoxy under vacuum with carbon reinforcement, aluminum and carbon
tube fitted.
•Fully molded composite fin with carbon tube fitted.

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•2 Fully molded composite canards with carbon spare fitted.
•Scale fiber details (servo covers, …).
•ABS cockpit interior and scale accessories.
•Clear formed canopy in 2 parts for Rafale C single seater version or Rafale B twin seater
version.
•Hardware package (includes ball link M3, threaded rod, aluminum control horn and hatch
latches)
•Instructions in English.

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Parts required to complete the kit :
•Cockpit detail kit incl. 1/5 ejector seat &
scale instrument panel.
•Scale retractable landing gear for air
force version incl. 2 main retracts + 1 front
steering retract + air control system + 3
scale oleo legs. All gears are CNC
machined, with steel struts and aluminium
cisors. Very strong and reliable for grass
operation.
•Scale retractable landing gear for Navy version.
Same as the above version but with a modified special front retract. Front gear is fully
CNC machined.

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•Wheels set + brakes incl 2 main wheels +
2 front wheels, aluminium hub + bearings
+ scale brakes + air control system.
•Gear doors set incl. air cylinders, air
control system, gear door sequencer and
door hinges.
•Kevlar fuel tanks + BVM upper tanks.
2 kevlar Fuels cells . Capacity : 2 x 4.4 liters
Includes tubing, nipples and clunks + 2 BVM
upper tanks
•Details set incl. refueling probe, ECM pod
in resin, scale details.

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•Stainless steel double walded tailpipe.
•Twin exhaust double walled stainless steel
tailpipe
•2 Magic wing tip missiles.
Molded in one part in fiber with rudders and
fins included
•2 Mica wing tip missiles
Molded in one part in fiber with rudders and
fins included
•2 Mica missiles + fuselage launch rails.
Missile molded in one part in fiber with rudders
and fins included
Rail molded in fiber
•1 Supersonic centerline fuel tank +
launch rail.
Fuel tank molded in fiber with panel line and
rivets engraved
Rail molded in fiber

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•2 Supersonic underwing fuel tanks +
launch rails.
Fuel tank molded in fiber with panel line and
rivets engraved
Rail molded in fiber
•2 large underwing fuel tanks + launch rails.
Fuel tank molded in fiber with panel line and
rivets engraved
Rail molded in fiber
•2 Afterburner ring lights.
•Lights control unit.
Including strobes, landings lights and navigation lights
•LCD lightning cockpit instrument panel.
•Cockpit voice recorder

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•High visibility water decals
•Low visibility water decals
•Wings and rudder protection covers.
Jet Engine :
1 single BF 300 turbine (30-32 kg thrust)
or 2 twin Jet Cat P160SX – P180RX turbine ( 2x16 kg thrust)

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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.
It is possible to let the fuselage in 2 parts for transportation.
You can also glue the 2 parts together.
If you want to dismantle it easily, you'll have to screw the 2 parts together with 6 x 4 mm diameter screws
+ blind nuts.
Don't forget to glue the screws with threadlock before to fly ......

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CONSTRUCTION
FRONT FUSELAGE for Air Force version
Doors :
Cut the 3 front gear door according to the engraved panel lines and photos.
Glue 3 plastic door hinges with cyano on the
front door.
Take care to glue the first front hinge as
forward as possible. Otherwise the front wels
will touch the hinges during retraction
Glue 2 plastic door hinges with cyano on the
2 small doors.
Secure all door hinges with small parker
screws

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Air cylinder
Fit the small air cylinder on the front
door .
The ball link must be screwed on the
central door hinge
The 2 small rear side doors will be
closed by a spring
Glue the internal gear door
reinforcement on the front gear door
with epoxy

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Assembling the nose gear
Screw the front landing gear on the
plywood
Fit the leg in the gear
Screw the 2 wheels
Steering servo :
Used a strong servo for the steering
Screw the servo on a plywood support
Connect the servo with M3 threated
rod, steel link + aluminium ball link.

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FRONT FUSELAGE for NAVY version
Doors :
Cut the 3 front gear door according to the drawn panel lines and photos.
Glue 2 plastic door hinges with cyano on the front door.
Glue 2 x2 plastic door hinges with cyano on the 2 rear door.
Secure all door hinges with small parker screws

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Glue a flat plastic door hinge on the small rear
door
Assembling the nose gear
Steering servo :
Used a strong servo for the steering (25 kg.cm)
Screw the servo inverted on the support.
Screw the front landing gear box on the plywood with the 6 parker screw
Screw the rear back fork to the plywood with the M8 allen screw

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Door Air cylinders
Screw the small air cylinder on a wood block with a small parker screw.
Screw the ball link to the wood frame as the photo
Glue the wood frame to the front gear door with CA.
Open the gear door
Extand the air cylinder
Glue the wood block to the fuselage with door fully open

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Rear Door :
Screw the small air cylinder on a wood block
with a small parker screw.
The ball link must be screwed on the external
hole of the door hinge
Fit one air cylinder for each rear doors

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Glue the wood block to the fuselage
with door fully open
Glue the internal gear door reinforcement on the front gear door with epoxy
Small rear door
The small rear door will be connected the rear aluminium strut by a spring
Drill a 1 mm hole in the rear aluminium strut
Connect the spring to the strut

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Drill a 1 mm hole in the
fiber gear door in front of
the strut
Connect the strut to the
dood
When the gear will be extend, the rear door will stay open and the front door will stay closed. For
this reason, connect the front cylinder to an electrovalvle and the 2 rear cylinder to a second
electrovalve. The door sequencer will make the correct sequence
Front Navy details
Glue the 2 lights on each side
of the gear

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FOR ALL VERSIONS
CANARDS
Servo must be a 9 kg.cm servo (ex S 9402)
Screw the servo on the plywood support.
Fit the canard in the tube.
Fit the aluminium control horn on the carbon rod and
secure it with the 2 screws.
Connect the servo with steel link and M3 rood

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Main gear doors :
Assemble the aluminium gear doors according to the photo
Cut just one side of the main gear
doors according to the engraved panel
lines and photos. Cut them only close
to the gear door hinge position.
Glue the 4 metal door hinges with
cyano (take care of the position
according to the photos .
Finish to cut the main gear doors.
Secure all door hinges with small
parker screws (due to aerodynamic
loads)
Glue the internal gear
door reinforcement on the
main gear door with
epoxy.