Aviation Design sukhoi su-35 User manual

AVIATION DESIGN - ZI le Chenet - 91490 MILLY LA FORET – FRANCE - Tel : int+ 33 1 64 98 93 93 - aviation.desig[email protected]r – www.adjets.com
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SUKHOI
SU-35
SU-37
for 2 AMT Mercury
or 2 Jet CAT P 120
Assembly Manual
AVIATION Design
AVIATION Design AVIATION Design
AVIATION Design
ZI le chenet, 91490 Milly La Foret, FRANCE
Tel : [phone]
Fax : [phone]
E-mail : aviation.desig[email protected]
www.adjets.com
Version 01/09/2009

AVIATION DESIGN - ZI le Chenet - 91490 MILLY LA FORET – FRANCE - Tel : int+ 33 1 64 98 93 93 - aviation.desig[email protected]r – www.adjets.com
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INTRODUCTION
The Su-35 from AVIATION DESIGN 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 fins.
The Sukhoi will operate from prepared grass fields (70 meters long) or tarmac surfaces.
KIT FEATURES
- High quality, grey gel-coated epoxy-glass fuselage. All the panel lines are engraved. The fuselage is in 2
parts for shipping.
- Nose cone and central tail boom
in epoxy glass
- Air brake molded in epoxy-glass
- Main gear doors
- Canopy frame molded in epoxy-
glass
- 2 Exhaust nozzle.
- 2 Epoxy-glass inlets
- 2 Epoxy-glass ductings
- Fully molded epoxy carbon wings
and stabs with aluminium spar
already glued.
- Fully molded epoxy carbon fins
with aluminium spar already glued.
- 2 ventral fin in epoxy
- Wing tip rails
- 2 canards in epoxy
- All plywood and wood parts pre-cut to shape where necessary.
- Air cylinder for air brake.
- All hardware necessary.
Following items are included in the kit
For the fuselage :
a set of screws + blind nuts for the gear
For the canopy, 1hatch latch
For the stabs :
4 ball bearing for the stabs
4 ball bearing mounting
8 screws M3x16 mm long
2 aluminium link M4
2 threaded rod M4
2 carbon control horns
For the canards :
2 screws M3x16 mm long
2 link M3 + threated rod
2 threaded rod M4
2 aluminium control horns
- ABS cockpit interior .
- Clear formed canopy.
- vacuum parts
- instructions in English and plan.

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To complete the kit :
The following items are not included in the kit. They are available from AVIATION DESIGN.
Cockpit detail kit :
This kit include :
1/8full body jet pilot, 1/8 ejector seat & instrument panel.
Probes set :
- pitot probes and incidence probes for the Su 35.
Landing gear :
Aviation Design scale retractable landing gear is
specially designed for the Sukhoi.
It is made all CNC in aluminium
For the gear, it includes 3 rotating retracts system, 3 oleo
legs, 4 way valve, tubing, connectors, air tank, filling valve.
It also includes 2 x 125 mm diameter wheels + scale cover
+ brakes and 2 x 75 mm diameter front wheels
It includes valve, tubing, connectors, air tank, filling valve.
Gear doors kit :
Include 3 air cylinders, electronic gear door cycler, 4 way valve, tubing,
connectors, air tank, door hinges, ball links
Air brake :
Include special air cylinders, 4 way valve, tubing, connectors,

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2 Kevlar Fuel tanks : ref ADJ 450
2 Fuels cells molded in kevlar. Capacity : 2 x 2.4 liters
It includes also all tubing and upper tank
2 stainless steel tailpipe : ref : ADJ 460
Super scale water decals :
Jet Engines :
2 Complete AMT Mercury
or 2 Jet Cat P120
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
Front FUSELAGE
Gear doors :
Cut just one side off the front gear door according to the engraved panel lines.
Glue the 3 door hinges with cyano (take care of the position according to the plan).
Finish to cut the front gear door .
Make 2 fence in the front gear door according to the engraved panel line
Glues with CA the plastic vacuum parts in the front gear door

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Frame :
Assemble the frame C1, C2 and C3
Desassemble them , fit them in the fuselage and assemble them.
Glue them in the fuselage with CA according to the plan (distance beetwen the C2 former and the fuselage
end)
Glue the plywood extension C2bis on C2 with CA
Epoxy the bulkheads in place : the 2 formers must be glued with epoxy and glass fiber.
Cut some glassfibre tapes (30 mm large and 10 cm long).
Glue this tape with epoxy overlapping all the formers and the fuselage.
Let them dry overnight.

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Rear FUSELAGE
Cut the 2 gear doors according to the engraved panel lines.
Also cut some 4 mm larg slot for the wood location, according to the photos and line drawn on the
fuselage
Gear frame :
Insert 4 M3 blind nuts in C10
Screw the gear on C10 with 2x M3 x 12 alen screw
These 2 plywoods will be
glued under the skin

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Epoxy all the bulkheads in place : C10, C11, C12, C13, C14 must be glued with epoxy and glass fiber.
Cut some glassfibre tapes (30 mm large and 5 cm long).
Glue this tape with epoxy overlapping all the formers and the fuselage.
Screw the gear box to C14 with M3x12 alen screw puting some epoxy to C14.
Insert some tape IN the fuselage overlapping all the formers and the fuselage.
Check to glue very strongly C14 in the fuselage against the main fraime
Let them dry overnight.

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Rear frame and bearing installation :
Cut out all hatches and make the necessary holes in the fuselage according to the photos.
Cut the back of the fuselage at the bearing position.
Cut the slot (6 mm larg, 20 mm height) in the fuselage (fin root location) for the elevator control horn
It will be covered by the fin
Glue the bearing in the mounting with threadlock glue
Screw the 4 bearing mounting to the rear frame with M3x16 alen screw.
Screw the 2 servos (9 kg.cm torque) on each
plywood frame C20.
Connect the 2 servos together and try them with
your radio. They must move without any bad
noise
Insert them in the fuselage.
Check that they can move without problem.
Glue C20 with CA for the moment.

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Canards :
Glue the plywood support in front of the canard hole.
Screw the servo on the plywood
Fit the canard in the brass tube and slide the aluminium
control horn on the aluminium tube. Secure the horn with
a M3 screw. Connect the control arm the the M3 link
Fin assembly :
Trim all the parts of the fin.
Trim also the aluminium tube and pins
If necessary, drill again all the holes in the fuselage for the fin tube and pin
Insert some greass in the fuselage aluminium tube
Cut a fence in the back of the fit for the servo and ball link
Fit the fin on the fuselage.
Check that the servo can move without problem.
Drill a hole through the aluminium joining tube to secure the fin
Insert a screw to secure the fin

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Stabs assembly :
First you have to balance the stabs.
Drill a hole in the stab root (leading edge)
Insert some lest (about 75 grammes) in each stabs
Fit the stab on the bearing fuselage to see if it is balanced
well.
Glue the lest with epoxy
Insert the 12 mm washer on the aluminium tube
Fit the stab in the fuselage bearing
Secure the stab with a screw through the aluminium tube
Draw a line on the stab just in front of the servo arm
Cut a 2 mm larg slot for the carbon control horn
Fit the control horn in the stab and fit the fin on the fuselage.
Check that the control horn is just in the middle of the fin slot
Sand the carbon control horn for a best glue adhesion
You can also drill some small holes in the bottom of the horn for best gle
adhesion
Glue the control horn in the stab with epoxy
Let them dry overnight.
Connect the servo to the carbon control hon with the 2 M4 aluminium ball
link and the M4 threated rod

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Air brake :
Fit the air brake on the fuselage.
Draw a line on the fuselage at 18 mm from the fuselage edge
Cut 2 slots in the air brake location fuselage
Check that the air brake can move without problem in this
slot
Fit the air brake on the fuselage.
Drill a 2 mm diameter hole through the fuselage and the air
brake just on the line
Take care that the 2 side holes are parallel
Fit a 2 mm piano wire through the fuselage and the air brake
And check that it can move without problem
For the air cylinder location, Cut a slot in the top of the
fuselage according to the plan
Fit a 2 mm piano wire in the cylinder hole and glue the piano
wire IN the fuselage according to the plan
Cut a slot in the air brake according to the plan
Glue the plywood control horn C24 in the air brake with epoxy
Fit the air brake on the fuselage with the piano wire
Connect the air cylinder to the control horn with the
aluminium link

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Air intakes
Glue with epoxy the plywood reinforcement C26
Cut the air intakes as engraved
Fit the air intake on the fuselage.
Drill a 3 mm hole throught the plywood reinforcement and the fuselage
Insert a 3 mm screw
Insert M3 blind nut in C25
Glue with epoxy C25 in the fuselage
Screw the air intake on the fuselage with a M3 screw
Drill 4 x 2 mm holes through the intake and C10
Screw the 4 parker screws
Unscrew the air intake from the fuselage. You will have
now to glue the ducting in the air intake
Cut the back of the ducting so that it will not touch the
engine mounting frame.
Fit the ducting in the air inlet and glue the leading edge
with epoxy and microballon
Glue also the rear of the ducting to the air intake
Put some clothes pegs all around the intake leading
eadge during drying.
Let them dry overnight.
Trim all the leading edge.

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14
Gear doors
Cut the main gear doors in 3 parts
Cut 2 slots in the fuselage as engraved for the 2
Robart door hinges.
Glue the 2 Robart hinges against the fuselage with
CA, just in front of the 2 slots.
They must be outside of the fuselage.
Glue the plywood reinforcement C28 on the
main gear door with quick epoxy
Put 4 cloth pegs
Glue the 2 hinges on the gear door with
epoxy. Adjust carefully them so that the
gear door is in front of the fuselage hole
Secure the hinges with 2 parker screw and
plywood reinforcement C29 inside

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Drill a 2 mm hole at the end of the rear hinge
Insert the steel ball ling for the air cylinder
Srew the ball link plastic end to the 2 ’’ air cylinder
Screw the air cylinder on the obechi block C30 with
the parker screw
Extend the air cylinder
Fit the plastic ball ling on the metal ball.
Glue with CA the obechi wood block on the fuselage to have to
correct gear door angle (when the door is open)
Check that it close without problem
Rear gear door :
Glue the 2 door hinges
with cyano (take care of
the position according
to the plan).
Cut the rear gear door
according to the
engraved panel line.

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Glue with CA the fix piece on the fuselage
Check that it can open and close without problem
Fit a spring on the rear door hinges so that the
door automatically close when the gear goes up.
Wings:
Cut the location of the 2 gear doors hinges
in the wing according to the engraved panel
line.
Wing tip missile rails :
Fit the wing tip missile rails with 2 parker screws 3x20

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Drill a hole (about 15 mm diameter) in the top of the
main frame for the electric wire and air tubing
Landing Gear :
Main gear :
You have now to connect all the gear, door and brake
tubing.
Front gear
Screw the front landing gear on C2
Fit the steering control arm + the oleo legs on the
retracts
Glue the ABS cover on the wheel hole

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Screw the M2 ball link on the central door hinge
Screw the air cylinder on the ply renforcement C29.
Connect the 1‘‘ air cylinder 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.
Glue C29 on the fuselage.
Connect all tubing to the retract and the door cylinder.
Screw the steering servo on the C4 frame
The steering servo should be a 4 kg.cm servo
Glue C4 on C2 just in front of the steering control arm
Connect the servo to nose gear steering arm with 2 x M3
link and M3 threaded rod.
Nose
C33 will be removable for an easier access in the fuselage.
Glue the 4 plywood reinforcement C32 in the fuselage acording to the plan.
C33 must slide beetween the 4 plywood parts C32
Epoxy C32 in place : they must be glued with epoxy and glass fiber, overlapping all the formers and the
fuselage.
Insert C33 beetween C32. Drill a hole through C32 and C33 and fit a M3 screw + blind nut
Fuel tanks
You will now have to install the 2 fuel tanks in the fuselage before to continue the assembly.
Fit the 2 kevlar tanks in the fuselage against the main frame. Secure them with silcon glue
Glue with silicon glue the 2 upper tanks just in front of the main tanks

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Assemble the fuselage
You have now to assemble the 2 part of the fuselage together.
If you have a Su 27, you can only screw the 2 parts together. It will be easier later to repair any damage.
Fit the 2 parts in front of each other.
Drill a 15 x 1.5 mm hole through the 2 parts to insert parker screw.
If you want only to screw the fuselage together (disassemble
later), glue 15 x 3 mm plywood reinforcement on the hole
location. Screw the 2 parts with 15 parker screws.
If you glue the 2 parts, put some epoxy on both side.
Fit the 2 parts together and screw au the parker screw. Let it dry
overnight. Remove the screw after drying.
Assemble the central tail boom
If you want, you can only screw the 2
parts together. It will be easier for
handling.
But it is also possible to glue it.
Fit the 2 parts in front of each other.
Drill a 6 x 1.5 mm hole through the 2
parts to insert parker screw.
Glue 6 x 3 mm plywood reinforcement
on the hole location.
Screw the 2 parts with 6 parker screws

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CANOPY :
Front canopy :
Cut the front fiberglass canopy
Cut the clear canopy in 2 parts
Cut the front clear canopy according to the
engraged line
Glue the glear canopy INSIDE the fuselage
with Zap canopy glue
Let it dry overnight.
Cut the front vacuum part. Paint it in black
Glue it inside the front canopy with Zap
canopy glue
Let it dry overnight.
Glue the on the canopy with canopy with Zap canopy glue
Rear canopy :
Cut the rear fiberglass canopy from the
canopy frame
Cut the rear clear canopy according to the
engraged line
Glue the glear canopy INSIDE the canopy
frame with Zap canopy glue
Let it dry overnight.
Cut the rear vacuum part. Paint it in grey
Glue it inside the canopy frame with Zap
canopy glue
Let it dry overnight.
Insert the hatch latch in the fuselage to secure the canopy frame on the fusleage.