Direct Connection RC Kaos Manual

1
©Direct Connection RC
Kaos Kit Build Instructions
Thank-you for your purchase of the new Kaos kit, the following instructions are meant to
guide you in assembling your plane.
Advanced builders may find they need to make slight deviations in order to better suite
their abilities and desired plane outcome.
As always due to the type of wood used slight bends or warping to the wood may occur
but should not affect the overall structure.
Parts
Each Kit Contains:
1 –Fuselage Bottom
2 –Fuselage Sides
1 –Motor Mount
1 –Center Fuse Former
1 –Rear Servo Mount
1 –Fuselage Motor Mount Top piece
1 –Battery hatch cover (3 pieces to assemble)
2 –Pieces of Top fuselage sheeting
10 –Main Ribs
2 –Wing Tip Ribs (3 slots within the rib)
2 –Fuselage Doubler Ribs (notch at top)
2 –Half Ribs
4 –Wing Tip Supports
2 –Elevons
2 –¼ x ¼ Hardwood Leading Edge
2 –Main Spars
4 –1/16 trailing edge pieces
1 –sheet of Trailing edge Spacers
2 –Trailing Edge Tips
2 –Fins (4 pieces to assemble)
2 –Sets of Decal

2
©Direct Connection RC
Additional Requirements
•CA or Wood Glue
•Hobby Square
•CA Glue Accelerator
•Pins
•Plane
•Airplane Covering
Recommended Parts
•CA Hinges
•3S 1000mah Lipo Battery
•2206KV –2400KV motor
•20 –30amp speed controller
•9G Servos
Pre-Build
Elevons
Taper elevons joint to 45°, and round the tips. Cover as desired, then cut hinge slots.

3
©Direct Connection RC
Battery Hatch Cover
To assemble the battery hatch cover, locate the 3 required pieces (Top and 2 sides). Lay the battery
hatch cover on a flat surface. Glue the side rails in an upright position, allow glue to set. Cover as
desired.
Fins
Lay all pieces flat, glue together one of the larger pieces to the smaller triangle shaped piece at the glue
line, allow to set. Complete by sanding fins to prepare for plane covering. Round the leading edge of the
fin as desired and cover.

4
©Direct Connection RC
Wing Tips
Lay wing tip rib flat, identify wing tip, glue into upright position on the wing tip rib; aligning the 3 tabs
into the 3 slots.
Add wing tip supports using glue, each wing tip will have 2 wing tip supports (top and bottom).

5
©Direct Connection RC
Main Spar
Lay main spar flat, Glue together at center ‘W’ cut line, allow to set.
Fuselage
Lay fuselage bottom piece flat, identify fuselage side pieces. Note that Right fuselage piece goes to the
wider side of the fuselage and the Left fuselage piece goes to the narrower side of the fuselage.
With the fuselage sides still aligned insert the centre former into the fuselage with the small notched
tabs facing up. Secure with glue.
Narrow
Wide

6
©Direct Connection RC
Insert the motor mount onto the fuselage bottom and sides. Secure with glue. Glue the top motor
mount piece into place.
Glue the front tabs of the fuselage sides down into the fuselage bottom, the back 2 tabs of each side will
not meet the fuselage bottom at this time. Allow to set.
Curve the fuselage bottom to align the remaining back tabs of the fuselage side, glue. Glue in the rear
servos mount at this time.
*Thrust angle should now be noticeable.

7
©Direct Connection RC
Main Build
Once the battery hatch cover, fins, wing tips, main spar and fuselage have been
assembled the remaining pieces can be put together to assemble the plane.
Ribs
Insert the half rib into the main spar doubler slot (3rd slot from the ‘W’ cut line).
Insert the doubler rib into the 1st slot from the ‘W’ cut line on the main spar.
Insert the main ribs into the remaining slots on the main spar.
Trailing Edge
Glue each set of the trailing edges at the ‘W’ cut line; allow to set.
Place one of the 1/16 trailing edge sheets on a flat surface, aligning with the wing; pin as required. Align
the rib spears on the trailing edge, ensuring all ribs are flush with the main spar and square to the
trailing edge using your hobby square. Glue bottom trailing edge.

8
©Direct Connection RC
Insert and glue the 15 trailing edge spacers between each of the ribs on the wing to allow for hinges.
Some trimming and/or sanding may be required for fit.
Glue top trailing edge onto wing; allow to set.
Round the trailing edge wing tips and glue onto wing flat with no reflex.

9
©Direct Connection RC
Wing & Leading Edge
Insert the wing into the fuselage and glue. When mounting the wing onto the fuselage ensure the back-
trailing edge is flush with the fuselage when sheeted. This can also be accomplished by ensuring the rib
is flush with the fuselage. This may take a bit of finessing to get the 2 pieces to sit properly.
You may wish to glue the top fuselage sheeting pieces together before attempting to mount the wing to
the fuselage, so you can use the sheeting as a guide. See images for examples.
CORRECT
Top sheeting is flush with trailing edge

10
©Direct Connection RC
INCORRECT –Fuselage and rib wing is NOT flush

11
©Direct Connection RC
Locate the 2 pieces of top fuselage sheeting. Glue the 2 pieces together as shown below and allow glue
to set. Glue the fuselage sheeting over the servo plywood mount and trim any excess.
Install the leading edge (¼ x ¼ hardwood) to each side ensuring it is seated properly and glued straight
on the wing.

12
©Direct Connection RC
Cut off any excess (overhang) once the leading edge has been glued and allowed to set.
Wing Tips
Install wings tips onto the wings with glue and allow to set.

13
©Direct Connection RC
Completing your plane
Lightly sand the plane before covering.
Cover the plane, apply decals as desired. Paint splotch decals are designed to be installed in the
following order (left to right, with nose of plane facing you): blue, green, purple, red. Varying the order
of the decals may result in overlapping or other undesired effects.
Install the elevons and fins. We recommend removing the covering from the bottom slots of the fins and
applying with epoxy or CA glue to ensure proper adhesion.
To install the battery cover, hold down, you can use permanent magnets, 2 servo horns (creating a
latching system) or any other fitting that suites your needs.
Plane is complete, finish your plane with your required hardware (servos, hook up linkages, mount
motor, CA hinges, install your rx, etc).
With the battery installed the CG should be just in front of the main spar.
Damaged one of your parts or need to rebuild?
Replacement parts are available, please contact us at [e-mail] or visit us at
Directconnectionrc.com