Evolution MEGA FUSION User manual

0
Petrol and Electric Instruction
Manual
FEATURES
 Precision Laser Cut Parts
 Lightweight Strong Airframe
 Excellent Low Speed Stability
 Comprehensive Instruction Manual
 High Quality Balsa and Ply parts
 Excellent Precise Handling Characteristics, ideal first large trainer
 High Quality Comprehensive Hardware Pack

1
Introduction
The Mega Fusion was the natural progression from the Fusion. It can be used for a large model
trainer or glider tug (with appropriate alterations) as it provides a stable base which a pilot of any
experience will enjoy and feel confidence with. Wind up the rates and put a hot motor in it then like
the Fusion it will loop on the spot, roll in the blink of an eye, again, inspiring confidence as it
remains rock solid and stable. This model that has been designed to be highly manoeuvrable, but
also to be attractive with style and flair.
Building Recommendations (Please read)
Check all parts from the box to ensure that they are present; if not then please contact us at the e-
mail address at the back of the instructions. We do from time to time make mistakes!!
Ensure that you use a completely flat base on which to build the model, this should be large
enough the build the wing 50” (1270mm) x 18” (450mm) as a minimum.
Read through the instructions before starting to build, understand each step before applying glue.
Any glue detailed in the instructions is for a guide only, this is what we used for the prototypes, it is
at the builders discretion which glue is used, but ensure that it is suitable for the intended purpose.
Always read the application instructions to ensure you achieve a strong joint. Always read the
safety instructions supplied with the glue.
Take your time building the model, build a straight and strong model, this will ensure the model will
fly well!
!!! Warning. During the construction you will be asked to sand balsa. Ensure that you are wearing
an appropriate mask for sanding balsa and are in a well ventilated area. We recommend sanding
in free air (outside).!!!
Enjoy. Building is part of aero modelling! By building you will understand how the model works
and how to handle it correctly.
This radio controlled model is not a toy. It can cause serious injury to the operator, public and
property if misused or abused. Ensure that you read all the instructions supplied with this kit and
instructions provided with the engine and radio control system or any other components purchased
separately carefully. Also make sure that any parts bought separately are suitable for their
application.
The kit contains small and potentially sharp parts, keep away from children.
Additional Materials Required Recommended Tools
Uhu Por
Cyano
Standard Thin or Medium Cyano
Aliphatic Wood Glue
Epoxy Resin
Tinned Copper Wire (For Undercarriage)
Solder
Heat Shrink Covering Material
Power Set or motor
Radio Gear
Modelling Knife
Razor Plane
Set Square
Sand Paper
Sanding Block
Blow Torch
Drill
Drill Bits
Building Board – Completely flat 1270 x
450mm Min
Bradawl
Please visit our online shop at www.evolution-models.com if you require any supporting materials.
We stock motors and ESCs and all the materials you will require to build your model.

2
Fusion Part List
Wood Pack
Hardware Pack
Description
Sheet Size
Quantity
Metric
Imperial
Leading Edge Sheet 2 x 100 x 915mm 3/32 x 4 x 36” 4
Leading Edge
(
cut into 2 pieces
)
9.5 x 75
x 915mm
3/8 x
3
x 36”
1
Trailing Edge Sheet (
cut into
4
pieces
) 2 x 100 x 915mm 3/32 x 4 x 36” 1
Main
Spars and Trailing Edge Spar
6 x 6 x 915mm
1/4 x1/4
x 36”
6
Leading Edge Spar 4.5 x 4.5 x 915mm 3/16 x 3/16 x 36” 4
Wing Centre Section Sheet
2 x 100
x 915mm
3/32 x 4 x 36”
2
Fuselage
Bottom and Front Deck Sheet
3 x 150
x 915mm
1/8 x 6
x 36”
1
Rib Capping Strips 2 x 9.5 x 915mm 3/32 x 1/4 x 36” 14
Aileron/
Rudder
/
Elev
ator
/
Tail
Plane
Strip
9.5 x 12 x 915mm
3/8 x1/2 x 36”
5
Fuselage Triangular Fillet 9.5 x 9.5 x 915mm 3/8 x 3/8 x 36” 8
Tail Plane Spar Cover
1.5 x 6 x 915mm
1/16 x 1/4 x 36”
1
Description
Quantity
75mm (3”) Wheels
2
Metal Clevis (M3) 8
Metal Extender (M3)
2
Nuts (M3) 8
Aileron Control Rod (M3)
2
Closed Loop Adaptors
4
Closed Loop Crimps 8
Closed Loop
Wire
4 m
Control Horns 6
5mm x 450mm Carbon rod
1
Single Saddle Clamp 6 swg and Screws (12) 6
6
Swg Wheel Collet
2
Captive Nuts, bolts and washers
2
Pinned Hinges 19
Servo Mount Spruce 6 x 6 x 25mm (¼ x ¼ x 1”)
2

3
Laser Cut Ply
1
2
3
4
3
4 1
13
14
5
6
7
8
9
10
11
12
15
16
20
17
18
21
22
19
W1
W2
W3
W4
W5
W6
W7
Rib
Identification

4
Laser Cut Balsa
39
23
23
24
25
27
26
28
29
30
31
32
33
34
35
36
37
38
40
41
42
43
44
45
44
43

5
Part No.
Description
S
heet Material
1
Main Wing Spar (2)
3mm (1/8”)
Ply
2
Left and Right Fuselage
s
ides
Rear S
ection
(2)
3mm (1/8”) Ply
3
Fuselage Doubler (2)
3mm (1/8”) Ply
4
Wing Tube End Plates (2)
3mm (1/8”) Ply
5
Inner Front Undercarriage Mount
3mm (1/8”) Ply
6
Oute
r Front Undercarriage Mount
3mm (1/8”) Ply
7
Inner Rear Undercarriage Mount
3mm (1/8”) Ply
8
Outer Rear Undercarriage Mount
3mm (1/8”) Ply
9
Wing Bolt Plate (2)
3mm (1/8”) Ply
10
Hatch Plate
3mm (1/8”) Ply
11
Servo Mounting Plate
3mm (1/8”) Ply
12
Ha
tch Latch Plate
3mm (1/8”) Ply
13
F2
3mm (1/8”) Ply
14
Wing Dowel Plates
3mm (1/8”) Ply
15
Left and Right Fuselage
sides Front section
(2)
3mm (1/8”) Ply
16
Tail Skid plates (2)
3mm (1/8”) Ply
17
Outer Wing Bolt Plate
3mm (1/8”) Ply
18
Upper Wing Bo
lt Plate
3mm (1/8”) Ply
19
Lower Wing Bolt Plate
3mm (1/8”) Ply
20
Fin Core
3mm (1/8”) Ply
21
Aileron Servo Mounting Plates
3mm (1/8”) Ply
22
F1 (2)
3mm (1/8”) Ply
23
Wing Tip (2)
9.5mm (3/8”
) Balsa
24
Tail Plane Tips (2)
9.5mm (3/8”
) Balsa
25
Eleva
tor Trailing Edge
9.5mm (3/8”
) Balsa
26
Tail Plane Centre Section
9.5mm (3/8”
) Balsa
27
Tail Plane Leading Edge
9.5mm (3/8”
) Balsa
28
Tail Plane Trailing Edge
9.5mm (3/8”
) Balsa
29
Elevator Leading Edge
9.5mm (3/8”
) Balsa
30
Rudder Leading Edge
9.5mm
(3/8”
) Balsa
31
Elevator Tips (2)
9.5mm (3/8”
) Balsa
32
Rudder Bottom
9.5mm (3/8”
) Balsa
33
Rudder Top
9.5mm (3/8”
) Balsa
34
Elevator Centre Section
9.5mm (3/8”
) Balsa
35
Aileron Outer Tips (2)
9.5mm (3/8”
) Balsa
36
Aileron Horn Plates (2)
9.5mm (3/8
”
) Balsa
37
Tail Plane Centre Section
9.5mm (3/8”
) Balsa
38
Aileron Inner Tips (2)
9.5mm (3/8”
) Balsa
39
Aileron Trailing Edge (2)
9.5mm (3/8”
) Balsa
40
Aileron Leading Edge (2)
9.5mm (3/8”
) Balsa
41
Fuselage Backbone
9.5mm (3/8”
) Balsa
42
Rudder Tra
iling Edge
9.5mm (3/8”
) Balsa
43
Rudder Outer Cladding (Rear) (2)
3mm (1/8”) Balsa
44
Rudder Outer Cladding (Middle) (2)
3mm (1/8”) Balsa
45
Rudder Outer Cladding (Front) (2)
3mm (1/8”) Balsa

6
Des
cription
Quantity
Undercarriage Front Leg 1
Undercarriage Rear Leg 1
Undercarriage Support 2
Tail Skid 1
Suspension Parts Set ( 2 large and 2 Small) 1
Front Leg 6 swg
Rear Leg 6 swg
Piano Wire U/C
Fusion Parts List
Supports 8 swg
Tail Skid 10 swg

7
Building Instructions
Fin and Rudder
Take the 7 parts that form the Fin (Parts 43(2), 44(2), 45(2) and 20), sandwich the ply part between the
sheets of 1/8th balsa
Take the four parts that form the rudder (Parts 30, 32, 33 and 42) and assemble as shown below using the
12.5 x 9.5mm (1/2” x 3/8”) strip wood to create the riblets.
With a pencil mark the centre line of the leading edge of the rudder and chamfer to a 45° angle with a Razor
Plane ready to receive the hinges. The hinged part of the pinned hinges sits in the chamfer as shown below.
With a file remove a section of the chamfered face to accept the centre of the hinge, then Carefully drill the
balsa to accept the hinge. The fin has already been cut to accept the four hinges, make adjustments if
necessary.
Sand all parts to a smooth Finish and round off the leading edge of the Fin ready for covering.
Tail Plane and Elevator
Take the pre-cut parts which form the Tail Plane (Parts 24(2), 26, 27, 28 and 37), trial fit, ensure the tips are
at 90° to the leading and trailing edge before gluing. With the supplied strip of 12.5 x 9.5mm (1/2” x 3/8”) cut
to length to form the eight ribbing pieces, glue in place.
Using the elevator parts (Parts 25, 29, 31(2), and 34), and 12.5 x 9.5mm (1/2” x 3/8”) strip wood, make up
the elevator in the same way as the Tail Plane
The Tail Plane and Elevator are separate parts do not glue together.

8
Tail Plane parts laid out Tail Plane assembled
Riblet pieces inserted
Use the 1.5 x 6 x 915mm (1/16 x 1/4 x36”) balsa strip and glue it in the pre-cut spar slot flush with the
surface, insert the 5 x 450mm (18”) carbon spar and glue in place with epoxy before capping with the
remaining strip.
With a pencil mark the centre line of the leading edge of the Elevator. Chamfer to a 45° angle with a razor
Plane ready to receive the hinges. Use 5 hinges attach the elevator to the tail plane as describe above for
the rudder.
Fuselage
Lay the two Fuselage sides (Parts 2(2) and 15(2)) on the work bench ensuring that you have a left and right
hand side. Glue the front and rear sections together before attaching the Fuselage Doubler (Part 3 (2))
Using the 9.5mm (3/8”) triangular fillet, glue to the outer edge of the Fuselage as shown hatched below.
Make cuts in the fillet to allow it to follow the bottom curve of the Fuselage If Building the petrol version also
fill the section at the bottom of the fuselage.

9
Glue the two F1’s (Part 22(2)), two Wing Bolt Plates (Part 9(2)) and two Wing Dowel Supports (Part 14(2))
together to form 6mm (1/4”) thick parts. Insert the two captive nuts by using a hammer on a flat surface. If
you are building the Petrol Version your kit will have a 6mm (¼”) Birch Ply F1 to replace the two 3mm Poplar
ply pieces.
Draw a centre line on your bench as long as the fuselage to create a centre line to work from.
Using F1, F2, the Wing Dowel Support, Tank Hatch Latch (Part12) and Wing Bolt Plate begin to form the
fuselage. Insert F2 (Part 13), the Wing Dowel Support, Battery Hatch Latch and Wing Bolt Plate (so the
captive part of the nut is on the underside) into the corresponding slots in the Fuselage Doubler and glue in
position. Offer up the second side, before gluing turn the whole assembly over so that the fuselage sides are
vertical. Place the centre of F2 on the centre line marked on your bench and insert F1 (so that the cut is at
the bottom), again on the centre line. When satisfied that the fuselage sides taper evenly either side of the
centre line and F1 is at 90o glue the whole assembly together. F1 should be glued into position using epoxy.
Once the epoxy has set, glue the top decking (Part 41) to the Fuselage, ensuring the rear Fuselage remains
square and the cut out for the fin remains along the Fuselage centre line.
With epoxy glue the front (Part 5) and rear (Part 7) undercarriage plates into position. (Fuselage shown
upside down). The plates fit within the recess created by the ply doublers.
Epoxy the outer undercarriage plates (Part 6 and 8) into position, these sit on top and fit flush with the outer
sides.
Go to the next step for the electric version. With the supplied the sheet of 3mm (1/8”) balsa plank the
front top deck of the Fuselage. If you are building the petrol version continue to plank the whole of the
bottom. The planking grain should run from side to side to provide maximum strength.
F1
F2
Wing dowel
Support
Battery Hatch
Latch
Wing Bolt
Plate