Extreme Flight YAK-54 ARF User manual

88 inch YAK-54 ARF
Instruction Manual
©Copyright 2007 Extreme Flight RC, Ltd.

Please take a few moments to read this instruction manual before
beginning assembly. We have outlined a fast, clear and easy method to
assemble this aircraft and familiarizing yourself with this process will
aid in a quick, easy build.
Please read the following paragraph before beginning
assembly of your aircraft!
THIS IS NOT A TOY! Serious injury, destruction of property, or even
death may result from the misuse of this product. Extreme Flight RC is
providing you, the buyer with a very high quality model aircraft
component kit, from which you, the buyer, will assemble a flying model.
However it is beyond our control to monitor the finished aircraft you
produce. Extreme Flight RC will in no way accept or assume
responsibility or liability for damages resulting from the use of this user
assembled product. This aircraft should be flown in accordance to the
AMA safety code. It is highly recommended that you join the Academy
of Model Aeronautics in order to be properly insured, and to operate
your model at AMA sanctioned flying fields only. If you are not willing
to accept ALL liability for the use of this product, please return it to the
place of purchase immediately.
Extreme Flight RC, Ltd. guarantees this kit to be free of defects in
materials and workmanship for a period of 90 days from the date of
purchase. All warranty claims must be accompanied by the original
dated receipt. This warranty is extended to the original purchaser of
the aircraft kit only. Please inspect the model immediately upon receipt.
Extreme Flight RC in no way warranties its aircraft against flutter. We
have put these aircraft through the most grueling flight tests imaginable
and have not experienced any control surface flutter. Proper servo
selection and linkage set-up is absolutely essential. Inadequate servos or
improper linkage set up may result in flutter and possibly the complete
destruction of your aircraft. If you are not experienced in this type of
linkage set-up or have questions regarding servo choices, please contact
us. It is your responsibility to ensure the airworthiness of your model.
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Congratulations on your purchase of the Extreme Flight RC 88 inch
YAK-54 ARF! This all new design is the result of applying what we
have learned from 5 years of flying the Yak-54 design. Highly refined
and thoroughly tested, this new Extreme Flight Yak-54 is being brought
to you as a complete package, including all first rate hardware and
components and thorough instructions to ensure a trouble free assembly
and set-up. Weight saving components are used throughout, such as
carbon fiber wing and stab mounting tubes, aluminum landing gear,
titanium pushrods and a carbon fiber tail wheel assembly, all ensuring
the lightest, most high performance aircraft possible. You will notice
there is a box built into the bottom of the Yak’s fuselage. This is a pipe
tunnel and will accommodate the full range of canister mufflers and
tuned pipes sold for the current makes of 50-60cc engines. Also
included is a set of protective wing and stab bags and a canopy/hatch
cover to keep your investment looking great season after season.
The performance ability of the Extreme Flight RC Yak-54 is
phenomenal! With its low weight and enormous control surfaces, the
Yak-54 is a 3D monster, capable of all current 3D maneuvers as well as
possessing the ability to forge new ground in this exciting new style of
flying. The Yak is also a topnotch precision aerobatic machine. It is
capable of performing the entire FAI catalog of maneuvers and it has
the kind of “big plane” presence in the air that will impress the judges.
This makes the 88 inch Yak a great candidate for all classes of IMAC
competition.
We have spent a great deal of time and effort to provide you, the
discriminating aerobatic enthusiast, with the highest quality, most
complete package possible. We are very proud of the end result of our
labor and wish you great success with the assembly and flying of your
Extreme Flight RC 50cc Yak-54!
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A few tips to ensure success and airframe longevity
1. We are very pleased with the level of craftsmanship displayed by the builders
in our factory. Through many grueling test flights containing maneuvers
that no aircraft should be subjected to, our Yak prototypes have remained
rigid and completely airworthy. However, it is impossible for us to inspect
every glue joint in the aircraft. Take a few minutes and apply some medium
CA to high stress areas such as servo mounting trays, landing gear blocks,
the intersection of the wing root rib and wing sheeting, anti rotation pins, etc.
A few minutes spent here inspecting the joints and applying glue where
needed is time well spent
2. Having survived the journey half way around the world while experiencing
several climate changes, it is not uncommon for a few wrinkles to develop in
the covering. Fear not! These are not manufacturing defects, and are easily
removed with a little bit of heat. Use a 100% cotton tee-shirt and your heat
gun and heat the covering while gently rubbing the covering onto the wood
with the t-shirt. Be careful not to use too much heat as the covering may
shrink too much and begin to lift at the edges. Take your time, and a
beautiful, paint like finish is attainable. The black covering may require a
little bit more attention than other colors due to its tendency to absorb heat.
3. By the time the Yak arrives at your door step it will have been handled by a
lot of people. Occasionally there are small dings or imperfections on some of
the surfaces. A neat trick to restore these imperfections to original condition
is to use a very fine tipped hypodermic needle to inject a drop of water under
the covering material and into the ding in the wood. Apply heat to the area
with a sealing iron and the imperfection will disappear. Deeper marks may
require that this process be repeated a couple of times to achieve the desired
result, but you will be surprised at how well this technique works.
4. DO NOT SKIMP ON SERVOS! The Yak-54 is equipped with very large
control surfaces that deflect over 45 degrees. A lot of servo power is required
to prevent flutter and to maintain the required deflection for maneuvers. We
absolutely recommend the use of high torque METAL GEAR servos. We
have had great success with the Hitec HS-5955 servos in our prototypes. We
recommend this servo or the JR 8611A or new 8711 for all flight surfaces.
5. Use a high quality epoxy for installing the composite control horns and
hinges. We highly recommend the use of Pacer Z-Poxy 30 minute formula.
We have used this glue for many years with zero failures.
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Hardware
Your new Extreme Flight 88 inch Yak includes all necessary hardware with the
exception of main wheels, axles and collars. These items were omitted as I have
been unable to source satisfactory versions of these items in China. I
recommend Dubro 3/16” axles and collars and 4 inch main wheels. If you intend
to use the wheel spats I highly recommend that you use a stiff set of wheels
versus soft foam wheels. This will help to prevent the spats from touching the
ground and possibly damaging them.
On the following page is a photo of the various connectors used for the Yak.
You will notice 3 sets of 3mm bolts. The 4 shortest of these 3mm bolts are the
stab retention bolts which mate up with the pre-installed blind nuts in the rear
of the fuselage. The 2 medium length 3mm bolts are for securing the carbon
fiber tailwheel assembly (the appropriate blind nuts are already installed in the
bottom rear of the fuselage to accept these bolts). The 4 longest 3mm bolts are
for securing the cowl.
You will find a complete pull-pull system, as well as high quality heavy duty ball
links, titanium turnbuckle pushrods and composite control horns, and a carbon
fiber tailwheel assembly. You will also find 3 white ball links. 2 of these are for
use with the included 2mm pushrod for the throttle assembly (this set-up is for
the DA-50-other engines may require a longer pushrod), the other is for the
bottom of the rudder to retain the tailwheel tiller arm.
The bonded sealing washers are used when mounting the cowl and
canopy/hatch. When the bolts used to retain the canopy/hatch and cowl are
tightened against the bonded sealing washer, the rubber on the washer
compresses, preventing the bolt from backing out. The rubber on the washer
also protects the surface of the cowl. Tighten the bolts until the rubber
compresses, but do not allow the metal part of the washer to make contact with
the cowl.
There are 4 titanium pushrods included in the hardware package. The 2 longest
are for the elevator linkage, the other 2 for the aileron linkage.
For best results, remove all set screws from the tailwheel assembly and
disassemble the unit. File flat spots on the tailwheel wire so that all set screws
will seat properly. Place a drop of blue Loctite on all set screws and re-insert
them into their holes.
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Let’s Begin!
Elevator Assembly
1. Locate the horizontal stabilizer/elevator assemblies as well as the
composite control horns and base pieces from the elevator hardware
package.
2. Use a sharp #11 blade to open the 2 slots near the bottom leading
edge of the elevator.
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3. Insert the 2 control horns into the base plate as shown in the
following picture. Carefully insert the control horns into the slots and
push down until the base plate is flush with the control surface. Use a
fine tipped felt marker to trace the outline of the base plate onto the
covering. Remove the control horn assembly. Use a sharp #11 hobby
blade to remove the covering 1/16” inside the lines you drew. Do not
cut into an open bay area. Make your cut only where there is
sheeting below the covering.
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4. Use some denatured alcohol to remove any residue or oils from the
composite control horns and base plate. If you wish to paint the control
horns for a more finished appearance now is the time to do so. Use some
fine sandpaper to prepare the control horns for paint. Mix up some 30
minute epoxy (add a little milled fiberglass if you have it) and fill the 2 slots
in the elevator with epoxy. Use an old #11 blade to force glue into the slots
and make sure they are thoroughly coated with epoxy. Us an epoxy brush to
thoroughly coat both sides of each control horn as well as the bottom of the
base plate. Use an abundance of glue here, as any excess will be forced out
of the slot when you insert the horns.
5. Insert the horns and push them into the slots until they are seated flush
with the base plate and the base plate is flush with the control surface. Insert
one of the 3mm bolts through the 2 control horns as shown to insure proper
alignment. Use some denatured alcohol and paper towels to remove the
excess glue and inspect the assembly. When satisfied set this assembly aside
to dry. Repeat this process for the other elevator half.
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6. Remove the covering from the holes for the hinges. We use an old
soldering iron for this and it works well. Locate 4 hinges per elevator
half. You will need to cut 2 hinges just beyond the second knuckle to
clear the fiberglass tube socket in the stabilizer. Insert the carbon
fiber wing tube into the socket while testing for proper hinge length to
avoid damaging the fiberglass sleeve.
7. In this step I will outline the procedure we use to install the hinges.
There are several ways to do this and several adhesives you can use.
We will describe the way we do it, as this method has proven itself
over many years of model building. If you are new to this type of
hinging process then I recommend that you install a single hinge first
just to acquaint yourself with this method. Before starting the process
get a few items together that will aid you as you proceed. You will
need the following items: 30 minute epoxy (again, we recommend
Pacer Z-Poxy), a scrap piece of pushrod or 1/8” dowel, paper towels
and denatured alcohol. Mix a generous batch of 30 minute epoxy.
Use the pushrod or dowel to thoroughly coat and fill the hinge hole
with epoxy, then coat the hinge with epoxy. Push the hinge into its
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hole until the joint is about a ¼” from its final position and use a paper
towel to remove the excess epoxy that has been forced from the hole.
Push the hinge the rest of the way in and make sure the hinge pin is
centered in the hinge line. Use some denatured alcohol and a paper
towel to remove all excess epoxy, especially on the hinge pin. When
you are satisfied with the result set the surface aside to dry. Position
the drying piece so that any excess epoxy will pool around the rear of
the hinge.
8. When you are comfortable with this process you should be able to do
one side of a surface per batch of epoxy. Glue all hinges into the
stabilizer first. After the glue has set trial fit the elevator to the stab
and adjust if necessary. There should be as little gap as possible
between the stab and elevator. When satisfied with the fit remove the
elevator and repeat the gluing process outlined above. Be sure to
wipe away all excess epoxy! Set aside to dry. Repeat this process for
the other stab/elevator half.
9. After the hinges have dried thoroughly, pull on them to make sure
they are properly installed. The hinges will probably feel a little stiff
as it is almost impossible to get all of the glue out of the joint. Use a
fine tipped hypodermic needle and place one (only one!) drop of
acetone on each side of the hinge pin. Move the elevator back and
forth a few times and you will feel it loosen up. Be careful to only
use one drop as you don’t want to weaken the glue joint! Add a
drop of penetrating oil to each hinge pin and you will ensure a smooth
operating surface with no binding. Seal the bottom of the hinge gap
with a strip of Ultracote or Blenderm tape. Be sure to fully deflect the
control surface when applying the tape or Ultracote to allow full
deflection once the gap is sealed.
10. Use a sharp #11 blade to remove the covering from the slot for the
elevator servo control horn. You may have to slightly enlarge this
hole to allow for maximum travel.
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11. Before installing the elevator servos, I highly recommend that you
temporarily install the servo arms and electronically center the servos.
It will be much easier to match up the servos at this point than when
they are installed. I also recommend that you thin a small amount of
epoxy with a few drops of alcohol and apply a light coat to the inside
of the stab and to the servo mounting rib as well as to the root rib and
mounting tabs. Over time exhaust residue begins to collect here and
by sealing it with epoxy you will prevent degradation of the wood.
12. Use the manufacturer supplied mounting hardware and install the
elevator servo with the output shaft toward the front of the stab.
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13.Thread 2 of the heavy duty ball links onto one of the 2 longer of the
titanium pushrods. Remember that the ends of the pushrods are
reverse threaded so that they can be adjusted like a turnbuckle without
removing the linkage. Insert a 3mm socket head cap screw into the
ball link and into the servo arm. If using the SWB arms you will
need to drill out the hole to accept the 3mm bolt. Secure with a 3mm
nylon insert locknut.
14.Place the servo arm onto the servo (which you should have
electronically centered in a previous step) and make sure the elevator
is in the neutral position. Adjust the ball links until the linkage fits
between the composite control horns and lines up with the pre-drilled
top hole. Insert a 3mm socket cap screw, through one side of the
composite control horn, through the ball link, and finally through the
other composite control horn. Secure with a 3mm nylon insert lock
nut. Use blue Loctite on all bolts! Below is the finished set-up.
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15.As mentioned previously, you may need to adjust the size of the servo
arm exit slot to achieve maximum travel. A ¼” Drum sander in a
moto-tool makes quick work of this. Repeat these steps for the other
stab/elevator half. Before you set aside the stabs take a moment with
your covering iron and go over all of the seams with a medium heat
setting, paying special attention to the ends of thin trim stripes. At
this point clean the 2 elevator/stab assemblies with Windex and a soft
cloth and put them away in their protective bag.
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Wing Assembly
16.The assembly process for the wing is almost identical to that of the
stab/elevator. For this reason we will not go into quite as much detail
as in the previous procedure. Remove the aileron from the wing
panel. Locate the 2 slots for the control horns and remove the
covering from the slots with a sharp #11 blade. Follow the same
procedure as outlined previously to install the control horns into
the control surface and hinge the wing. You may need to trim
1/16” from the front of the composite base plate to prevent
overhanging the bevel. Repeat this procedure for the other wing.
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17. Locate the aileron servo mount and remove the covering from this
area. Use a sealing iron to seal the edges of the covering to the sides
of the servo opening. Take a few minutes to apply some CA to the
joints of the servo rails and the ribs.
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18.Attach a 12” servo extension to your servo and secure with thread or
heat shrink tubing. Use the manufacturer supplied mounting hardware
and install the servo with the output shaft toward the leading edge of
the wing.
19.Electronically center your servo. We will fabricate the linkage much
in the same way as the elevator linkage. Aileron control horn length
should be 1.50”. As always, use blue Loctite on ALL bolts!
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20. Before beginning the next assembly process, take a few minutes with
your sealing iron on a medium heat setting and go over all seams,
paying special attention to thin trim stripes and the seam at the leading
edge of the wing. If there are wrinkles in the covering on the leading
edge sheeting use a heat gun with a 100% cotton t-shirt to remove
them and prevent digging into the wood with an iron. Use caution and
avoid excessive heat as you may cause the Ultracote to shrink too
much and lift at the seams. Also take the time to seal the hinge gaps
with Ultracote or Blenderm tape. Clean the wings with Windex and
put them away in their protective bag.
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Rudder Assembly
21.Locate the rudder, the rudder control horns and the 2 slotted base
plates. Use a sharp #11 blade to remove the covering from the 2 pre-
cut slots in the rudder.
22. Trial fit the 2 servo horns through the base plate and into their proper
position flush against the rudder surface. You will need to trim the
front of the base plate so that it does not overhang the hinge line as
shown in the photo.
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