Extreme Flight YAK-54 ARF User manual

YAK-54 ARF
1.60 Class
Instruction Manual
©Copyright 2006 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 30 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.
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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Thank you for your purchase of the Extreme Flight RC 1.60 classYAK-
54 ARF! The Yak-54 represents the state of the art in modern, high
performance aerobatic ARF aircraft technology. Highly refined and
thoroughly tested, the 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
reinforced balsa spars, carbon fiber wing and stab mounting tubes, and
a carbon fiber tail wheel assembly, all ensuring the lightest, most high
performance aircraft possible.
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 top notch 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 1.60 Yak-54 ARF 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 1.60 Yak-54!
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A few tips to ensure success
1. We are very pleased with the level of craftsmanship displayed by
the builders in our factory. Through hundreds of 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, anti rotation pins, etc. We like to use the Bob Smith
Industries IC-2000 on the servo trays. This is some amazing glue!
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.
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 METAL GEAR servos with a minimum of 100 oz. in of
torque. We have had great success with the Hitec HS-5645 servos
in our prototypes. We are using the new HS-5985 for the rudder,
and recommend this servo or the JR 8611 for this position.
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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.
6. You may want to add a bead of silicone glue (Pacer Zap-A-DAP-
A-GOO, etc.) to the intersection of the plastic canopy/hatch and
its wood frame for additional strength and resistance to vibration.
DO NOT USE CA here as it will fog the canopy.
7. Add a fillet of epoxy over the hatch pin mechanism where it
mounts to the turtledeck and plywood former on the front of the
turtledeck. Be careful not to get any epoxy on the actual hatch
pin.
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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.
4. 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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5. 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. 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 slot 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.
6. 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. 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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7. Remove the covering from the holes for the hinges. We use an old
soldering iron for this and it works well. Locate 3 hinges per
elevator half.
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8. 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 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.
9. 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.
10. 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 clear packing tape. Be sure to
fully deflect the control surface when applying the tape or Ultracote
to allow full deflection once the gap is sealed.
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Wing Assembly
11.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. Use the same procedure to hinge the aileron
as outlined for the elevators. Repeat this procedure for the other
wing.
12. 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 (we use
and recommend the Bob Smith Industries IC-2000 in this
application) to the joints of the servo rails and the plywood rib
doublers.
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13. 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.
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14. Electronically center your servo. Aileron servo arm length should
be 1.25”. Although the picture below shows a clevis on the servo end of
the linkage, we have upgraded the hardware to include 2 ball links. We
highly recommend the use of a high quality aluminum servo arm such as
those manufactured by SWB or JR. When attaching the ball link to the
servo arm, be sure to use one of the brass standoffs between the ball link
and servo arm to prevent binding. As always use blue Loctite on ALL
bolts! You may find it necessary to snip off a couple of threads from the
ends of the included pushrods for proper fit in the aileron linkage.
15. 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 clear packing tape.
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Rudder Assembly
14.Locate the rudder, the rudder control horns and the 2 open slotted
base plates. Use a sharp #11 blade to remove the covering from the
2 pre-cut slots in the rudder.
15.Trial fit the 2 servo horns through the rudder and into their proper
position. You will want to measure so that the holes in the ends of
the rudder horn are equidistant from the hinge line and in-line with
the hinge line. Slide the open ended base plates over the rudder horn
and trace around them with a fine tipped felt marker. Before
removing the horns for gluing you may want to make a few
reference marks so it will be easy to re-align the control horns once
glue is applied.
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16. Remove the control horns and use a sharp #11 hobby blade to
remove the covering 1/16” inside the lines you drew in the previous
step. Mix up some 30 minute epoxy and milled fiberglass and use a
small blade to fill the 2 slots with epoxy. Use plenty of epoxy and
be sure to completely fill the two slots. Use an epoxy brush to
completely cover the areas on the rudder horns that will glue into the
rudder. Slide the rudder horns back into their proper position and
immediately wipe the excess epoxy from the horns. Paint the 2 flat
base plates with epoxy and slide into position. Carefully check and
re-check alignment to insure proper positioning. Use some
denatured alcohol and a paper towel to remove any excess epoxy.
Re-check the alignment one more time and set the assembly aside to
dry.
17. Locate the small brass connector in the hardware package.
Measure back 2 inches from the leading edge of the rudder and drill
a small hole in the bottom of the rudder. Apply some epoxy in the
hole and onto the threads of the connector and screw it into the
bottom of the rudder. Use some epoxy to make a small fillet around
the base of the connector.
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18.Using the same procedure as before, attach the rudder to the rear of
the fuselage with the three hinge points.
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Fuselage Assembly
19. We’ll begin by assembling the landing gear and attaching it to the
fuselage. Open the two holes in the landing gear with a drill to
accept the axles. Insert the threaded shaft into the gear and retain
with the nylon insert lock nut. Repeat for the other axle.
20.Place a wheel collar on the axle 1/4” from the inside edge of the
axle. I recommend that you file a small flat area in the axle for the
setscrew in the wheel collar to seat against. Place the wheel on the
axle followed by another collar to retain the wheel. Be sure to use
blue Loctite on the setscrews.
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21. Use a ball driver to insert the bolts through the holes in the
aluminum landing gear mounts from inside the fuselage. This is made
much easier by slipping a piece of large fuel tubing over the end of the
ball driver and over the end of the 8-32 socket head cap bolt. Push the
bolt through the landing gear and retain with a #8 flat washer and a 8-
32 nylon insert lock nut. Repeat for the other 3 bolts.
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21. Locate the carbon fiber tail wheel assembly. Slide the steering rod
through the hole in the connector on the bottom of the rudder. Center
the assembly on the rear bottom of the fuselage and drill 2 1/16”
inch pilot holes, using the predrilled holes in the carbon fiber gear as
guides. Mount the gear using the supplied wood screws. The Yak is
now ready to be flipped over onto its “feet”.
22. Mount the rudder servo as shown in the servo tray under the
canopy.
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23.You will need to use a 3” servo arm for the rudder pull-pull system.
We highly recommend one of the high quality aluminum servo arms
from SWB or JR. Assemble the pull-pull components as shown in
the picture below at both the rudder horn end and servo end
(although the rudder servo arm you provide will probably be a single
truss design). The pull-pull cables will exit the fuselage through the
tubes installed on each side of the fuselage as shown.
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