Flatfoilz Extra 300 User manual

FlatfoilZ Assembly Guide

EXTRA 300, EDGE 540, LEK-TRICK & STALKER

Version 1.0

10-27-11

Limited Warranty

FlatfoilZ takes pride in the care and attention given to the manufacture of the components in this kit. The

company warrants replacement of any materials found to be defective for their intended use prior to their

use in the construction of the model, provided the purchaser requests such replacement within a one year

period from the date of purchase, and the part is returned, if so requested by the Company. No other

warranty, expressed or implied, is made by the company with respect to this kit. The purchaser assumes

full responsibility for the risk and all liability for personal or property damage or injury resulting from the

purchaser’s use of the components of this kit whether assembled or not.

The Company reserves the right to provide a full refund to the purchaser if the model does not perform as

advertised. Any refund is at the sole discretion of the Company.

Introduction:

Thank you for choosing one of the FlatfoilZ Profile Series airplanes. The assembly of all the

FlatFoilZ planes is very simple and requires a minimum of building skills. This Quick Start Guide is

provided for those with some building experience. The full Assembly Manual is available at 3DX

Hobbies.com. Warning

This radio-controlled model is not a toy and, if operated inappropriately can cause serious

bodily injury and property damage. It is the buyer’s responsibility to assemble the kit correctly

and properly install the motor, radio and all other equipment. The model must always be flown in

accordance with the safety standards of the Academy of Model Aeronautics (AMA).

Recommended Power System:

The FlatFoilZ series of planes have been designed to use a 175 to 250 watt power system.

Recommended motors include the Hacker A20-20L, Scorpion 2215-18, or AXI 2217-16. The

prototypes were flown with a 1350 mAh, 3S Li-poly battery and a 25 amp ESC. Other power

systems with similar capabilities can be used. Performance will vary depending on the specific

power system selected. For information on alternate power systems please visit

http://3dxhobbies.com or your local hobby shop.

General Comments on Assembly:

While not difficult to assemble, the FlatFoilZ Series kits are intended for persons with some building

experience. As such, the instructions are presented as a simple sequence that, when followed, will

help ensure that the airframe turns out straight and light. Improperly aligned surfaces and

unnecessary weight will only hinder its performance. All the FlatFoilZ prototype wings and fuselages

were laminated using 15 minute epoxy thinned with alcohol. Apply glue and epoxy in a thin uniform

coat, using only enough to achieve a strong bond. Excess glue or epoxy will only add unnecessary

weight and will not increase the strength of your model. Trial fit all components to ensure fit and

alignment before applying any glue or epoxy. Keeping joints tight fitting will minimize the amount of

glue required and will ensure a strong bond. Use a light touch while sanding. Foam cuts very

quickly and excess pressure can limit your ability to accurately shape the foam. Take extra care not

to over sand. Avoid scratching the surface of the Depron foam.

Fuselage Assembly:

The fuselage assembly on the FlatfoilZ NX Profile Series kits consists of a 6 mm depron laser cut

core, over which are laminated 3 mm depron skins. A 6 mm carbon tube is embedded in the 6mm

core piece.

Exploded View of Typical Fuselage Assembly

Fuselage with Right Skin and Carbon Fiber Spar in Place

Completed Fuselage Assembly

Follow the steps in the order outlined below to ensure accurate alignment of the

components.

Step 1

Apply thinned 15 min

epoxy to one side of the

6mm fuselage core and

position the core on the

3mm fuselage skin .

Step 2

Apply epoxy into the

center slot in the

fuselage core and insert

the 6mm carbon tube

spar into the slot.

NOTE: Lightly sand the

surface of carbon tube

for better glue adhesion.

Step 3

Apply thinned 15 min

epoxy to the other side

of the 6mm fuselage

core and position the

other 3mm fuselage skin

over the core.

Step 4

Place the glued

assembly on a flat

building surface and

weigh down to ensure

the assembly dries flat

and true.

Step 5

Glue the 3mm depron

nose doublers on both

sides of the fuselage.

Step 6

Test fit the ply motor

mount in the fuselage

opening.

Step 7

Cut the balsa tri-stock

motor mount supports

to the proper length and

check their fit behind

the motor mount.

Epoxy the motor mount

and balsa tri-stock rear

supports in place

making sure that the

motor mount is square

to the fuselage.

If you would like to finish the edges of the fuselage, use your sanding block to smooth and

either bevel or round the edges approximately 1/8inch. Sand the edges of the motor mount

and motor mount supports smooth using a sanding stick or emery board.

Wing Assembly and Installation

The fuselage assembly on the FlatfoilZ NX Profile Series kits consists of a 6 mm depron laser cut

core, over which are laminated 3 mm depron leading edge skins. A 6 mm carbon tube is embedded

in the 6mm core piece.

Exploded View of Typical Wing Assembly

Wing with Bottom LE Skin and Carbon Fiber Spar in Place

Completed Wing Assembly

Wing Assembly:

Step 8

Join the two wing cores

together using 5 minute

epoxy.

Step 9

Cut the spar slot through

the center joint.

Step 10

Apply thinned 15 min

epoxy to the bottom side

of the 6mm wing core

and position the core on

the 3mm bottom LE

skins. NOTE: Test fit the

bottom LE skins on the

wing core and lightly

mark where the rear edge

is located on the wing

core. Only apply the

epoxy up to that line.

Step 11

Apply epoxy into the spar

slot in the wing core and

insert the 6mm carbon

tube spar into the slot.

NOTE: Lightly sand the

surface of carbon tube

for better glue adhesion.

Step 12

Apply thinned 15 min

epoxy to the top side of

the 6mm wing core and

position the top 3mm LE

skin over the wing core.

Step 13

Place the glued assembly

on a flat building surface

and weigh down to

ensure the assembly

dries flat and true.

Step 14

After the epoxy has

cured, sand the wing LE

round.

Wing/Fuselage Assembly:

Step 15

Test fit the wing in the

fuselage. DO NOT

FORCE! If the fit is

tight, gently sand the

fuselage opening to fit.

Make sure the wing is

centered on, and square

to the fuselage. With

the wing properly

aligned, tack glue it in

place with medium foam

safe CA.

Permanently glue the

wing in place by forming

a fillet from mixture of

15 or 30-minute epoxy

and micro balloons.

Tail Feather Assembly:

Installing the Elevator Joiner: (Note: Not required on the Stalker)

Step 16

Using the end of the

3/16” diameter carbon

elevator joiner, gently

create a shallow grove

in the elevator joiner

cutout.

Step 17

Secure the 3/16”

diameter carbon

elevator joiner in place

with epoxy. Tip: For a

lighter joint, a mixture of

15 minute epoxy and

micro balloons can be

used.

Step 18

Cut out the foam bridge

behind the wood joiner,

between the elevator

halves.

Installing the Horizontal Stabilizer Spar: (Note: Not required on the Stalker)

Step 19

Glue the 1/8” x 1/4”

balsa horizontal

stabilizer spar to the

rear of the horizontal

stabilizer

Step 20

Test fit the horizontal

stabilizer in the fuselage

and check that it fits

square to the fuselage

and wing. Glue the

stabilizer in place with

medium foam safe CA.

Step 21

Trim the rear of the

horizontal stab slot in

the fuselage. Install the

elevator and apply the

hinges. (Not required

on Stalker)

Note: See Control

Surface Hinging section

below for installing tape

hinges.

Step 22

Glue the 1/8” x 1/4”

rudder post in position

using foam safe CA.

Sand the rudder post

flush with the top of the

vertical stabilizer and

with the bottom of the

fuselage. (Not required

on Stalker)

Step 23

Trim the back of the

fuselage at an angle to

match the rudder post

using your Exacto knife.

This allows clearance

for the rudder control

horn. (Not required on

Stalker)

Control Surface Hinging:

All the control surfaces on the prototypes were hinged with tape. Any number of schemes can be

used. However, we prefer the Over/Under method outlined below.

Making Over/Under Tape Hinges:

Step 24

Using a sanding block,

bevel the edge of the

both mating surfaces

along the hinge line.

Step 24a

Hinges are made by

overlapping 2 pieces of

tape together along the

hinge line. One side

goes on top of one

surface and the other

side goes on the bottom

of the mating surface.

Step 24b

Attach the 2 pieces of

tape together before

attaching to the

surfaces.

Step 24c

Apply the hinges in

groups of three along

the length of the hinge

line.

Typical Control Horn Installation:

Step 25

Sand the edges of the

plastic control horn

parts to remove the

edge caused by the

laser cutting. Test fit

the pieces together.

Note: The control horn

with the short mounting

tab is for the elevator.

Step 26

Mark the location of the

control horn on the

control surface and cut

a slit in the control

surface with an Exacto

knife to accept the

control horn mounting

tab.

Step 27

Glue the control horns

in place with medium

foam safe CA or Epoxy.

Servo and Pushrod Installation:

Servo Installation:

Step 28

Test fit the servos in

their mounting holes.

Install the plastic servo

mounts using medium

foam safe CA. Secure

the servos in place with

the servo mounting

screws provided with

the servos. Do not over-

tighten the screws as

you may strip the screw

holes.

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