PCM SAL-DLG FIREWOR-X-TEND Instruction Manual

Firewor-X-tend Building instruction January 2009
Wing span [mm]: 2000
Takeoff weight [g]: 420
Airfoil: AG 455ct-02f
AG47ct-02f
von Mark Drela
BUILDING INSTRUCTION
SAL-DLG FIREWOR-X-TEND
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Firewor-X-tend Building instruction January 2009
CONTENTS
DATA
1. Kit – contents
2. What else do you need?
3. Electronic equipment
4. Settings for the first flight
ASSEMBLING THE MODEL
5. Stabilizer
5.1 Installation of the CFR-stab
5.2 Torsion spring for the rudder
5.3 Connection of the wire for the rudder
5.4 Installation of the elevator
6. Fuselage – radio board
7. Controlling of the ailerons
8. Installation of throwing blade
9. Optimizing
10. Installation of antenna
OTHER
11. Check list before starting
12. Notes for the use
3
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4
6
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7
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Firewor-X-tend Building instruction January 2009
DATA
1. Kit – contents
Fuselage + canopy
Wing, two parts, + connector
Elevator and rudder CFR
Radioboard
Carbon rods for mounting elevator, 2 pieces
Carbon lever for rudder, 1 piece
Carbon levers for ailerons, 2 pieces
Plastic tube for push rods, 2 pieces
Carbon pipe for push rods, 2 pieces
Carbon covers, 2 pieces, for mounting rudder
Carbon covers, 2 pieces, for wingservos
Carbon cover, 1 piece, for wing/fuselage
Kevlar wire for controlling rudder
Steel wire for spring, 1 piece
Screws for fixing wing, 4 pieces
Aerodynamical fences, 2 pieces
Throwing blade, 1 piece
Building instruction
2. What else do you need:
Epoxy-glue (for example UHU 300 endfest or Stabilit, no fast
hardening epoxy resin)
Super glue
Cotton flocks (for thickening glue)
Electrical equipment (On/Off-switch, cables, plug, ...)
Electronic equipment
Steel wire, shrinking tube...
(Voltage control recommended, f.e. DLG-saver from Simprop)
3. Electronic equipment
Servos rudder:
- Dymond D47 - Futaba FS31
- Expert X31
Servos elevator:
- Dymond D47 - Futaba FS31
- Expert X31
Alternative (stronger):
- HS 5055 MG
Servos ailerons:
- Dymond D60 - Hyperion HP-DS09SCD
Accumulators: - GP NiMH Zelle 400mA/h, (+35g lead necessary)
- Enelope 800mA/h, AAA, (+19g lead necessary)
- Sanyo HR-40 1000mA/h, AAA, (also app. +19g lead necessary)
Receiver: - MZK Sexta
- Jeti Rex 540MPD
- Rx Schulze 835
Logger: - Logo
- Lola
- Ram3
- Z-Log
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Firewor-X-tend Building instruction January 2009
4. Settings for the first flight
Centre of gravity: 65mm (62-70mm)
(measure from the leading edge of the wing to the back)
Ailerons (measure near fuselage)
Flaps negative (start, speed) (measure near fuselage)
Flaps positive (thermal) (measure near fuselage)
Landing position (measure near fuselage)
Snap Flap (measure near fuselage)
Rudder (measure at deepest point)
Angle of attack of elevator (for first flight): set elevator parallel to axis of boom, slightly pulled
(1,5mm)
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Firewor-X-tend Building instruction January 2009
ASSEMBLING THE MODEL
General information on DLG-models
DLG-models are constructed strong enough to withstand the demands of starting, flying and
landing and at the same time light enough to achieve the least possible flying weight. Each part is
dimensioned to its possible minimum and produced using lightest and fewest material.
In order to continue this concept, please account the following when you assemble the model:
- Always use glue sparingly. Grind all gluing spots thoroughly, before you apply the glue.
- Try to save weight especially when you finish and mount the stabilizer to avoid additional
lead in the nose of the fuselage for the correct centre of gravity.
As Firewor-X-tend is constructed very similar to Fireworks 4, you will find some pictures of Fireworks 4
and also Mini-Fireworks in the following instruction. Don’t let yourself be confused by this, the way of
building is quite the same.
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Firewor-X-tend Building instruction January 2009
5. Stabilizer
5.1 Installation of the CFR-stab
Sand the rudder wedge-shaped on the hinge line, so that you can move it in both directions. Note
that the hinge line must be placed on the left side (looking towards flight direction) for right-
handers and the other way round for left-handed persons.
Next, glue the lever in extension of the axis of the boom. The hole of the lever should be above
the hinge line. Fix the control surface of the rudder with adhesive tape.
Before you fix the stabilizer to the fuselage, thread the
kevlar wire through the boom to the hole in the fuelage
cone.
Then, check the good fit of the rudder. The axis of the
boom should be right-angled to the hinge line of the rudder.
The kevlar wire should not chafe on the sharp carbon. It
must be free movable.
Sand the part of the boom which will be positioned in the
stab and about 1-2cm before.
If the stabilizer is aligned correctly on each axis, let super
glue run into the upper and lower join from both sides. Pay
attention to the kevlar wire, so that it keeps free movable.
Last, glue the two carbon covers left and right of the join
also with super glue. Note, that the hole for the installation
of the elevator must be kept open.
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Firewor-X-tend Building instruction January 2009
5.2 Torsion spring for the rudder
Bend the wire according to drawing.
Tip back the control surface of the rudder completely.
(You see it here at Fireworks 4.)
Stick the spring into the balsa material and then harden
the balsa with super glue.
5.3 Connection of the wire fort he rudder
Now you can hook in the kevlar wire into the lever.
Make a loop, twist the end and put the end of the wire into
a shrinking tube. Shrink it and fix it with a drop of super
glue.
(Here show on Mini-Fireworks.)
In order to lead the wire into the boom, drill a little hole in
the carbon cover.
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Firewor-X-tend Building instruction January 2009
5.4 Installation of the elevator
Fix the carbon rod (2mm) with superglue in the rudder.
he elevator will keep the distance between the two carbon
evertheless, check the elevator for free movability. If
Now you can mount the elevator.
T
rods. If you move the spring without the elevator mounted,
the spring may disappear inside the rudder. Only when the
elevator is mounted, the spring will move along the track cut
out.
N
necessary, enlarge the hole in the rudder.
You can stick the 2 halves of the elevator to each other on
the leading edge with an adhesive tape to avoid
unintended demounting.
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Firewor-X-tend Building instruction January 2009
6. Fuselage – radio board
In order to gain full strength, it is absolutely necessary to
fix the servoboard in the fuselage!
Before you fix the servoboard in the fuselage, grind the
gluing spots thoroughly and strengthen the edges of the
servo board with super glue.
Before you glue the servoboard, you should first find out
the optimal position. To do so, place the servoboard
inside the fuselage without gluing and mount servos for
vertical and horizontal stab.
Make sure that all levers are freely movable (also with
canopy mounted), and that the deflections of the levers are
big enough.
Note, that the holes in the servoboard are accessible and
that the servos can be screwed without problems from
outside.
You can variate the position of the servos with small blocks
of wood.
(Here you see the fuselage of Fireworks4.)
You can fix the servoboard with a drop of super glue to
make the position check easier.
Then, glue the board carefully with epoxy-glue (for
example UHU 300 endfest or Stabilit, no fast hardening
epoxy resin). You can add carbon rovings left and right of
the gluing spots for additional strength.
If you have a hard landing, always check if the servoboard
is still fully glued before you make the next start!
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Firewor-X-tend Building instruction January 2009
7. Controlling the ailerons
Cut a hole on the underside of the wing with a sharp knife
app. 26-28cm from the mid of the wing. Note not to cut
the carbon roving grid.
If the carbon disser is
behind the balsa,
hold the wing
against light to see
it. The hole should be
slightly bigger than
the servo itself.
Shorten the lever of
the servo, so that it
can be moved inside
the wing.
Pack the servo inside
a shrinking tube, so
you will be able to
remove it again.
Glue the servo with
Stabilit Express or
with a 5minute
Epoxy.
Use a steel wire,
d=1mm, as pushrod.
You can make a
variable joint by
cutting the steel and
gluing a piece of
carbon pipe on one
end.
Drill a hole to lead
the push rod
through the wing and
glue a plastic tube for
better leading of the
push rod.
Cut 2 slits as shown
for fixing the lever.
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Firewor-X-tend Building instruction January 2009
The hole in the lever
should be a little bit
in front of the
turning axis of the
rudder.
Glue the lever with
epoxy glue or Pattex
Stabilit.
Now you can thread
in the steel wire.
Hook the second part
of the pushrod into
the lever of the servo
and thread it into the
joining carbon pipe.
Hold the aileron in
zero-position with a
ruler. Now put a drop
of super glue in the
carbon pipe to fix the
length of the
pushrod.
Cover the hole in
the shell with the
carbon cover.
You can install the
plug for the servo in
the wing as shown.
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Firewor-X-tend Building instruction January 2009
8. Installation of the throwing blade
(Shown at Fireworks 4.)
Grind the blade, so that it gets an aerodynamical cross-
section and it feels handy when you hold it in your fingers.
Don't make the trailing edge too sharp, you might injure
yourself when throwing your DLG.
Lay the paper
template on the
wingtip and thrill a
hole at the marked
spot.
(Both wingtips - left
and right - are
prepared for the
installation of a
throwing pin or
blade.)
Mark the length of
the blade.
Remember, that the
axis of the blade
should be turned a
little bit to the
fuselage (looking in
direction of flight).
Now cut an opening
into the wing with a
small driller or a
milling cutter.
Alignment
Side view:
Tilt the blade on the upper side of the wing a little bit in
the direction of flight.
Front view:
Mount the blade right-angled to the wing.
View from above:
Turn the axis of the blade a little bit to the fuselage
(looking in direction of flight).
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Firewor-X-tend Building instruction January 2009
If the cut is big enough, put the blade through and align it
in all directions (see above).
When the position is correct, fix the blade with super glue.
Ready mounted
throwing blade
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Firewor-X-tend Building instruction January 2009
9. Optimizing
In order to optimize the aerodynamical transition
between aileron and fuselage, you can glue the
aerodynamical fences enclosed.
Ready mounted fences on Firewor-X-tend.
In order to move the triangular ends of the ailerons, you can
bend a piece of steel wire (1mm) and glue it into the end of
the aileron as shown. Let the wire jut out about 6mm. You
can bend the end of the wire to ensure not to cause damage
to the shell on the inside.
The easier way is to connect the control surfaces with
adhesive tape (see picture).
As you nearly don’t recognize a damage of the leading edge
of the wing (f.e. after hard landing), we advise to put a strip
of adhesive tape over the leading edge.
The film is thin enough not to disturb the aerodynamic, but it
surely will extend the lifetime of your Firewor-X-tend.
Cover the screws with a piece of tape in order to improve
aerodynamics.
Cover the gap behind the rear screw either also with tape
… (as you see it here with Fireworks 4 carbon lite)
…or with the little carbon tile enclosed. Glue it on the part of the fuselage that is placed between
the two ailerons.
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Firewor-X-tend Building instruction January 2009
You can thread in the wing from the front when mounting
the wing on the fuselage.
Firewor-X-tend fuselage with ready glued carbon tile.
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Firewor-X-tend Building instruction January 2009
10. Installation of antenna
In order to have an undisturbed reception a part of the
antenna must be situated outside the model.
An easy solution is to fix the antenna to the end of the
elevator. Lead the antenna inside the fuse behind the wing
and then leave the fuselage.
Another possibility is to lay the antenna inside the gap of
the aileron. For improving reception on carbon wings you
can solder the antenna to a steel wire, d=0,3mm, which you
fix at the end of the wing and let stand out to the back about
10-15cm.
Always TEST THE RECEPTION on ground before you
fly!
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Firewor-X-tend Building instruction January 2009
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OTHER
11. Check list before starting:
1. Check centre of gravity
2. Check control surfaces:
Do control surfaces move in the correct direction?
Check the greatest swings
3. Check reception:
Leave the antenna inside the radio control and go
away from the glider up to a distance of about 60m.
The control surfaces should not tremble.
12. Notes for the use
Firewor-X-tend ist parly built with visual carbon fibre. To
avoid heating of the carbon surface, the model should not
lie in the sun too long. During flight heating by the sun is
no problem, as the model is cooled by the wind. On
ground the glider should be kept in the shade.