Pilot Communications Bergfalke II-55 Glider User manual

Bergfalke II-55 Glider
5,5meter/217’’ wing span
-Instruction manual-

1-) Locate the stab/elevator
assembly. From the bottom Left
side, cut into the covering,
exposing both pre-cut slots.
2-) Using a sanding bar, sand
the top section of two supplied
control horns on both sides and
clean with alcohol.
3-) Sand one side only of the
horn retainer as shown. The
sanded side will face on the
elevator surface.
4-) Trial fit both horns with the
horn retainer and adjust as
required for perfect matting.
Sanded
surfaces
-Bergfalke II-55 Glider- 2

5-) Insert the horn assembly into
the Left elevator and cut the
covering around the horn
retainer.
8-) Align both horns so that the
holes in both of them are
parallel to each other. Let the
epoxy cure. Repeat the same
process for the Right elevator.
7-) Also apply epoxy on the
horn assembly, where it will fit
into the elevator.
6-) Remove the covering. Mix
some 30-minute epoxy and
apply some into the elevator
slots.
-Bergfalke II-55 Glider- 3

9-) Locate the rudder and
repeat the same process as the
elevator to open the cavity for
the rudder horn.
12-) Slide one retainer as
shown to keep the assembly in
line. The sanded surface must
face inwards of both horns.
11-) Also sand the two rudder
horn retainers (Left/Right) and
clean with alcohol.
10-) Sand the two rudder horns
(center-section only) and clean
with alcohol.
-Bergfalke II-55 Glider- 4

13-) Like the elevator, apply
epoxy to the horn assembly
and insert into position.
16-) Locate the wheel &
accessories.
15-) Repeat the horn assembly
proceedure for both ailerons.
14-) Position the second horn
retainer with epoxy and adjust
both horns so that they
properly match.
-Bergfalke II-55 Glider- 5

17-) Insert the screw from one
side, slide on one spacer and
the wheel.
20-) Do the same on the front of
the stab fuselage saddle section
to expose the pre-installed blind-
nuts.
19-) On the top and bottom (front
section) of the stab, locate the
two small holes. Remove the
covering to expose the holes.
18-) on the other side, slide the
other spacer, push in the screw
and secure the screw using the
Nylon lock-nut.
-Bergfalke II-55 Glider- 6

21-) Underneath the stab, at
the rear section, notice the
small notch.
24-) Position the rudder onto the
fin by aligning the pre-installed
hinges and slide the steel wire
through all of the hinges as
shown.
23-) Position the stab by sliding
it into the inter-lock inside the
fuselage and secure it with two
40mm screws and washers. Once
positioned, glue the stab to the
fuselage, after final assembly
only.
22-) This notch will inter-lock
with the fuselage stab saddle
section.
-Bergfalke II-55 Glider- 7

25-) Push the steel wire until it
reaches the bottom hinge as
shown.
28-) On the rear Left side of the
fuselage, in front of the stab
saddle, open the elevator servo
cavity by cutting the covering
film.
27-) Then, cut the steel wire
flush with the wheel collar.
26-) From the top, slide the
plastic round disc and secure it
with the small wheel collar.
-Bergfalke II-55 Glider- 8

29-) The elevator servo requires a
48’’ (121cm) servo lead extension.
Secure both the servo and the
extension with one of the supplied
Grey safety clips.
32-) Insert the elevator servo.
Drill small pilot holes and
secure with servo screws.
NOTE: The front of the servo
must go towards the front of
the fuselage.
31-) Cut off the string and
attach it to the servo extension
lead. Use tape to “wrap”the
string around the connector.
Inside the cockpit section, pull
on the other end of the Red
string and pull in the extension
lead.
30-) Inside the fuselage, there
is a small wood piece with a
Red string attached to it. Snap
off the wood piece.
-Bergfalke II-55 Glider- 9

33-) Secure the stab to the
fuselage. Plug your elevator
servo in your receiver and
center it. Attach the supplied
elevator pushrod to the servo
arm. That pushrod as two ball-
links factory installed onto it.
36-) Carefully seek the small
cavity for the rudder pull-pull
cables on both sides of the
fuselage. Look at the picture
carefully for reference. Use a
knife to cut and remove the
covering.
35-) Completed elevator
assembly. Now, remove the
stab for the next step. Repeat
the process for the Right
elevator servo.
34-) Attach the other end of
the pushrods to the elevator
horn. Use the supplied key to
adjust the pushrod
mechanically.
-Bergfalke II-55 Glider- 10

37-) The opened cavity will
look like this on the Right side.
40-) Secure your arm
underneath the composite arm,
making sure that both center
holes are in line.
39-) Use one of your servo
arms and the supplied
composite rudder arm.
38-) Left side. Go around any
covering openings with a
“covering iron”to prevent the
covering from peeling off.
-Bergfalke II-55 Glider- 11

41-) Once centered, secure
both of them using thick C.A.
Let cure.
44-) Install your rudder servo, plug
it into your receiver and center it.
Secure the rudder servo arm
assembly. Locate the pull-pull
cables. Two of the ball links are not
crimped on the cables. Remove
them and screw them to the rudder
arm as shown.
43-) On the other side, install
small nuts on the small screws
and secure them with thick
C.A.
42-) Drill two holes
(more/depending of your servo
arm choice) and insert some of
the supplied small screws.
-Bergfalke II-55 Glider- 12

45-) A simple trick to “fish-in”
the pull-pull cables is to use a
small diameter pushrod and
“tape”one end of one of the
cables. Then, pull the cables in.
48-) Cut the remaining cable
and slide over the heat-
shrinkable tube over the Brass
crimps. Using a heat-gun,
shrink the tube as shown.
47-) Attach the other ends to
the ball link connectors as
shown and “crimp”the Brass
retainers. NOTE: Crosse the
cables in an “X”fashion inside
the fuselage. This will provide
a thither pull-pull cable set-up.
46-) Secure the pre-assembled
cable ends to the rudder horn.
-Bergfalke II-55 Glider- 13

49-) In the cockpit, front
section, there is a cavity for the
“tow release system”. Install a
servo in that cavity.
B-) Open
position.
A-) Closed
position.
50-) Look for a pushrod with
one ball link on one end only.
Attach it to this servo. This
pushrod will exit from the nose
and will secure the towing
cable to your glider (see next
two pictures)
-Bergfalke II-55 Glider- 14

51-) Wing spoilers. Temporarily
secure the spoilers in place on
the wing panels using masking
tape at both ends of each
spoilers.
54-) Then, add another smaller
Brass spacer as shown. You will
need to “shave”the spacers for
proper fitting between the
spoiler hinges. Then, secure the
screw with an M3 nut (Do not
over thigh the nut)
53-) Start with either tip
spoiler hinges. Insert one Brass
spacer using one of the M3
screws.
52-) Also place a strip of
masking tape in the middle of
the spoilers (important)
-Bergfalke II-55 Glider- 15

55-) Same process for the
center spoiler hinge.
B-) Spoilers up
position.
A-) Spoilers down
position.
56-) Remove the masking tape.
Using your finger, locate the
three slots in the wing, in front
of the spoilers. Once located, cut
the covering to allow the
spoilers to move upwards.
-Bergfalke II-55 Glider- 16

57-) Prepare the spoiler servo by
attaching an appropriate servo
lead extension and securing with
a Grey safety clip. As for the
elevator, you will find a Red
string attached to the root rib
and near the servo cavity to
“fish-in”the servo lead
extensions.
60-) Slide the pushrod from the
bottom of the wing into the
front servo cavity. Attach one
end of the pushrod to the
center spoiler rib as shown.
59-) Prepare a 3 ¼’’ (82mm)
long pushrod and put one ball
link at each ends.
58-) Position the servo exactly
as shown and secure with servo
screws. A long screwdriver will
work fine to secure the screws
in place.
-Bergfalke II-55 Glider- 17

A-) Spoilers DOWN.
61-) Secure the top spoiler servo
cover at each corners with the
supplied wood screws.
B-) Spoilers UP.
62-) Secure the bottom spoiler
cover at each corners and center
with the supplied wood screws.
-Bergfalke II-55 Glider- 18

66-) Make sure that there is no
play or friction at all pivot
points in the linkages.
65-) The picture is self-
explanatory. Secure the cover
with the supplied wood screws.
64-) Secure one servo on the
cover with four servo screws.
63-) Aileron servo. Bond two
supplied wood blocks with 30-
minute epoxy as shown. Just
follow the laser-burned lines
on both W39L covers for
reference.
-Bergfalke II-55 Glider- 19

-Surface deflections-
Elevators:
-Low rate: 15 degrees (up/down)
-Hi rate: 21 degrees (up/down)
Rudder:
-Low rate: 15 degrees (Right/Left)
-Hi rate: 20 degrees (Right/Left)
Ailerons:
-Low rate: 13 degrees up/4 degrees down
-Hi rate: 18 degrees up/7degrees down
Spoilers:
-Full speed: Flush with the wing skin
-Brake speed: 40 degrees open/up position
-Centre of gravity-
-The C.G is located at ¾”/19mm behind the leading edge of
both wing panels, near the fuselage section.
-It is normal to add up to 4 pounds/1.8 kilo in the nose
section to balance this glider.
-Bergfalke II-55 Glider- 20