Polycote ECS DORNIER DO 27 Installation and operating instructions

DORNIER DO 27
SEMI SCALE SPORT MODEL
Assembly
and
Operations Manual
Please review this manual throughly
Before assembling or Operating
The
DORNIER DO 27
Semi scale sport model
DORNIER DO 27
We’ve used our ULTRA TOUGH POLYCOTE ECS Enhanced Covering System
for this Model
TM

Stage 1
JOINING THE WING HALVES
To join the wing halves you will need the following items :
2 aluminium wing joiner tubes supplied with kit (dia. 19mm,
900mm length)
One 4-30 machine bolt with 1 butterfly nut
Two 1.5 mm steel washers
Two 2.5 mm wooden washers
2
1.2 Trial fit the aluminium wing joiners
1.4 Pushing slowly the aluminium wing joiner tubes
to the second wing panel and slowly close the gap
TM
1.1 Two aluminium
wing joiner tubes and
wing bolt clam set
Wing joiner slots
Wing bolt clam hole
Center lines
1.3 Push two alu. joiner tubes into the slots of the
first wing pannel all the way to the center lines
Center lines
1.5 Use wing bolt clam set to hold the both wing
panels together
1.6 Cut away wing bolt set
WING ASSEMBLY

Stage 2
Stage 3
3
FITTING AILERON SERVOS
To install the aileron servos into the wing you will need the
following items :
- 2 servos
- Servos mounting screws and grommets as supplied with
servos.
- Servo control arms as supplied with the servos.
- Two aileron control rod assemblies supplied with the kit.
The assemblies consist of a metal rod with a plastic clevis
screwed onto one end.
- Low tack masking tape.
- 2 aileron control horn assemblies
2.1 Prepare the servos by fitting the rubber
grommets & ferrules supplied with your radio
Carefully remove the cover plates from the aileron servo
cavities. Ensure you know which cover plate is for the right
wing and which is for the left. Remove the white cover plates
and retain the mounting screws. Notice that there are wood-
en servo rails pre-installed into each servo cavity end. Locate
the wiring harness tubes that are protruding slightly into
each aileron servo cavity. The tube can be moved slightly at
this point. Check out the other end of each tube for a clean
position and then using C/A glue secure the wiring harness
tubes at the aileron servo cavity end.
Install a servo in each aileron servo cavity and connect the
servo wire to the servo extension wires and run the extension
wires through wiring harness tubes to the centre of the wing
Install the aileron control horns
Aileron servos cavity
2.2 Aileron servos location
2.3 Aileron servos mount 2.4 Srew servo in position 2.5 Install aileron control horn
Step 1 Consult your radio instruction manual and center each aileron servos by plugging it into the aileron channel
in the receiver. Turn on the transmitter and then the receiver. Center the aileron trim lever on the transmitter.
Remove the servo arm mounting screw and the servo arm.
Step 2 Mount the servo arm back on the servo. Position the arm to be parallel with the back edge of the wing. Screw
the arm into place with the servo arm mounting screw supplied with the servo.
Locate the two aileron control rods in the hardware bag. Ensure the clevises are screwed well onto the threaded
portion of the rod. Rotate and tug aggressively on the clevises and ensure that they are not loose on the rods.
Tape the ailerons into their neutral position so that they are even with the trailing edge of the wing and not pointing
either up or down.

Stage 4
4
Step 3 Ensure that the aileron control horns are screwed onto the threaded aileron control horn bolts and that both
control horns are in approximately the same place on their respective bolts.
Step 4 Connect the aileron servo rods to the aileron control horns.The one end with clevis will be attached to the
servo output arm.
Step 5 Connect the other end of the rod to the control horn pre-installed with an EZ connector
Step 6 Remove the masking tape holding the ailerons.
Step 7 In the case of computer radios the servos together by connecting them to the appropiate receiver channel.
In the case of analog radios couple the servos together using a Y harness
Step 8 Turn on your radio and activate the ailerons, using the aileron stick and ensure a smooth full motion can be
achieved.
Step 9 With the wing top side up and viewed from the back, ensure that moving the transmitter aileron stick to the
left raises the left aileron and lowers the right aileron. Movement of the stick to the left will roll the aircraft to the left.
(Counterclockwise roll of the wing when viewed from the back ).
Step 10 With the wing top side up and viewed from the back, ensure that moving the transmitter aileron stick to the
right raises the right aileron and lowers the left aileron. Movement of the stick to the right will roll the aircraft to the
right.
3.1 Aileron control rod assembly 3.2 Aileron control horn assembly 3.3 Aileron control installed
FITTING FLAP SERVOS
To install the aileron servos into the wing you will need
the following items :
- 2 servos
- Servo mounting screws and grommets as supplied
with the servo.
- Servo control arm as supplied with the servo.
- Two flap control rod assemblies
- Low tack masking tape.
4.2 Flap servo location 4.3 Flap servo installed in position 4.4 Final flap instalation
Flap servo location
4.1 Flap control rod assembly

Stage 5
Stage 6
5
4.5 Flap down 4.6 Flap up
FITTING THE HORZONTAL AND VER-
TICAL STABILIZERS
To install the stabilizers to the fuselage you will need.
- Fuselage
- Vertical stabilizer with pre-installed rudder
- Horizontal stabilizer with pre-installed elevator
5.2 The completed fuselage slot should look
like this
Vertical slot
Horizontal slot
5.1 Horizontal stabilizers with pre-installed elevator
5.3 Vertical stabilizers with pre-installed rudder
Check the fit of the horizontal stabilizer
in its slot. Make sure the tail is square
and centred to the fuselage by taking
measurements as shown in the dia-
grams on the right, but don’t glue any-
thing yet.
Equal
distance
Equal distance
900
6.1 Trial fit the horizontal stabilizer in
its slot
FITTING THE HORIZONTAL STABILIZER WITH ELEVATOR

Stage 7
Stage 8
Stage 9
6
With the horizontal stabilizer correct-
ly aligned, mark the shape of the
fuselage on the top and bottom of
the tailplane using a water sol-
ublenon-permanent felt-tip pen as
shown here. 7.1 Mark the top of the horizontal
stabilizer
7.2 Followed by the bottom
Now remove the horizontal stabiliz-
er, using a sharp knife and a ruler
CAREFULLY cut 2mm inside the
marked lines and remove the cover-
ing on the top and bottom of the tail
as shown. Make sure you only cut
the film and not the wood, otherwise
the horizontal stabilizer wiil be
severely weakened.
8.1 Marked lines on horizontal
stab
8.2 Cutting inside the lines
8.3 Removed covering from top
surface
8.4 Exactly the same underneath 8.5 Clean off any traces of pen
Now apply sufficient epoxy to the top and bottom of the
horizontal stabilizer. Use 30 minute epoxy to ensure a
strong bond and give yourself plenty of working time.
Insert the horizontal stabilizer in its slot in the fuselage
and re-check the alignment as in Stage 9. Excess epoxy
should be cleaned off with a rag or tissue before it cures.
9.1 Apply plenty of epoxy 9.2 Slide the horizontal stabilizer
in place
9.3 Wipe off excess epoxy

Stage 10
Stage 11
Stage 12
7
Check the fit of the vertical stabilizer in its slot.
Make sure that it is glued square to the horizon-
tal stabilizer and fuselage
FITTING THE VERTICAL STABILIZER WITH RUDDER
10.1 Trial fit the vertical stabilizer onto fuselage.
11.1 Mark both sides of the verti-
cal stabilizer
11.2 Carefully cut through the
covering
11.3 Remove covering from both
sides
Mark the shape of the fuselage on the left and right
sides of the vertical stabilizer using a felt-tip pen. Now
remove the vertical stabilizer, using a sharp knife &
ruler, CAREFULLY cut just 2mm inside the marked
lines and remove the covering on both sides of the fin,
just as you did with the horizontal stabilizer, making
sure you only press hard enough to cut the covering,
not the vertical stabilizer.
Now apply sufficient epoxy to both sides and the bottom
of the vertical stabilizer. Use 30 minute epoxy to ensure
a strong bond and give yourself plenty of working time.
Insert the vertical stabilizer in its slot in the fuselage
and re-check the alignment. Excess adhesive should
be cleaned off with a rag or tissue before it cures.
12.1 Apply plenty of epoxy 12.2 Slide the fin in place

Stage 13
Stage 14
8
FITTING THE MAIN LANDING GEAR
Identify the main landing gear components shown
below
- 2 main landing gear esemblies
- 2 main wheels ( 60mm x 20mm)
- 1 ABS main landing gear cover (with 6 mounting
screws)
- 4 sheet metal screws 5 x 35 mm with traps
- 2 colars
13.1 Main landing gear components
13.2 Turn over the fuselage to
located the pre-drilled main land-
ing gear mounting holes
13.3 Use 4 sheet metal screws and
2 traps to mount the main landing
gear onto the fuselage
13.4 Pilot drill mounting holes
with 1/16 (or 1,6 mm) drill-bit
13.5 Mount the main landing gear
fairing with 2x10 screw
13.6 Install the wheel 13.7 Install the main landing gear
cover
FITTING THE TAIL WHEEL
14.1 Insert the tail wheel steering
wire into the steering guide tube
14.2 Screw the tail wheel assem-
bly to the fuselage
14.3 Trim off the excess tail steer-
ing wire
Install the tail wheel assembly. Note that the tail wheel
assembly has a loose wire end. Slide the loose wire
end into the sleeve tube that has been installed into
bottom of the rudder. Position the plastic bracket on
the bottom of the fuselage. Mark the location of the
screw holes. Tap the holes with the screws and then
fasten the plastic bracket to the fuselage. See the
illustration below.

Stage 15
Stage 16
9
FITTING THE FUEL TANK
To assemble the fuel tank you will need the following
items:
- The fuel tank and fuel stopper assembly (supplied)
- The clunk (supplied)
- About 7” (20 cm) of medium ID silicone fuel line (DUB
197 or similar)
- Cross head Philips screw driver
15.1 Use 100 mm (4 in) for fuel line
and 50 mm (2 in) for pressure line
15.2 Illustration of fuel line posi-
tioning inside the tank
15.3 Fuel tank installed on the
power module
100 mm (4 in) for fuel line
50 mm (2 in) for pressure line
fuel line
pressure line
INSTALLING THE ENGINE
The engine and the fuel tank are installed onto the
power module. First remove the power module from
the fuselage by removing the 4 nuts & washers
16.1 Aluminum engine mount 16.2 Power module assembly 16.3 Engine thrust line
Fuel tank
holder dowel Engine thrust line
16.4 Engine and engine mount
recommentdation orientation.
16.5 Engine and fuel tank posi-
tioned on the power module
16.6 Throttle control connection
to the engine

Stage 17
Stage 18
10
16.7 Cowl installation 16.8 Install the muffer and con-
nect the fuel and pressure line
16.9 Install the suitable prop and
spinner
FITTING ELEVATOR AND RUDDER CONTROL HORN
The elevator control is fitted on the underside of both right and left
of the elevator halves. Pierce the covering over the pre-drilled hole
for the control horns installation as shown.
17.2 Elevator control horn location 17.3 Rudder control
horns location
17.4 Elevator and rudder control
horn connected to the contrrol rod
17.1 Control horn assembly
Elevator control horn location
INSTALLING THE SERVOS
Install the rubber servo grommets and brass ferrules supplied with your radio
equipment. The three servos that control the elevator and rudder are
Installed in the servo tray mounted in the fuselage. Remove servo tray from
the fuselage, mounting the servos to the servo tray as shown. 18.1 Universal servo mount
18.2 Servo tray located under the seats. Remove
the seats to install servos
18.3 Pre-installed push rods on the fuselage
Unscrew
Rudder pushrod
Pilot stick con-
trol pushrod
Elevator pushrod