Sawn Craft Micro F-16 User guide

Revised 2013-12-30
Micro F-16 Assembly
and Setup Manual
Specifications
Recommended Power System
Wingspan
12”
RX/ESC/Servo
Spektrum AR6400 (or similar)
Overall Length
17.28”
Motor
Parkzone P-51 Motor & Gearbox (PKZ3624)
Wing Area
66.86 in2
or
Flying Weight
1.1oz
Hobbyzone Champ Motor & Gearbox (HBZ4930)
Intended Use
Indoor/Calm Winds
Battery
160mAh 1S 3.7V 25C LiPo (or similar)

Thank you from Sawn Craft.
Thank you for purchasing the Sawn Craft Micro F-16 aircraft. Like the full-scale USAF F-16, in your hands
is a remarkably versatile airplane designed to deliver a pleasure cruiser with an incredible look. The
lightweight and rigid EPS and carbon construction makes it possible for you to experience a wide
performance envelope. This means that no matter how you like to fly, you’ll enjoy both stability and
maneuverability without any sacrifice in precision or control feel.
Your Sawn Craft Micro F-16 aircraft represents the benchmark of ultra-micro performance and aerobatic
versatility. All you have to do next is read and apply the information presented in this instruction
manual.
I sincerely hope that you enjoy your model as much as we do! If you have any troubles with these
instructions or in the setup of your model feel free to contact us and we will provide you with the
service you expect from a hobbyist-owned and operated business.
Jonathan Sawn
Owner, Sawn Craft
[email protected]

Table ofContents
1 Introduction 1
1.1 Style Conventions 1
1.2 Required Tools & Supplies 1
1.3 Required Parts for Completion 2
1.4 Included Parts Description 3
2 Assembly Instructions 4
2.1 Fuselage Lamination 4
2.2 Wing Reinforcement Lamination 5
2.3 Elevator/Elevon & Rudder Hinging 6
2.4 Skid Installation 9
2.5 Fuselage Installation 10
2.6 Vertical Stabilizer Installation 11
2.7 Electronics Installation 12
3 Setup and Tuning 14
3.1 Center of Gravity 14
3.2 Control Throws and Expo 14
3.3 Launching 14
3.4 Flying Tips 15
3.5 Decorating/Finishing 15
3.6 Spare Parts 15

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1 Introduction
The contents of this manual assume the operator will have the following prerequisites:
Understanding of all appropriate safety procedures and requirements
The ability to follow written procedures and possess basic hobby building skills
1.1 Style Conventions
Below are the important style conventions that will be used throughout the guide.
Note: Key points or hints for success will be formatted in this manner.
Warning: Any area that poses either a physical hazard or the danger will be formatted in this manner.
Arrows inform where to click or to perform the specified operation.
Circled items inform of items of interest for the specified operation. Circled items will typically be
accompanied by text further identifying the region of interest.
1.2 Required Tools & Supplies
The list below contains all of the required tools and supplies that are required for the assembly and
tuning of this model.
Clean, flat work surface
#11 hobby knife
Straight-edge ruler
Soldering iron & solder
Heat gun
Wire cutters
Needle nose pliers
Foam-safe adhesive
Clear packing tape
200-grit Sandpaper on sanding block

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Sawn Craft recommends the use of Beacon Foam-Tac adhesive and 3M Blenderm Hinge Tape for the
construction of this model due to its strength, light weight, and easy use. Both Blenderm and Foam-
Tac can be purchased by visiting the Building Supplies tab on Sawn-Craft.com
1.3 Required Parts for Completion
This model was designed with the intention of putting to use the electronics that are used in today’s
popular 1S LiPo-powered Ultra-Micro aircraft. Once you have worn out the airframe on your
Hobbyzone© Champ or Parkzone© UM P-51 Mustang, simply remove the electronics and use them to
power this model. If you choose to purchase your power system components separately, Sawn Craft
does offer the Micro Electronics Kit that includes every part of the power system that you need. The list
below contains all of the required and recommended parts for the successful operation of this model.
1S LiPo “Brick”
Ultra-Micro Motor and Gearbox
Propeller
1S LiPo Battery
Please note that other power systems and components may be compatible and may work without
issue, but the listed components have been used successfully by Sawn Craft.
Optional Parts for Completion
To make your build easier and ensure the nicest looking finished product, the following products are
offered on Sawn Craft.com. See the Building Supplies tab for these products.
6” 1S Battery Lead Extension
5” Micro Motor Lead Extension
Colored Packing Tape

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1.4 Included Parts Description
Please inspect your kit and ensure that all listed parts are present and undamaged. If you find missing
parts or signs of damage please contact [email protected] for assistance.
a) Main Wing
b) KFm Step
c) Fuselage Half (2 each)
d) Vertical Stabilizer (2 each)
e) Elevator
f) Elevon (2 each)
g) Skid (2 each)
h) Vertical Stab Angle Template & Foot (2 each)
i) Micro Control Horn (4 each)
j) 2” x 0.024” Control Wire with Z-Bend (2 each)
k) 5” 0.051” Carbon Rod (2 each)
l) 6” 0.083” Carbon Rod
m) 1.5” 3mm Heat Shrink Tube (4 each)
n) 12” Micro Wire
o) 2” 1mm Heat Shrink Tube (2 each)
a
b
c
d
e
f
g
h

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2 Assembly Instructions
The order of assembly presented in this instruction has been tested and it is recommended that you
do not differ from them to provide the most accurate and easiest assembly possible.
2.1 Fuselage Lamination
Parts Required:
oFuselage Half (2 each)
o6” 0.083” Carbon Rod
1) Lay both fuselage halves flat on the table with the recessed slot facing up. Apply a bead of glue
around the entire perimeter of one of the fuselage halves.
2) Press the unglued fuse half onto the glued fuse half, recessed slots facing each other, and gently
slide the parts around to spread the glue evenly.
3) Separate the two fuse halves and insert the carbon rod into one of the recessed slots.
4) Rejoin the two fuse halves, glue side toward each other, ensuring that the carbon rod already in
the slot aligns with the recessed slot on the other fuse half. Set the assembled fuse lamination
aside to allow the glue to cure. If desired you can place a flat weight (book, etc.) on top of the
lamination while curing to ensure a flat assembly.
5) Once cured, sand leading edges to your liking.

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2.2 Wing Reinforcement Lamination
Parts Required:
oMain Wing
oKFm Step
1) Lay the main wing on the table with the front-to-back vertical stabilizer location markings slot
facing up. Apply a bead of glue around the entire perimeter of the KFm Step.
2) Press the glued side of the KFm onto the Main Wing, aligning the leading edges of both parts, and
gently slide the parts around to spread the glue evenly.
3) Set the assembled fuse lamination aside to allow the glue to cure. If desired you can place a flat
weight (book, etc.) on top of the lamination while curing to ensure a flat assembly.
4) Once cured, sand leading edges to your liking.

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2.3 Elevator/Elevon & Rudder Hinging
Parts Required:
oElevator
oVertical Stabilizer
oMicro Control Horn (2 each)
oMain Wing
or
oElevon (2 each)
oMicro Control horn (2 each)
oMain Wing
Elevator/Rudder Setup
Warning: This process involves using extremely sharp cutting blades. Care must be taken to avoid injury.
1) Lay the elevator on the table with the leading edge facing yourself and the control horn slot to the
left. Use a straight edge ruler and a hobby knife or a sanding block to cut an approximate 45° bevel
into the leading edge of the control surface. Set elevator aside.

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2) Lay the vertical stabilizer on the table with the bottom facing you. Carefully crack the rudder along
the rudder line or use a straight edge ruler and a hobby knife to cut down the rudder cut line in
order to separate the rudder. Remove the lower rudder extension below the control horn slots
using the same technique.
3) Lay the rudder on the table with the leading edge facing you. Use a straight edge ruler and a
hobby knife to cut an approximate 45° bevel into the leading edge of the control surface, ensuring
that the bevel is on the correct side.
If you choose to use a glue hinge for your surfaces ensure you bevel the mating surface as well.
4) Place the vertical stabilizer and rudder back together with trailing and leading edges touching,
oriented the proper direction for the bevel to face to the left when installed. Cut approx. ¼” x 1”
pieces of hinge tape. Use two of these small pieces of tape to attach the smooth sides of the
rudder and vertical stab together. Flip the assembly over and install two additional pieces of tape
on the bevel side of the hinge to complete the tape hinge. Dry fit a micro control horn into the
slot, ensuring that the hinge bevel is facing down. Set assembly aside.
Tape hinge

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5) Place the elevator and main wing together with trailing and leading edges touching, oriented such
that the hinge bevel faces down when the KFm Step is facing up. Use three small pieces of tape to
attach the smooth sides of the elevator and main wing together. Flip the assemblies over and
install three additional pieces of tape on the bevel side of the hinge to complete the tape hinge.
Elevon Setup
1) Lay the elevons on the table with the leading edge facing yourself and the wide part of the elevons
on the outside. Use a straight edge ruler and a hobby knife or a sanding block to cut an
approximate 45° bevel into the leading edge of the control surface, ensuring that you have both a
left and right elevon. Dry fit a micro control horn into the slots, ensuring that the hinge bevel is
facing down.
2) Place the elevon and main wing together with trailing and leading edges touching, oriented such
that the hinge bevel faces down when the KFm Step is facing up. Use two small pieces of tape to
attach the smooth sides of the elevon and main wing together. Flip the assembly over and install
two additional pieces of tape on the bevel side of the hinge to complete the tape hinge.

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2.4 Skid Installation
Parts Required:
oMain Wing Assembly
oSkid (2 each)
1) Lay the main wing assembly on the table with the KFm step facing down. Apply a bead of glue
down the entire length of the top of the skid.
2) Press the glued side of the skid onto the Main Wing, aligning the slots on the wing with the tabs on
the skids, and gently press the parts together to spread the glue evenly. Allow glue to cure before
proceeding.
Slot

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2.5 Fuselage Installation
Parts Required:
oMain Wing Assembly
oFuselage Assembly
1) Apply a bead of glue down the entire length of the flat spot on the top rear of the fuselage
assembly. Also apply glue on the inside edges of the main wing assembly fuselage slot.
2) Press the glued side of the fuselage assembly onto the main wing assembly, sliding the fuse all the
way back, and gently slide the parts back and forth to spread the glue evenly. Check that the front
of the wing that is glued to the side of the fuse is straight and even on both sides of the fuse. Allow
glue to cure before proceeding.
Glue

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2.6 Vertical Stabilizer Installation
Parts Required:
oMain Wing Assembly
oVertical Stabilizer Assembly
1) Apply a bead of glue down the entire length of the bottom of the vertical stabilizer assembly. Press
the glued vertical stab assembly onto the top of the main wing assembly onto the proper slots,
ensuring that the stab sits evenly on the wing. Allow the glue to cure fully prior to proceeding.
2) Secure the push rod z-bends to the carbon rods by using glue and heat shrink tube. Glue one
rudder joiner control horn and dry fit the other. Adjust the control rod length and then shrink the
heat shrink tube to “lock” the z-bend wire in place to ensure that the rudder is straight with the
vertical stabilizer. Once the rod length is set, attach the unglued control horn to the z-bend and
then glue the assembly in place.

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2.7 Electronics Installation
Parts Required:
oComplete Model Assembly
oRX/ESC/Servo “Brick”
oMotor & Gearbox w/Prop
o12” Micro Wire
o1mm Heat Shrink Tube
oHook and loop material
1) Glue the RX/ESC/Servo “Brick” on the top of the main wing at the location marked by a square, just
behind the prop slot. Ensure that the servo gears are facing forward and the brick and all wires are
completely clear of the prop.
2) If you have purchased motor and battery extensions, simply install the extensions to the respective
wires and continue by gluing the electronics. If you did not purchase wire extensions, cut the
motor and battery wires approximately in the center. Strip the insulation off the wire about 1/8”
and tin the wires. Strip and tin one end of the micro wire as well. Cut pieces of shrink tube to
cover the exposed wires. Slide the shrink tube onto the wires leading to the motor. Solder the
micro wire to the motor wire ends, matching polarity. Once soldered, slide the shrink tube over
the completed solder joint and use a heat gun to shrink the tubes.
Warning: This process involves using soldering equipment that is extremely hot. Extreme caution must
be taken

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3) Dry fit the motor onto the top of the main wing by inserting the motor mounting pins into the pre-
cut alignment holes in the wing with the prop located inside the open slot. Route the motor wires
around the slot and to the brick and cut the micro wire to the proper length. Solder the motor
plug onto the micro wire and cover with heat shrink tube. Use small pieces of clear packing tape or
glue to secure the motor wires around the slot. Plug the completed, longer motor wire into the
brick.
4) Use glue to secure the motor to the airframe. Let glue cure fully before proceeding. Secure all
loose wires with tape or glue around the prop slot to ensure it is not damaged by the prop.
5) Attach a piece of hook and loop material to the side of the fuse, under the canopy for battery
mounting and adjustment.
6) Secure the push rod z-bends to the carbon rods by using glue and heat shrink tube. Adjust the
control rod length and then shrink the heat shrink tube to “lock” the z-bend wire in place to ensure
that the elevator and rudder are straight with the main wing and vertical stabilizer. Once the rod
length is set, install the control rods to the brick and control horns then attach the unglued control
horn to the z-bend and then glue the assembly in place.
Alignment Holes

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3Setup andTuning
3.1 Center of Gravity
The CG of this plane is located approximately ½” in front of the prop slot and is marked by a slot cut in
the foam on the main wing. Moving the CG fore and aft will dramatically change the handling of the
plane so adjust to your liking. An aft CG will allow for slow, high-alpha flight while a more fore CG will
provide a faster flight experience. Use the included hook and loop fastener to adjust the fore/aft
location of the battery to adjust the CG without adding additional weight.
3.2 Control Throws & Expo
By altering the amount of control throw the surfaces have you can fine-tune the handling and
performance. Below are the recommended settings as tested that will provide a successful flying
experience. Throws are measured at the point farthest from the hinge.
Control Surface
Low Rate Throw
Low Rate Expo
High Rate Throw
High Rate Expo
Elevator
1/2in (70%)
0%
3/4in (100%)
25%
Rudder
5/16in (70%)
0%
3/8in (100%)
30%
Elevon
1/2in (70%)
10%
3/4in (100%)
25%
3.3 Launching
Launching this aircraft is very simple and is easy to do. Simply hold the airplane by the wingtip in one
hand with your radio in the other. Advance the throttle to full and gently swing the aircraft forward,
releasing it with wings level and a slightly up attitude.

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3.4 Flying Tips
This aircraft is designed to fly in the space as small as a single basketball court. Being such light weight,
it is recommended that this aircraft be flown indoors or outdoors in calm wind conditions. Always
ensure that you are comfortable with the aircraft and its flight characteristics prior to flying in a small
venue. Never fly over people or animals.
This aircraft flies much “bigger” than it really is and the techniques of flying larger aircraft apply. Rudder
turns will bank the aircraft so elevator will need to be added to maintain altitude. The delta-wing design
is inherently stable and makes this model a pure joy to fly! This model can fly slowly in high alpha flight,
but when you drop the nose it is remarkably quick and nimble. Landing the aircraft is simple; keep some
throttle applied and as the plane nears the ground, pull back on the elevator to flare.
3.5 Decorating/Finishing
The beauty of this aircraft is that you have the opportunity to finish it with the look that you desire. We
recommend using colored packaging tape (available on the Building Supplies tab) for decorating as it is
easy to use, lightweight, and provides a nice, glossy finish. Water-based paints have been used with
success in the past as have permanent markers. Prior to using any paints or markers, test on a scrap
piece of foam to ensure that it doesn’t melt the foam.
Remember that any weight you add to the airframe will affect its performance so keep heavy
applications of paint and decals to a minimum.
3.6 Repairs & Spare Parts
Due to this models extremely light weight, it is surprisingly durable! If a part of the model is damaged it
can typically be repaired using small pieces of packaging tape or by gluing using Beacon Foam Tac.
If a part is damaged beyond repair, simply send us an email at [e-mail] as we have
replacement parts for purchase.