Sawn Craft Micro F-4D Skyray User guide

Revised 2015-01-13


Micro F-4D Skyray
Assembly and Setup Manual


Specifications Recommended Power System
Wingspan 12” RX/ESC/Servo Spektrum AR6400 (or similar)
Overall Length 16.78”
Motor
Parkzone P-51 Motor & Gearbox (PKZ3624)
Wing Area 73.75 in2or
Flying Weight 1.25oz / 34g 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‐4DSkyrayaircraft.Likethefull‐scaleF‐4DSkyray,in
yourhandsisaremarkablyversatileairplanedesignedtodeliverapleasurecruiserwithanincredible
look.ThelightweightandrigidXPS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‐4DSkyray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
Jonathan@Sawn‐Craft.com

Table of Contents
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PartsSheetRemoval4
2.2FuselageLamination5
2.3WingReinforcementLamination6
2.4Elevator/Elevon&RudderHinging7
2.4ElectronicsInstallation10
2.5SkidInstallation12
2.6ControlRodInstallation13
2.7FuselageInstallation14
2.8VerticalStabilizerInstallation15
3SetupandTuning16
3.1CenterofGravity16
3.2RadioSetupandMixing16
3.3ControlThrowsandExpo17
3.4Launching17
3.5FlyingTips18
3.6Decorating/Finishing18
3.7Repairs&SpareParts18

SawnCraftMicroF‐4DSkyrayManual
Page1141216MicroF‐4DSkyrayManual.docx
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
•Foam‐safeadhesive
•3MBlendermtapeorClearpackingtape
•200‐gritSandpaper
•Solderingiron&solder
•Heatgun
•Wirecutters
•Needlenosepliers

SawnCraftMicroF‐4DSkyrayManual
Page2141216MicroF‐4DSkyrayManual.docx
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.Thelistbelowcontainsthetestedandrecommendedpartsforyourmodel:
•1SLiPo“Brick”‐ParkZoneReceiver/ESCDSM2/X‐Part#PKZ3352
•Ultra‐MicroGearbox–HobbyZoneGearbox(NoMotor):Champ‐Part#HBZ4929
•Ultra‐MicroMotor–HobbyZoneMotor:Sukhoi/Champ–Part#PKZ3516
•Ultra‐MicroMotor(HP)–ParkZoneMotor:UltraMicroP‐51‐Part#PKZ3616
•Propeller–E‐FlitePropandSpinner130x70(2)‐Part#EFL9051
•1SLiPoBattery–TurnigyNano‐Tech160mAh25c1SLiPo‐AvailablefromSawnCraft
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.
•SawnCraftCustomDecalSheets
•ColoredPackingTape
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.Also,the
constructiontechniquesofmanyofouraircraftareextremelysimilar.Thoughwewilltrytoinclude
asmanyphotosofyourspecifickitinthisinstruction,otherkitassemblyphotosmaybeusedifthe
instructionand“look”oftheassemblyisthesame.


SawnCraftMicroF‐4DSkyrayManual
Page3141216MicroF‐4DSkyrayManual.docx
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Support@Sawn‐Craft.comforassistance.
a) MainWing
b) KFmStep
c) FuselageHalf(2each)
d) VerticalStabilizer(2each)
e) elevon(2each)
f) Skid(2each)
g) VentralFin
h) MicroControlHorn(4each)
i) 1”x0.024”ControlWirewithZ‐Bend(4each)
j) 2”0.051”CarbonRod
k) 4"0.051"CarbonRod
l) 6”0.083”CarbonRod
m) 2”3mmHeatShrinkTube(3each)
n) 12”MicroWire
o) MicroVelcro
p) 3.5”0.024”MusicWire(notshown)

a
b
c
d
e
f
g
hi
j
k
l
m
n
h

SawnCraftMicroF‐4DSkyrayManual
Page4141216MicroF‐4DSkyrayManual.docx
2 Assembly Instructions
2.1 Parts Sheet Removal
•PartsRequired:
oKitPartsSheets
oHardwarePack

1) Laybothkitpartssheetsoutaswellasthehardwarepacktoinspectfordamageandconfirmthat
allpiecesareinthekit.Ifyoufindthatthereisanissue,pleasesendanemailtoSupport@Sawn‐
Craft.comandwe'llgetrightbacktoyou.
2) Usingasharphobbyknife,carefullycutthefoampartsoutofthesheets.Thesmalltabsholding
thepartsintothesheetcansometimesbetrickytofindsoifyouhavetroubleremovingapart
fromthesheetkeeplookingforthatlasttab.Onceoutofthesheet,youmaychoosetocleanup
theremainingtabonthefoampieceswithsomesandpaper.

SawnCraftMicroF‐4DSkyrayManual
Page5141216MicroF‐4DSkyrayManual.docx
2.2 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.



SawnCraftMicroF‐4DSkyrayManual
Page6141216MicroF‐4DSkyrayManual.docx
2.3 Wing Reinforcement Lamination
•PartsRequired:
oMainWing
oKFmStep

1) Laythemainwingonthetablewiththemilledbrick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.


SawnCraftMicroF‐4DSkyrayManual
Page7141216MicroF‐4DSkyrayManual.docx
2.3 Elevator/Elevon & Rudder Hinging
•PartsRequired:
oElevon(2each)
oVerticalStabilizerw/Rudder
o3.5”.024”MusicWire
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elevons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elevonsaside.






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fromthestabilizer.






SawnCraftMicroF‐4DSkyrayManual
Page8141216MicroF‐4DSkyrayManual.docx
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(thesidethathadthemilledslot).
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.







5) Bendthe0.024”musicwireintoasquare‐corneredU‐shapewith0.75”ontheshortlegsand2”on
themiddlelegtocreatetheelevatorjoiner.Becarefulwhenbendingthewireasifthetwoshort
legsaren’tparalleltheaircraftwilltrytorollonewayortheother.
6) Placetheelevons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.Aligntheelevatorjoinerwiththe
milledgrooveintherearofthemainwingsuchthatitiscenteredontheslot.Notewherethelegs
ofthejoinermeeteachelevon.Gentlypresstheendofthejoinerintotheleadingedgeofthe
elevonsuntilthelegisproperlyseatedintotheelevon.
Usingagentletwistingmotionwillhelptopreventthefoamfrom“ballingup”wheninsertingitinto
thefoam.
7) Usetwosmallpiecesoftapeoneachelevontoattachthesmoothsidesofthejoinedelevonsand
mainwingtogether.Fliptheassembliesoverandinstalltwoadditionalpiecesoftapeonthebevel
sideofthehingetocompletethetapehinge.

Tapehinge

SawnCraftMicroF‐4DSkyrayManual
Page9141216MicroF‐4DSkyrayManual.docx
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.





SawnCraftMicroF‐4DSkyrayManual
Page10141216MicroF‐4DSkyrayManual.docx
2.4 Electronics Installation
•PartsRequired:
oMainWingAssembly
oRX/ESC/Servo“Brick”
oMotor&Gearboxw/Prop
o12”MicroWire
o3mmHeatShrinkTube

1) Cutthemotorandbatterywiresonyourbrick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
2) 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.








SawnCraftMicroF‐4DSkyrayManual
Page11141216MicroF‐4DSkyrayManual.docx
3) Ifyoualreadyhaveaproponyourgearboxfromanotheraircraftyouwillneedtoremovetheprop
andinstallit"backwards".Bythis,youwillscrewthepropontothemotorshaftwiththemolded‐
innumbersonthepropfacingthemotor.Thisisdonebecauseofthelocationofthe
motor/gearboxascomparedtotheotheraircraft'sstocklocation.
4) Gluethemotorontothetopofthemainwingbyinsertingthemotormountingpinsintothepre‐
cutalignmentdots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tapeorglueto
securethemotorwiresaroundtheslot.Plugthecompleted,longermotorwireintothebrick.







Wehavefoundthatsomepilotsprefertohavesomedown‐thrustintheirmotorasopposedtoit
beingmountedflushonthemainwingwhenusingmorepowerfulmotors.Todothis,simplyadda
smallpieceofscrapfoambelowtherearofthemotor/gearboxassembly(thenon‐propside)andglue
theassemblydownasyouwouldnormally.Doingthiscanpreventsomeunwantedclimbingunder
power,butotherwisedoesn’tnoticeablychangetheflightcharacteristics.

AlignmentDots

SawnCraftMicroF‐4DSkyrayManual
Page12141216MicroF‐4DSkyrayManual.docx
2.5 Skid Installation
•PartsRequired:
oMainWingAssembly
oSkid(2each)
oVentralFin

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.Theroundedprotrusion
onthebottomoftheskidwillgotowardtherearoftheplane.












3) Gluetheventralfininthecenterslots.Theroundedprotrusiononthebottomoftheskidwillgo
towardtherearoftheplane.Allowgluetocurebeforeproceeding.



Slot

SawnCraftMicroF‐4DSkyrayManual
Page13141216MicroF‐4DSkyrayManual.docx
2.6 Control Rod Installation
•PartsRequired:
oMainWingAssembly
o0.051"CarbonRods
oMicroZ‐Bends
o3mmShrinkTube

1) IfyouchosetobuildaMicroSkyraywithelevoncontrolyouwillneedtocutthe4"long0.051"
carbonroddownto2"long.
2) 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.





SawnCraftMicroF‐4DSkyrayManual
Page14141216MicroF‐4DSkyrayManual.docx
2.7 Fuselage Installation
•PartsRequired:
oMainWingAssembly
oFuselageAssembly
oMicroVelcro

1) Applyabeadofgluedowntheentirelengthoftheflatspotontheslotatthe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.





3) Applyapieceoftapejustundertheleadingedgeofthewingwhereitattachestothefuse.Attach
apieceofhookandloopmaterialtothetopofthetapeforbatterymountingandadjustment.





MicroVelcro

SawnCraftMicroF‐4DSkyrayManual
Page15141216MicroF‐4DSkyrayManual.docx
2.8 Vertical Stabilizer Installation
•PartsRequired:
oAircraftAssembly
oVerticalStabilizer

1) Youmaychoosetogentlyroundtheedgesofthefoamontheleadingedgeoftheverticalstabilizer
withsandpaperbeforeproceeding.




2) 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.Thiscompletesthebuildprocess!














RoundEdges

SawnCraftMicroF‐4DSkyrayManual
Page16141216MicroF‐4DSkyrayManual.docx
3 Setup and Tuning
3.1 Center of Gravity
TheCGofthisplaneislocatedapproximately1/4”infrontofthepropslot.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 Radio Setup & Mixing
Dependingonthetransmitterand“brick”thatyouareusingtocontrolyourmodelyoumayfindthat
youneedtodosomespecialsetuptomakethecontrolsworkproperly.Thisisespeciallytrueforelevon
controlssobelowarealistoftestedradiosandthemixesusedtomakethecontrolsfunctionproperly
withtherecommendedbrick.
ElevonMixingReference
TransmitterWingModeMix1Mix2Notes
SpektrumDX6iDeltaN/AN/A
Youmustreverseeithertheelevatoror
aileronforpropermovement
SpektrumDX7s
&DX8ElevonELE>LEL=‐125%AIL>REL=‐125%
Controlthrowsmaybereducedwhenusing
thismix,sothehighandlowratecontrol
throwswillneedtobeadjustedtosuityour
flyingstyle.
SpektrumDX9&
DX18Elevon‐BN/AN/A

Note:Themixesgivenabovereflectwhatwastestedusingourprototypesetupsandelectronics.Theyshouldbeusedasa
startingpointandyoumayfindthatyouendupwithadifferentsetting.Ifyouarehavingtroublepleasecontactusfor
assistance.


SawnCraftMicroF‐4DSkyrayManual
Page17141216MicroF‐4DSkyrayManual.docx
3.3 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1/4in(70%)20%3/4in(100%)25%
Rudder1/4in(70%)20%3/4in(100%)30%
Elevon1/4in(70%)25%3/4in(100%)40%

3.4 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.






