Timeless Wings CASA C-101 AVIOJET Instructions for use

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CASA C–101 AVIOJET
CONSTRUCTION MANUAL Version 2.1
SCALE
APPROX 1:13.5
WING SPAN
31 INCHES
WEIGHT
22.5 OZS
WING AREA
170 SQ INS
WING AIRFOIL
SELIG 3021
WING LOADING
19 OZS/SQ FT
FAN
50MM (e.g. Dr Mad Thrust 50mm, XRP-
50mm,WeMoTec 50mm)
CELLS
3S – 4S LiPo1000mAh - 1300mAh
POWER required
180W +

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PRELIMINARY NOTES
Before commencing construction, please take the time to mark the part numbers on
the CNC-cut balsa and ply sheets, referring to the Parts Location Guide included in
this kit. The full-size wing plan is taped together from the three included sheets of
A4 paper. The reduced-scale fuselage side view and top view contain full-size
drawings of the noseblock, to assist shaping.
Unless otherwise noted, thin cyanoacrylate glue is the adhesive of choice for
construction of this model. Other wood glues such as PVA and Aliphatic Resin are
also suitable, but will require a longer drying time.
This model is optimised around 50mm fans with brushless motors and power input
of 180W and up.
There are very many photographs of the full-size CASA Aviojet on the Internet, and
they are an invaluable reference source when building this model. A search using
combinations of the keywords “CASA C-101 AVIOJET” will provide a multitude of
pictures which will assist both constructing and detailing the model.
For those desiring further details of the full-size machine, there is a book titled
“CASA Aviojet C-101” (ISBN 84-95493-05-5) published in Spain by Reserva
Anticipada, S.L., in the Spanish language. This book contains dozens of hitherto
unpublished photographs of the Aviojet, making it useful even to non-Spanish-
speakers.

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FORWARD FUSELAGE CONSTRUCTION
Glue two F14 FWD LONGERONS on top of FUSELAGE FLOOR.
Insert F1 and F2 in place on FUSELAGE FORMER F13.
Insert F3 into F13, then glue all formers to the FUSELAGE FLOOR and F13.

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Glue F6A to FRONT of F6.
Assemble F4, F5, F6 and F15 in place as shown in the photograph below, and when
aligned correctly, glue in position.

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INLET DUCT CONSTRUCTION and INSTALLATION
Using a permanent marker pen, draw a 5mm wide border around all sides of
the 2 vac-formed PETG outer duct walls, as shown in the photograph below.
Using a sharp blade and a steel rule, trim to the border.
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Place the trimmed duct outer walls onto the flat 0.5mm PETG sheet which
forms the duct inner walls, and trace around the perimeter of the DUCT
OUTER onto the DUCT INNER as shown.

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The resulting rectangle should look like the picture below. Trim to the lines,
as before.
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Using 80-grit sandpaper, roughen the ducting where the surfaces mate, then
glue together with a good quality plastics glue that is designed for PETG. We
use and recommend UHU All-Plastics Glue. Use small bulldog clips to hold the
parts together while the glue dries.

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Using a hacksaw blade or flat file, make vertical slots 5mm long in the inside
edge of F5 & F6 to allow the ducting to slide into position, so there is a similar
amount protruding front and back. Glue in position with UHU All Plastics glue
or similar.
Note: the inboard edge of the ducting sits flush against F6, the gap around
the outboard side of the duct at F6 is filled in the next step.

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Use masking tape to form a "dam" on the front face of F6, then fill the void between
the former and the duct with epoxy or flexible filler. Any residual void at the back of
F5 may be filled now too.

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The ducts are now trimmed so that they are flush with the front of F5, and flush or a
few mm protruding from the rear of F6. You may need the following tools:
MID-FUSELAGE CONSTRUCTION
F22 is temporarily attached centrally to the underside of the Fuselage Floor with
tape, as shown in the two photos below. IMPORTANT - DO NOT GLUE!

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Laminate F9 as shown – the spring clips are useful holding the assembly in position
until the glue dries. The balsa parts go to the front (important!).
Place F7, F8 and F9 in position on F22. Do not glue just yet.

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FT1 needs to be slightly modified before it can be used - a 30mm wide tab needs to
be added centrally to the front end - as shown in the before and after pictures
below:

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Glue FT1 to top of formers F6, F7, F8 & F9. Trim FT1 to the red line (flush with the
front of F6). A small amount of sanding may be necessary to ensure the fit of this
part.
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Glue the two parts F16 to both sides of the fuselage assembly as shown below, only
gluing the areas where the flat parts of the formers make contact with the sheet
balsa at this stage. Remove from the building board and wrap (curve) both F16
pieces around the formers and glue in position.

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Trim/remove F22 between F6 & F8. The section of F22 between F8 & F9 remains,
trimmed flush with the front of F8.
Laminate the WING BOLT PLATE WB1 from the three pieces, then fit the 4mm blind
nut by giving a gentle tap into the hole with a hammer. Glue into place centrally in
the front of F8 as shown.

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Turning our attention to the forward fuselage now, sheet between the front of F5
and F3 with 1.5mm balsa, both sides
Bevel the bottom of F3A, and glue in place.
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Each side of the forward fuselage is now sheeted with 1.5mm balsa. Trace the shape
required with a piece of paper first, using a separate piece of balsa between each
former. Scrap pieces of balsa glued to the formers will support the sheet during
assembly.
Fit the NOSEBLOCK, which can now be roughly shaped.

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Study the plan and photos, then fit FUSELAGE TOP DECKING FT2, FT3, and FT4 in
position (as well as FJ1 and FJ4), then shape roughly so that the 1.5mm side sheeting
can be added. Once this sheeting has been added and trimmed, the AIR INTAKES
(AI#1,2,3 & 4) can be laminated (two per side), fitted into position, then shaped. The
lower section of F7 is removed to allow for wing positioning.
The fuselage so far should look like below:
REAR FUSELAGE CONSTRUCTION
10. Glue F17 to F18, then glue this assembly to FT6 as shown. The rear fuselage is
initially assembled with the components upside-down on the building board. Later photos
will make this obvious.

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Glue former F9C2 to F9C1, then glue this structure to the front of FT6 and formers
F17 and F18 as shown.
Laminate F10 to F10A, then glue in place as shown (ply side may be forward or
rearward, it doesn’t matter which).
Glue F11 in place then F20. Turn up the right way, and it will look like this:

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Identify the parts that will be used in the tailplane/elevator construction (below).
Glue T5#1 and T5#2 to T4, the ELEVATOR JOINER to T6, then cut off the section of T6
forward of the leading edge of the elevator. Sand the whole tailplane/elevator
assembly to shape, then hinge, using CA hinges.
Referring to the side view on the plans, cut a small section out of FT5 to allow
movement of the elevators, then glue the tailplane in place on the lower side of FT5.
Laminate the four pieces of F21 together, roughly shape, then glue into position as
shown. Now glue F12 into position, followed by F20A.

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Identify the parts of the fin and rudder, then glue together. Note that the
rudder may be hinged, if a rudder is required (not necessary for normal flight
manoeuvres).
The fin/rudder assembly may now be glued in place, so the rear fuselage will look
like below:
The elevator pushrod sleeve is now fitted to the holes in the right hand side of the
rear fuselage assembly. This is first prepared by using a thicker piece of piano wire
threaded through the formers to “drill” through the F21 assembly, leaving a path for
the sleeve, which is now glued in place. See the photographs later in this manual
showing the installed elevator servo/pushrod for clarification.
The FUSELAGE TOP DECKING is bevelled to accept the side sheets, the remainder of
the 1.5mm balsa sheet is now added, from top to bottom. Scrap pieces of balsa may
be cyanoed to adjoining sheets to assist this process. Depending on personal
preference, these sheets may done in one piece per side (cut and fluted where
necessary to fit) or in several pieces.

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Glue FUSELAGE JOINERS FJ2 and FJ3 in their respective places as shown in the
photographs and on the plans.
After completing the steps outlined above, the end result looks like this:
FIN FILLETS (FF) may be added now and shaped. Refer to photos of the full-size to
assist.
Glue TAILPIPE RING TP1 in position at the rear of F12, then glue F9B to the front of
the rear fuselage assembly. Note that the slots for the ply FUSELAGE JOINERS may
need to be enlarged slightly with a flat file to get a comfortable fit. Ensure that the
sleeve for the elevator pushrod is protruding through this former. Fit the 6.5mm
LOCATING DOWELS and glue into place. (See assembled and covered photo below
for details).

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WING CONSTRUCTION
NOTE: Due to the thinness of the wings it is necessary to use sub-micro servos of 8mm
maximum thickness - good quality servos such as the Dymond D47 or some of the 8mm
digital servos that are now available.
Holes in the ribs for the servo leads have not been cut. These can be done using a sharpened
piece of brass tubing before assembly begins or using a Dremel tool after the ribs have been
added to the bottom sheet.
Glue CENTRE-SECTION SPAR (CS1) to the front of DIHEDRAL BRACE (WD1).
Glue the 3 CENTRE-SECTION RIBS (R1) in place on this assembly, using the plan to
confirm squareness.