TUD Modelltechnik Freestyler 3 Quick setup guide

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02 Aug. 07 page 1/21
Preliminary pilot information
Recommended RC-components:
RC-component suggestions for Freestyler 3, V-tail
version FLAPS AILERONS V-tail receiver battery
low-cost HS85 MG HS85 MG HS81 MG SMC 14 4 x AA NiMH 2100 mAh
(Sanyo, GP)
normal DS368, DS3068,
S3150 DS368, DS3068, S3150 S3150 SMC 14, SMC 19
4 x 2/3 A 1400 mAH (GP,
Intellect),
4 x AA NiMH 2100 mAh
(Sanyo, GP)
high-end DS3068 DS3068 DS3781 SMC 14, SMC 19,
SMC 19 DS
4 x 2/3 A 1400 mAH (GP,
Intellect),
4 x 4/5 A NiMH 2150 mAh
Note concerning cheap AA batteries – it seems possible that life time ends relatively abruptly. Don’t save
too much at the battery or replace upon slight doubt about capacity under load. Prepare new batteries by
charging/discharging several times, checking capacity and voltage.
Center of gravity:
95-98 mm measured from leading edge at wing root.
Tow hook:
CG ±2 mm, depending on desired launch safety.
Position measured from wing leading edge to rear edge of hook, see sketch below.

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02 Aug. 07 page 2/21
Settings:
The following table gives some hints on possible rudder deflections and positions for general usage.
Tweaking to individual preferences is required.
Settings Freestyler 3, V-tail
trim positions FLAPS AILERONS ELEVATOR RUDDER
CLIMB 2-3 -0.5 to flap 0 0
NORMAL 0 flush to flap 0 0
SPEED -1.5 flush to flap 0.5 0
WINCH LAUNCH 13 -1 to flap 0 0
BUTTERFLY 35 -8 3 0
deflections FLAPS AILERONS ELEVATOR RUDDER
CLIMB -5/3 -12/7 ±6 ±7
NORMAL -5/5 -13/8 ±6 ±6
SPEED -5/6 -13/9 ±5.5 ±5
WINCH LAUNCH 0 -14/2 ±6 ±7
wing mix ELEVATOR > FLAPS & AILERONS AILERONS > RUDDER
CLIMB -1/1 3
NORMAL -4/4 2
SPEED -4/5 1
WINCH LAUNCH 0 5
flap down = + , flap up = - , all measures in mm
Antenna routing:
Due to carbon fibre in the fuselage (electrically conducting) the antenna must be routed outside. It turned
out to be practicable to use spring steel of 0.5 mm diameter soldered to the (extended) receiver antenna.
See sketch below. Use shrink-tubing to isolate from the carbon fibres and glue to fuselage.

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02 Aug. 07 page 3/21
Some words and pictures on completion:
For stiffening the fuselage extension use a short piece of 2 mm carbon rod…
and glue it into the fuselage.

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02 Aug. 07 page 4/21
In case of too large gaps, strengthen the bonding of the tail joiner
before?
after!

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02 Aug. 07 page 5/21
Screw the ball links to the Bowden wires.
Reduce wall thickness of fuselage laminate where they move to gain space.

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02 Aug. 07 page 6/21
Bending the rudder horns from brass tube OD=3, ID=2, L=21 mm.
Use a 2 mm steel wire for bending, mark 5.3 mm position.

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02 Aug. 07 page 7/21
Insert until mark.
Bend until angle fits and lower legs are parallel when inserted into tails.

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02 Aug. 07 page 8/21
Inserting the ball it should look like this.
Check fit in fuselage.

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02 Aug. 07 page 9/21
Glue ball links with medium CA.
Check fit again.

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02 Aug. 07 page 10/21
Glue horns with 5-min Epoxy. Side view should look like this (horns below hinge line).
View from rear end. Flaps are fixed in neutral pos with tape.

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02 Aug. 07 page 11/21
Finished ball linkages on V-tail
Glue plugs with CA.

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02 Aug. 07 page 12/21
Shorten outer Bowden tubes.
Shorten inner Bowden wires.
Remove black Teflon coating on 9 mm length to insert them into the metal joints.

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02 Aug. 07 page 13/21
Connect metal parts and Bowden wires with thin CA.
Flaps and servos in neutral.
Open servo bays.

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02 Aug. 07 page 14/21
Prepare aileron horns (bevel lower end).
Drill hole into carbon tube.
Alternatively you can put the horns into the gap between shear web and horn cover.

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02 Aug. 07 page 15/21
Insert aileron horn to check fit.
Rim of bolt should be 0.5 mm above aileron surface, slightly protruding into horn cover.
Insert flap horn to check fit.
Rim of bolt should be flush to flap surface, slightly protruding into horn cover.

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02 Aug. 07 page 16/21
Fix aileron horns with little CA inside the tube. Clevis removed here.
Leave enough gap to let epoxy get inside the tube later.
Fix flap horns with little CA. Clevis removed here.
The blue foam will prevent epoxy to spread in the next step, by the way.

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02 Aug. 07 page 17/21
Glue horn with thickened epoxy.
Dito.

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02 Aug. 07 page 18/21
Prepare servo arms for ailerons.
Drill 2 mm hole touching bevelled rim of JR servo arm.
Remove excess material later.
For the flap horns use the thick disc supplied with DS368.

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02 Aug. 07 page 19/21
Clip off until it looks like this, let one or two holes with the smallest radius remain.
Round the edges. From a 2 mm spoke prepare pushrods by bending at 90°.
Lengths: Aileron 52, flap 55 mm.

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02 Aug. 07 page 20/21
With the clevises the pushrods should look like this (aileron).
For the flaps total lengths should be 67 mm.
Check for enough free movement.
Aileron: In servo neutral the horn should be rotated about 20° downstream to allow
enough deflection upwards.
Flap: Apply an offset of ±50 trim points (MC24), then put on the horns such that the
arm is rotated about 5° downstream.
Make a dry test before…