X Models Blade XL User manual

BUILDING INSTRUCTIONS - OPERATING MANUAL
Nuova FULCRO Service
Via Castelleone, 9 - Costa S. Abramo - 26022 Castelverde - CR (ITALY)
On the cover picture the carbon fiber version is shown & SUPER BLADE

Blade XL V.: 4.0 ENG - 01/05/2007
Copyright Nuova FULCRO Service
No parts of this document can be copied neither shared with any media without the author’s per-
mission.
Nuova FULCRO Service reserves the right to modify this document according to technical im-
provement requirements.

INDEX
I
INDEX
Blade XL .........................................................................1
Features........................................................................................................ 1
Technical data .............................................................................................. 2
CHAP. 1 PARTS LIST, MATERIALS AND TOOLS LIST..............3
1.1 Warning ....................................................................................... 3
1.2 Components included in the kit ................................................... 3
1.3 Parts needed to complete the kit, but not included ..................... 4
List of parts you will need to complete the model ......................................... 4
More options ................................................................................................. 5
1.4 Tools and materials needed (not included) to complete the kit ... 6
Tools ............................................................................................................. 6
Materials ....................................................................................................... 6
CHAP. 2 BUILDING INSTRUCTIONS ...........................................7
2.1 Preliminary operations ................................................................ 7
2.2 Fuselage ..................................................................................... 7
Balancing weights ......................................................................................... 7
Battery pack .................................................................................................. 8
Servos and ON/OFF switch .......................................................................... 9
Positioning battery pack and servos ............................................................. 10
Preparing and mounting servo horns............................................................ 11
2.3 V-tail ............................................................................................ 12
Finishing tail insertion holes.......................................................................... 12
Finishing fuselage end .................................................................................. 12
Finishing tail panels ...................................................................................... 13
Pushrods....................................................................................................... 14
Electrical connections for wing servos .......................................................... 17
Receiver........................................................................................................ 21
Antenna......................................................................................................... 23
2.4 Wing ............................................................................................ 24

II
Installing bushes for control horns.................................................................24
Electrical connection for the wing servos ......................................................26
Mounting servos inside the wing ...................................................................29
Wing pushrods...............................................................................................30
Servo covers..................................................................................................31
2.5 Tail connection ............................................................................32
Mounting the tail panels.................................................................................32
2.6 Nose ............................................................................................32
2.7 Connecting wing panels and tailplanes to the fuselage ..............33
CHAP. 3 MODEL SETTINGS ........................................................ 35
3.1 Servos settings ............................................................................35
Identifying the control surfaces......................................................................35
Travel values .................................................................................................36
3.2 Model balancing ..........................................................................37
CG .................................................................................................................37
Checking and correcting the CG position ......................................................37
Checking and correcting the lateral balance (both versions).........................37
How to add ballast.........................................................................................38
CHAP. 4 CONNECTIONS DIAGRAMS......................................... 39

Nuova FULCRO Service
1
BLADE XL
Features
Multipurpose glider model designed to offer the best performance in almost all flying conditions,
made for who loves the speed. All moulded fiberglass carbon reinforced wing with carbon spar,
thinned RG15 (7.8%), to offer high performance and a very broad flying speed range; fiberglass
carbon reinforced fuselage suited for slope soaring and towing.
Two different wingspans are available: (XL) 2.5 m or (SUPER) ~ 3.1 m.
Fig.1: Blade XL (& SUPER BLADE).
& SUPER BLADE

X-MODELS - Blade XL & SUPER BLADE
2
Technical data
Controls: ailerons, elevator, rudder, flaps.
Wingspan (XL 2.5 / SUPER 3.1): 2500 / 3080 mm
Length: 1510 mm
Weight - XL 2.5 version (empty / in flight): about 1400 g / 2100 g
Weight - SUPER 3.1 version (empty / in flight): about 1600 g / 2300 g
Profile: RG15 mod. (7%)
Radiocomando: 6 channels

Nuova FULCRO Service
3
CHAP. 1 PARTS LIST, MATERIALS AND TOOLS LIST
1.1 Warning
DO NOT EXPOSE THE MODEL TO HIGH TEMPERATURES. Exposing the model (or its parts) to high temper-
atures, over 50°C (example: in a car parked directly in the sun) may deform structures and make it unus-
able.
1.2 Components included in the kit
COD. QT. Item Remarks
FUSO 1 fuselage fiberglass, carbon reinforced (optional, all carbon fiber)
CONO 1 front cone fiberglass (optional, all carbon fiber)
ADXL 1 right wing-panel fiberglass, carbon reinforced with aileron and flap (optional,
all carbon fiber)
ASXL 1 left wing-panel fiberglass, carbon reinforced with aileron and flap (optional,
all carbon fiber)
CODX 1 V left tailplane balsa fiberglass sandwich with carbon spar
COSX 1 V right tailplane balsa fiberglass sandwich with carbon spar
BAIO 1 wing rod steel ~175 / ~ 235 mm - Ø 10 mm
BASE 1 servos mounting frame ply-wood
CARB 2 elevator pushrod carbon tube - length 100 cm - Ø 6 mm - hole Ø 4 mm
TCA4 1 spacer for pushrods carbon tube - length 20 cm - Ø 4 mm - hole Ø 2 mm
AMR2 8 metal pushrod length 30 cm - one tip M2 thread
UNIB 2 Nylon uniball M2 thread
VITE 2 screw length 20 mm - M2 thread
GIUN 2 ball for uniball M2 thread
FOR2 6 clevis M2 thread
DAD2 6 nut M2 thread
MPXF 2 MPX connector female plastic - 6 pin
MPXM 2 MPX connector male plastic - 6 pin
CAVS 1 wing servo cable twisted - three wires, length 2 m
CARS 2 servo hole cover 2 pair supplied to suit 4 holes
BOCC 4 threaded bush brass threaded M3
PERN 4 threaded horn brass threaded M3

X-MODELS - Blade XL & SUPER BLADE
4
Decal
If you like, you may stick the decal we supply
with the kit (see figure 2).
Fig.2: Decal “Blade XL”.
1.3 Parts needed to complete the kit, but not included
These are the parts you will need to complete the model (see “List of parts you will need to com-
plete the model”) and some you may need as option.
List of parts you will need to complete the model
To complete the model you will need the following (purchasing separately):
Note: not included in the table are glues and small parts that should obviously be present in every modeler’s house.
COD. QT. Item Remarks
SERW 4 wing servo HI-TECH HS-125MG
SERV 2 tailplane servo HI-TECH HS-322HD or HI-TECH HS-475HB
RXC6 1 receiver (+ xtal) max. dimensions: 65 x 40 x 22 mm
INTE 1 ON/OFF switch max. dimensions: 35 x 25 x 25 mm
BATT 1 rx battery pack NiCd o NiMH, 4 cells, SC size, from 1700 mAh
UNIM 4 cable with a RX (UNI) plug length: 30 cm

Nuova FULCRO Service
5
More options
Wings and fuselage made of carbon fiber
On request, wing, tailplanes and fuselage are available completely made of carbon fiber.
The model, made in this way, offers more torsional strength and an exceptional sturdiness.
The fuselage (see figure 3) is painted like the model but with the rear part unpainted (made to
save weight without to reduce the strength).
Fig.3: Carbon fiber fuselage.
Model carrying bag
A special bag (see figure 4) it’s available, made to measure, to safely carry your model around.
Each part (wing panels, tailplanes and fuselage), take place on a separate compartment.
Fig.4: Model carrying bag.
The bag is completely hand made. Other features: quilted and trimmed cloth, lined with internal
protections in polyethylene, velcro-fastening, handles for wing and fuselage.
Towing parachute
Hand made very strong towing parachute (see
figure 5) to help in successful winch towing.
Fig.5: Towing parachute.

X-MODELS - Blade XL & SUPER BLADE
6
1.4 Tools and materials needed (not included) to complete the kit
Tools
These tools may help you while assembling the kit:
— electric drill (and various size drill bits);
— modelling knife (or scapel);
— solder + soldering iron;
— hair drier (at least 1000W);
— set of files;
— usual tools like screwdrivers, pliers, etc.;
— vernier callipers (precision 1/20 of mm);
— sandpaper P400;
— Z-Bend pliers.
Note: other tools may help you too...
Materials
To complete the model, You need the following materials:
— super-glue (CA, cyano, like Green ZAP);
— “5 minute” epoxy;
— hot glue;
— approx. 200 grams lead;
— heat shrink sleeve (diameters: 3 mm e 6 mm);
— double adhesive tape, thin;
— velcro.
Note: other materials such as paints, brushes, pencils, etc. are not mentioned.
WARNING! PAY ATTENTION TO THE SAFETY INSTRUCTIONS FOR THE USE OF ANY KIND OF GLUE OR
TOOLS.
If you should need we may supply all you need to complete your model:
Nuova Fulcro Service S.r.l.
Via Castelleone, 9 - Costa S. Abramo - 26022 Castelverde - CR (ITALY).
Tel.: [phone] - Fax: [phone]
e-mail: [email protected]
www.xmodels.it

Nuova FULCRO Service
7
CHAP. 2 BUILDING INSTRUCTIONS
In order to achieve a correct assembling of the model, we suggest to follow carefully the instructions.
2.1 Preliminary operations
Kit components control
Have a look at the components (see “PARTS LIST, MATERIALS AND TOOLS LIST” at page 3)
in order to easily identify them.
It is strongly suggested to trial fit all the parts “dry” before gluing them.
2.2 Fuselage
Inside the fuselage, the following components will be arranged:
— balancing weights;
— battery pack;
— V-tail pushrods;
— V-tail servos and ON/OFF switch;
— electrical connections for the wing servos;
— RX receiver.
Balancing weights
• Using some double adhesive tape, fasten
about 80 ~ 100 g of weights in the position
shown in figure 6; the weights have to form
a layer with no more than 10 mm of thick-
ness (see figure 7).
Fig.6: Balancing weights position.
The layer will be used as a base for the battery
pack (see figure 7); the rest of the weights will
be added afterwards (during the model balanc-
ing) directly into the nose.
Fig.7: Max. thickness of the balancing weights.
max 150 mm
max 10 mm

X-MODELS - Blade XL & SUPER BLADE
8
Battery pack
• Cover the weights of epoxy (or hot glue) in order to form a uniform layer;
• cut a strip of velcro (8 x 4 cm);
• separate the velcro soft strip from the rough one;
• position the flat surface of the rough strip directly on the base in fuselage, in the position
shown in figure 8, leaving a gap of (at least) 85 mm from the ballast tube;
Fig.8: Rough strip of velcro in position.
• join four NC size cells in a battery pack ar-
ranged as shown in figure 9;
Note: the connector must be chosen according to the
ON/OFF switch used.
• wrap the battery pack with some heath
shrink sleeve;
Fig.9: Battery pack.
• uniformly cover of epoxy (or hot glue) one
side of the battery pack;
• position the flat surface of the soft strip di-
rectly on the glued side of the battery pack
(see figure 10);
• wait until the glue is dry;
Fig.10: Soft strip of velcro in position.
85 mm

Nuova FULCRO Service
9
Servos and ON/OFF switch
• Try to insert the servos mounting frame “BASE” in the fuselage as shown in figure 11 without
forcing too much and WITHOUT GLUING IT.
Fig.11: Position of the servos mounting frame.
If the frame doesn’t fit:
• on a flat surface, using some tape, fasten a
sheet of sandpaper (P400);
• using the sandpaper, finish the edges of the
mounting frame (see figure 12);
• try to insert the frame once again (always
WITHOUT GLUING IT) until it doesn’t fit cor-
rectly;
• remove the frame;
Fig.12: Smooth the edges of the mounting frame.
• try to mount the two servos “SERV” on the
frame as shown in figure 13 without forcing.
If the servos doesn’t fit
• using a file, adjust the housing and try again.
Once having inserted servos:
• using a pencil, mark the position of the ser-
vos fixing holes;
Fig.13: Position of the servos.
• using a calliper, take the dimensions of the switch;
• using a pencil, draw the shape of the ON/OFF switch lever movement (seen from top) and the
position of the holes for the fastening screws;
• remove the two servos;

X-MODELS - Blade XL & SUPER BLADE
10
• drill 1.5 mm diameter hole on the marked
points (see figure 14);
• using a knife, make the ON/OFF switch
housing;
Fig.14: Drill the marked points.
• mount the two servos on the frame as
shown in (see figure 15) and fasten with the
proper screws;
• mount also the ON/OFF switch;
• check that ON and OFF markings truly cor-
respond to the status “switched ON” and
“switched OFF”;
• check the correct travel of the ON/OFF
switch lever;
• fasten the switch using the proper screws.
Fig.15: Servos and ON/OFF switch.
Positioning battery pack and servos
• Insert the battery pack as
shown in figure 16;
Fig.16: Battery pack in position.
• position the servos mounting frame in order to remove freely the battery pack (see figure 17);
Fig.17: Frame with servos and ON/OFF switch in position.

Nuova FULCRO Service
11
Preparing and mounting servo horns
Preparing horns
For each servo horn:
• Using side cutters, cut the servo horns in
surplus (see figure 18).
Fig.18: Cut the servo horns in surplus.
• drill 1.5 mm diameter hole in order to widen
the servo horn hole (see figure 19).
Fig.19: Widen the servo horn hole.
Mounting horns
• Mount the two servo horns as shown in fig-
ure 20 and fasten with the proper screws.
Fig.20: Mounting servos horns.

X-MODELS - Blade XL & SUPER BLADE
12
2.3 V-tail
Finishing tail insertion holes
• Using a drill bit 6 mm diameter (larger than
the holes), trim exceeding metal edges from
the tail insertion holes (see figure 21);
Fig.21: Trim exceeding metal edges.
Finishing fuselage end
• Using a knife, modify the final part of the fu-
selage (see figure 22) in order to avoid any
interference with the servo pushrods;
Fig.22: Adjusting the end of the fuselage.
• using a file or some sandpaper, finish the
edge up to obtain the shape shown in figure
23.
The picture shows the difference from the initial
look and the final one (obviously both sides
must be molded in the same way).
Fig.23: Comparing the initial and the final look.

Nuova FULCRO Service
13
Finishing tail panels
Tail panels support pins
• Using a pair of pliers, bend a little bit the two
tail connection pins in order to make them
slightly diverging (see figure 25); this opera-
tion will avoid the tail to slip out from its sup-
ports during the flight;
Fig.24: Bend the two pins.
• using a sharp knife, remove the glue in ex-
cess from the root of the pins (see figure
25);
Fig.25: Remove the glue in excess.
Pushrods connections
• Fully fasten the ball “GIUN” on the screw
“VITE” (see figure 26);
Fig.26: Fasten the ball on the screw.
• screw the ball connector into the tail panel
unit (see figure 27);
• repeat the operation for the other tail panel;
Fig.27: Fastening the group screw-ball.
GIUN VITE

X-MODELS - Blade XL & SUPER BLADE
14
Pushrods
• using side cutters, cut two metal pushrods
“AMR2” at a length of 100 mm;
• cut the other two metal pushrods “AMR2” at
a length of 150 mm;
• using side cutters, carefully make some
dents in the (non threaded part of the) rod
“AMR2”, for a length of 5 cm, in order to in-
crease the adhesion of the epoxy (see figure
28), but careful not to cut through or weaken
it the wire rod;
Fig.28: Making some dents on the rod.
• using a little saw, cut the carbon tube “TCA4” in four parts 40 ~ 50 mm length each one;
• insert one of the two 100 mm length pushrod “AMR2” (from the NON threaded side) into the
carbon spacer “TCA4”;
• glue the carbon spacer
“TCA4” in the position
shown in figure 29;
Fig.29: Front pushrod group.
• screw the nut “DAD2” and a clevis “FOR2” to the 100 mm pushrod “AMR2”;
• repeat the operation in order to make two identical front pushrod groups;
• insert one of the two 150 mm length pushrod “AMR2” (from the NON threaded side) into the
carbon spacer “TCA4”;
• glue the carbon spacer “TCA4” in the position shown in figure 30;
Fig.30: Rear pushrod group.
• screw a ball link socket “UNIB” to the 150 mm pushrods “AMR2”;
• repeat the operation in order to make two identical rear pushrod groups;
• using a saw, cut the two carbon elevator pushrods “CARB” at 1 m length each one;
• insert and glue the rear pushrod groups into the elevator pushrods “CARB” (see figure 31);
Fig.31: Insert and glue the rear pushrod groups.
5 cm
AMR2 TCA4
DAD2
FOR2
AMR2TCA4 UNIB

Nuova FULCRO Service
15
• insert the front pushrod groups into the elevator pushrods “CARB” WITHOUT GLUING THEM
(see figure 32);
Fig.32: Inserting front pushrod groups (without gluing them).
• insert the two complete pushrod groups into
the fuselage (see figure 33);
Fig.33: Inserting a pushrod group into the fuselage.
• insert the tailplanes into the proper housings
(see figure 34);
Fig.34: Inserting tailplanes.
• temporary clip the ball socket ends “GIUN”
to the ball connectors “UNIB” (see figure
35);
Fig.35: Clip the ball socket ends to the connectors.

X-MODELS - Blade XL & SUPER BLADE
16
• using some masking tape, keep the V-tail
movable control surfaces aligned (see figure
36);
Fig.36: Keeping control surfaces aligned.
• connect the clevises to the servos horns in
fuselage;
• using a fibre-tip pen, mark the position of the
metal pushrods (see figure 37);
• remove the front pushrod groups from the
carbon pushrods.
Fig.37: Mark the metal pushrod.
For each front pushrod group:
• spread some “5 minute” epoxy on the carbon spacer of the front pushrod group;
• insert the pushrod group into the carbon
pushrod (see figure 38) up to the marked
point;
• before that the epoxy drys, clip the clevis to
the servo horn;
• wait until the glue is dry;
• repeat the operation with the other front
pushrod group;
• remove the masking tape from the tail-
planes;
Fig.38: Insert the front pushrod group.
• remove the ball socket ends “UNIB” from the ball connectors “GIUN”;
• remove the tailplanes.