ZAGI ZAGI-DC User manual

Airfoil Zagi 101.3
Flying Weight 17.5 oz
Wing span 48"
Wing area 2.03 sq ft
Wing loading 8.5 oz sq ft
Radio w/mixer
Servos 2 std
AssembAssemb
AssembAssemb
Assembly Manly Man
ly Manly Man
ly Manualual
ualual
ual
TRICKR/CProductsLLC 938VictoriaAvenue Venice, California 90291
Visit:www.Zagi.com Email:[email protected] Sales:[phone] Tech(310)827-2288 Fax: [phone]

These instructions are updated with each new production run. Any mods or changes to
the kit are included with each run.
3M Super 77 Spray Adhesive is the recommended adhesive for the assembly of the Zagi-
5C. Since the Zagi-5C is all EPP the 77 Spray Adhesive will not damage the foam. Shoe
Goo, Goop, or any of the other Goo or goop adhesives can be used with a weight penalty
of one to three ounces.
Balancing The Zagi-5C balances at 8 inches back from the nose. This means that most
of the outboard wing panels are behind center of gravity (CG). Adding weight behind CG
means that more weight will be needed in the nose to achieve balance. So you pay a
weight penalty twice or even more for adding the extra weight behind the CG.
Wing Panels The wing panels are die-cut for standard servos. The die-cut electronics
bay will accept a receiver and a square AAsize battery pack or Nicad batteries from 400
mAh to 1000 mAh. A small 220 mAh battery may be used for extra light conditions. The
electronics bay will accommodate almost any receiver size. The die-cut servo bays can
be glued back in place and re-cut if different size servos are preferred. Just push them out
and spray them with the adhesive and replace them. Balsa shims can also be used to
assure a snug fit. The wing is thick enough for the radio installation within the original
contours of the airfoil. Radio gear should be invisible when it's covered.
CG
8”
2

The Zagi-5C Kit Contents:
2 Expanded polypropylene (EPP) wing panels and beds
2 Pre-cut airfoil shaped balsa elevons
5 .03 X .31 X 24 Carbon fiber spars
1 Roll 2.2 mil color poly tape
2 Control horns with 2 screw plates and 4 screws
2 Threaded 2-56 control rods
2 Threaded 2-56 clevises
2 Die-cut clear plastic winglets
1 EPP foam block for repair and reinforcement
1 Roll of 2” wide fiber filament tape
1 2” x 5.5” Styrene electronics bay floor
Needed Components:
1 Receiver (RX)
2 Standard servos (cutouts are for “standard” servos but minis may be used)
1 Battery A600 mAh NicadAAsize battery will allow several hours of flying
before recharging.
Tools and Materials Needed:
Small 90 degree square
Sanding block
#150 to #320 grit sandpaper
X-acto knife with #11 blade
Dremel(optional)
Spray adhesive (3M Super 77)
Lead weights for balancing (if needed)
Additional roll 2.2 mil color poly tape in contrasting color (optional) - see text
Round pencil or ball point pen
Mixing (popsicle) sticks
Clear food wrap
Scissors
Z-bend pliers (optional)
3

The four carbon fiber spar channels extend the full length of both
wing panels on both sides.
The electronics bay is die-cut. The receiver and battery will be
installed in the electronics bay. Do not remove the assembly until
the wing panels are joined.
The servo bays are also die-cut. They are hard to see. An easy
way to find them is to rub the surface just ahead of the carbon spar
channel.
The center spar channels will become one continuous 18” spar
channel when the wings are joined
There are three parts to each wing panel. The wing core is
shipped between the top and bottom beds. The beds are used as
construction jigs so do not discard them. The top of the wing can
be identified by its greater curvature. The right wing is the wing that
would be on your right if you were in the cockpit. The right and left
panels can be identified by the color mark at the root (the big end
of the wing panel): Red on the right. Four important pre-cut fea-
tures on the wing panels are illustrated below.
DONOTREMOVEANYPRE-CUTPARTSATTHISTIME!
4

Tapethetopbedstogetherwithfiberfilamenttape. Thentapethebottombeds
together. Removethehairsandzigzagsfromthewingcoresandbedsby
rubbingthemwith EPPfoamblock. Laythebottombedsonaflatsurface. Set
thewingcoresonthebedstopsideupandlightlyblocksandthewingpanels
(cores)with#150or#320sandpaper. Blocksandtheleadingedge(LE)toround
theflatspot.Placethewingsinthetopbedsandrepeattheprocedureonthe
wingbottom.
Spraytheroot(wideend)ofthewingpanelswith3MSuper77SprayAdhesive.
Holdthesprayhead1inchfromtheroot. Sprayalongbeadalongtherootedge.
Spreadthebeadwithasmallbrush,amixingpopsiclestick,orfoamblock. Let
theadhesivedryuntilitwillnotcomeoffonyourfinger(approx.20min.) Join
thewingpanelstogethermakingsurethatthecentersparchannelsonthe
bottomsideofthewingarealigned. Puttwopiecesoffibertapeacrossthe
seamtoholdthewingpanelstogetherwhilethegluedries.
Usethepopsiclestickasatroweltodirecttheadhesiveintothesparslot.
Repeatthisuntiltheentireinsideofthegrooveiswetwithadhesive.
Laytwoflatcarbonsparsonapieceofnewspaperandspray themwith
adhesive. Startingtwoinchesfromthecenterline,pushthesparsintothe
channel. Makesurethattheentiresparisbelowthewingsurface.
Laythetopbedsonaflatsurfaceandcoverthemwithclearfoodwrapto
preventthewingsfromstickingtothebeds. Putthewingpanelsinthetopbed
bottomsideup.Repeatthecarbonfibergluingprocedureonthebottomside.
Gluethecarbonfibersparsinthetopsidefirst. Laythebottombedsonaflat
surface. Putthewingpanelsinthebottombedtopsideup. Holdthesprayhead
2inchesfromthesparslot. Sprayonelongpuddleofsprayadhesivethelength
ofthetwosparslots.
5

Cuttheremaining24”carbonsparto18”. Wirecuttersworkwell.
Withthewingsinthetopbedsonaflatsurface,spraythecentersparchannel
withadhesive. Repeatthecarbonfibergluingprocedure. Pushitintothecenter
sparchannel. Makesurethatthesparisflushatthecenterofthewing. Align
thewinginthebeds. Useweights(notincluded)toholdthepanelsinplace
whilethegluedries.
Weightsareveryimportanttomaintainalignmentandwinggeometry. Letthe
wingassemblydryandgoontothenextstep. It’sagoodideaatthispointtolet
thegluedryovernightoratleastafewhours.
The Zagi 5C servo bay was designed to fit standard servos.
Standard servos are cheap and rugged with more than adequate
torque. The servo bay may be expanded or shimmed to fit a
different size servo. Since the servos are mounted so close to the
center of gravity (CG), different size servos may be used without
effecting the balance. Find the straight control arm with two tabs in
the parts bag supplied with the servo.
Replace the round servo control arm with the modified arm. Avoid
stressing the gears by holding the control arm to limit travel when
removing and replacing. Do not over-tighten tie screw. Snug is
tight enough. To maximize servo life, avoid moving the servo
control arm with the radio off.
DONOTINSTALLTHESERVOSATTHISTIME.
The servos must be centered with the radio powered up before
they can be installed.
Cut one of the tabs off the control arm leaving only one tab.
If the servo is supplied with a four tab (+) shaped control arm,
remove three of the tabs leaving only one.
6

Computer radios have settings for elevon mixing. Check the radio
manual for flying wing, elevon or delta-wing mix setting. V-tail
settings will not work. Set the transmitter for elevons and deter-
mine the appropriate receiver slot for the controls. Position the
servos the way they will be in the wings, with the control arms
facing outboard. Plug the right and left servos into the receiver.
Check to see that the switch is off. Plug the switch into the battery
slot of the receiver. Plug the battery into the other side of the
switch.
With the transmitter and receiver powered up, the servos should
be 90 degrees to the servo case in the hands-off neutral stick
position. If they are not, remove the control arm and replace it at
90 degrees to the servo case. Use the trim lever to make micro
adjustments to the alignment of the control arm. When the elevon
control stick is pulled back (the opposite direction to antenna) the
servo control arms should both move forward. When the stick is
moved to the right, the right servo control arm should move
forward and the left servo control arm moves back.
The trim levers are located on all transmitters to the left and below
the control stick. Some trim controls are electronic and others are
mechanical. Trim levers are provided to adjust the zero position of
the servos. Center the trim levers to the zero position. For
details on electronic zero centering, refer to radio owner’s manual.
Power up the transmitter. Always turn the transmitter switch to the
on position before powering up the receiver. Check the battery
condition indicator on the transmitter to make sure that the battery
is charged.
Power up the receiver
7

Remove the pre-cut electronics bay cookie from the center of the
wing. Save the cookie, it will be used later. The servo bays are
cookie cutouts in the shape of a servos. The cutouts are not easy
to see. Poking a finger from the bottom while inspecting the top
helps. Locate the cutout and push the cookie about halfway
through into the bottom of the wing.
The shape of the cutout indicates the orientation of the servo.
Push the servo into the cutout forcing the cookie through to the
bottom side of the wing. Cut away any foam that prevents the
insertion of the servo.
Use the servo to push the cookie out to the bottom side of the
wing. Align the servo so that it is flush with the top of the wing
while pressing the cookie from the bottom.
Use a sharp kitchen knife to cut the cookie flush with the bottom of
the wing. Another method is to mark the perimeter of the cookie
with a pencil, remove the cookie and make the cut.
Push the cookie from top to bottom of the wing about 1/4 inch.
Spray a small amount of adhesive on the edges of the cookie and
push it back in place.
8

Cut the corners of the tape so it can be folded into the electronics
and servo bays.
Place the wing in the top beds and repeat the same procedures
on the bottom side of the wing.
Lay the wing in the bottom beds. Spray a medium mist coat of
adhesive on the top side of the wing. Make sure that the walls of
the electronics bay are covered. Let the adhesive dry for 15
minutes before taping.
Thefibertapewillnotappearasdarkaspicturedhere. Darkertapewasusedin
thesepicturestoenhancecontrastvisibility.
Apply a piece of fiber filament tape straight across center section
of the wing between the carbon spars.
Apply two pieces of fiber filament tape across the nose. The tape
will partially cover the battery bay. For extreme combat duty,
apply a strip of fiber tape around the leading edge (LE).
Apply a strip of fiber filament tape to the trailing edge (TE). Start at
the tip and cover across to the spar on the opposite wing.
9

Spray another mist coat of adhesive on all top surfaces of the wing
including the areas covered with fiber tape. Make sure to spray
the tips and trailing edges. Spray 2 inches of the bottom of the
wing at the TE. Let the adhesive dry for 20 minutes.
Put the wing top side up in the bottom beds. Put a weight on the
left panel to hold it steady while taping. Start taping at the TE and
work forward.
Covering the top and bottom of the wing in contrasting colors
enhances visual orientation. Use the darker color on the bottom
surface. An optional roll of color tape will be required.
Wrap the first strip of tape around the TE from top to the bottom
being careful to follow the shape.
Apply strips of tape working forward from the TE. Overlap each
strip of tape a quarter of an inch. Extend the tape two inches
beyond the center line of the wing. Extend the tape two inches
beyond the tips.
Continue overlapping the strips of tape until the entire top right
wing panel is covered.
Trim the tape that extends beyond the LE.
10

Fold the tape around the tip and cut it to the contour of the bottom
surface. Trim and fold the tape into the battery, servo and receiver
bays.
Cover and trim the top left wing panel. Repeat the same taping
procedure as on the right panel.
Cut out the electronics bay floor. Lay the part on a piece of
newspaper. Spray the part with adhesive. Center the floor over
the electronics bay and press it in place.
Spray a mist coat of adhesive to the bottom side of the part.
Apply two strips of fiber tape cordwise (parallel to the center line)
over the part.
Spray another mist coat of adhesive on all bottom surfaces of the
wing including the areas covered with fiber tape. Complete the
color tape covering on the bottom of the wing.
When the entire top and bottom are covered, wrap a spanwise
strip of color tape around the leading edge.
11

Position the elevon against the TE. Position a straight-edge
parallel to the center line at the inboard edge of the servo bay.
Make a cut line on the elevon. Position the straight-edge to match
the angle of the wing tip. Make a cut line on the elevon to match
the wing tip. Trim the ends off the elevons at the cut lines.
Sand a 45 degree angle into the front of the elevon. Sand the
elevons and smooth all the surfaces.
Spray the elevons with a mist coat of adhesive. Apply color tape
to cover the entire surface.
Position the elevon on the trailing edge of the wing. Align a
straight-edge with the wing tip. Leave a 1/16” space between the
end of the elevon and the straight-edge. Use small pieces of
masking tape to hold the elevon in position temporarily. Best to
leave a corner of the tape turned up for easy removal.
Color tape may be used to make a hinge. Holding the end of the
tape over the seam press the color tape in place while peeling it
back. Remove the small pieces of masking tape ahead of the
color tape. Press the tape down along the length of the elevon
with a squeegee.
Press the servos in place with the control arms centered at 90
degrees to the servo case. The servo case should be flush with
the surface of the wing and the control arms sticking straight up
above the wing surface.
12

Align a straight-edge from the outboard side of the servo control
arm to the elevon parallel to the center line. Make a line on the
elevon.
Align the control horn to the line on the elevon in line with the servo
control arm. Use a punch or any pointed tool to mark the position
of the holes in the control horn foot. Drill two holes big enough for
the 2 x 56 self tapping machine screws. Thread the machine
screws through the elevon into the nylon locking pad. Snug the
screws to make a slight impression in the balsa wood. Do not
over tighten!
Screw the threaded clevis onto the control rod so that equal
threads are showing on both sides of the clevis. Hold the elevon
in the neutral position and make a mark where the control rod
matches the top hole in the control arm.
The diameter of the control rod may be reduced with a file or belt
sander to fit better into the control arm. The control arm hole may
be enlarged with a drill or by spinning an X-Acto blade in the hole.
Attach control rods to the servo control arms with a Z-bend. (NOTE:
Z-bend pliers may be purchased from your local hobby dealer to
make this operation easier.) Long nose pliers will also work to
make a Z-bend.
Mechanical centering of the elevon can be achieved by removing
the clevis from the control horn and screwing it in or out.
13

Antenna
Spars
Using a straight-edge as a guide, make a half-inch deep cut for the
servo wire channels. The channels go between the servo wires,
where they exit the servos, to the middle of the electronics bay.
Push the servo wires into the channels with a flat blade screw-
driver. Apply a piece of color tape over the channels.
Alternate method: Drill a hole between the servo bays and the
electronics bay. Make the holes big enough to push the servo
plugs through.
Using a straight-edge as a guide, make a quarter-inch deep cut for
an antenna wire channel on the bottom of the wing. Begin with a
cut toward the nose 1/2 inch past the spar. Then cut the channel
the length of the wing panel parallel to the spar. The antenna may
hang off the wing tip or may be circled back on the wing behind the
spar. Push the antenna wire into the channel with a flat blade
screwdriver. Apply a piece of color tape over the channel.
DONOTCUTOFFANYOFTHE ANTENNA!
14
Drill a hole in the wall of the electronics bay at an angle to miss the
floor plate. Make the hole big enough for the antenna wire to fit
through to the bottom side of the wing. Push the wire through the
wing leaving a couple of inches of antenna in the electronics bay
for positioning.
Install the receiver, battery and switch. Assemble the components
the way they were assembled on page 7. Power the transmitter
and the receiver. Check the movement of the elevons. When the
elevon control stick is pulled back (the opposite direction to
antenna) the elevons should both move up. When the stick is
moved to the right, the right elevon should move up and the left
elevon moves down.
Hollow out a space in the wing behind the receiver between the
top and bottom skin. Make the cavity big enough to stow the extra
servo wire. The extra switch wire will also be stuffed in.

Put a piece of fiber filament tape through the slot in the winglet to
the top of the wing and wrap it around to the bottom of the wing.
Add two more pieces of tape to secure the winglet in place. Make
sure the elevons will not bind against the winglets as they move.
The winglets are at the very back of the airframe where excess
weight is a real balance factor. The tape method of fastening is both
light and strong. If a different winglet fastening system is preferred,
keep the weight down to the weight of two short strips of tape.
Use the cookie that was removed from the electronics bay to
make a hatch cover. Use the curved side to match the curvature
of the wing. Spray and tape the cover.
Turn the transmitter on and then the receiver. Set the wing on a
couple rolls of tape or anything that will let the elevons move
freely. Hold a ruler near the elevon. Pull the elevator stick back to
the full ‘up’ position without any right or left movement. The throw
should be 1/2”. The full down throw should be the same. Now
push the stick to the full right position. The right elevon should
move up and the left move down. The throw should be 1/2”. Less
throw can be adjusted by moving the control rod to the next hole
down on the servo control arm.
Turn the transmitter on and then the receiver. The initial trim
settings should be adjusted holding a straight-edge against the
bottom of the wing at the TE. The straight-edge should be flush
with the bottom of the wing and the elevon for the last three inches.
Use the threaded clevis to adjust them to the proper position, do
not use the trim levers on the transmitter.
15
Fit the hatch cover to the electronics bay to make sure that it fits.
Do not tape it in place until the wing is balanced.

CG
Nose heavy
CG
The Zagi 5C will balance with the elevons in a neutral position. No reflex is necessary for washout or other
stability reasons. The suggested starting point for balance is 8 inches back from the nose. The best way to find
the balance point is to keep moving the battery back between flights in 1/8” increments until it is almost unflyable
(too elevator sensitive). Remember, the elevator travel volume can compensate for pitch sensitivity.
If the Zagi 5C requires reflex (up elevator) for level flight it is nose heavy. The weight in the nose pushes the
nose down. The elevons compensate in the ‘up’ elevator position creating drag.
Balanced
Lay the wing bottom-side-up. Tape a 1/4” dowel 8 inches back
from the nose (over the center spar). A round pencil or ball-point
pen can be used. Place the wing right-side-up on a flat surface.
Balance is achieved when the wing balances momentarily on the
dowel. Do not add nose weight. Move the battery forward or aft to
balance.
16
Cut a piece of foam the size of the space between the battery and
the front of the electronics bay to maintain batterty position.
Tape the hatch cover over the electronics bay. Leave the last inch
without tape to provide access to the switch.

Preflight check and glide test
Do a preflight check before every flight. Always turn the transmitter power on before the receiver. Make sure that
the controls are working properly. Check the trim levers on the transmitter. Pull the elevator control stick back
and observe that both elevons move upward. Push the control stick to the right and observe the right elevon
moves up and the left elevon moves down. Hold the wing securely by the nose. The first glide test should be
done on flat land in a light breeze. The wing should be held by the nose with your palm up and your thumb
wrapped around to the top. Hold the wing over your head with the nose pointed straight ahead. Run slowly into
the wind. Give it a gentle push STRAIGHTAHEAD. Do not point the nose upward. Correct the flight path with the
radio control stick. The test is successful when the wing flies straight ahead with a slow sink rate to a sliding
landing. Trim levers on the transmitter can be used to adjust the glide path. If the wing turns in either direction
after the launch, compensate by adding 2 or 3 clicks of trim in the opposite direction. If the wing pitches up and
immediately dives, add 2 or 3 clicks of down trim. Repeat the glide test until the Zagi 5C flies straight ahead with
a slow sink rate to a sliding landing. Increase the launch speed each time to provide longer control flights.
First flight
Check the frequencies (channel number) of all pilots within visual range before turning on your transmitter. Turn-
ing on your transmitter with the same channel number as someone who is flying will certainly cause his plane to
crash.
The Zagi 5C is capable of high speed. Flights at a high rate of speed can cause considerable damage to
someone or something if a collision occurs. Please exercise caution while flying. It is recommended that you
jointheAcademyofModelAeronautics(AMA)(1-800-435-9262)toprovideinsurance,awarenessofsafe
flying practices, and knowledge of what’s going on in the modeling field. At some flying sites it is manda-
tory that you be a member of the AMA.
Hold the wing by the nose with your palm up over your head and your thumb wrapped around to the top. Take a
step or two forward and give the wing a good strong throw into the wind. Afollow through with a little finger tip will
increase the launch speed.
Good luck,
JT
17
Zagi is a registered trademark of Trick R/C Products LLC

Trick R/C guarantees this kit to be free from defects in both workmanship
and material at the date of purchase. This does not cover any components
or parts damaged by use, misuse or modification. In no case shall Trick
R/C’s liability exceed the original price of the purchased kit.
Since Trick R/C has no control over the final assembly, no liability shall be
assumed for any damage resulting from the use by the user of the final
user-assembled product. By the act of using the final user-assembled
product, the user accepts all resulting liability.
18