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AeroWorks 50cc Ultimate 20-300 ARF-QB Assembly Manual

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50cc Ultimate 20-300 ARF-QB
(Quick Build)
ASSEMBLY MANUAL
AEROWORKS™
4903 Nome Street, Denver, CO. 80239 - Phone 303-371-4222 - Fax 303-371-4320
E-mail - info@aero-works.net
2008 - Copy write Protected – All Rights Reserved by Aeroworks Inc.
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Summary of Contents for AeroWorks 50cc Ultimate 20-300 ARF-QB

  • Page 1 50cc Ultimate 20-300 ARF-QB (Quick Build) ASSEMBLY MANUAL AEROWORKS™ 4903 Nome Street, Denver, CO. 80239 - Phone 303-371-4222 - Fax 303-371-4320 E-mail - info@aero-works.net 2008 - Copy write Protected – All Rights Reserved by Aeroworks Inc.

  • Page 2: Table Of Contents

    TABLE OF CONTENTS Page Aeroworks Contact Information ………………………………………………………………. 3 Introduction ……………………………………………………………………………………... 4 Kit Contents……………………………………………………………………………………… 5 Items Needed To Complete ……………………………………………………………………... 8 Tightening and Re-shrinking The Covering ………………………………………………….. 9 Check Seams and Overlaps for Good Seal ……………………………………………………. 11 Wing Assembly………………………………………………………………….……………….. 12 Inner Cabane Installation ……………………………………………………………………….

  • Page 3: Aeroworks Contact Information

    Further, Aeroworks reserves the right to change or modify this limited warranty without notice. In that Aeroworks has no control over the final assembly or materials used for final as- sembly, No liability shall be assumed nor accepted for any damage resulting from the use by the user of the final user-assembled product.

  • Page 4: Introduction

    LIMITED WARRANTY READ It is important to notify Aeroworks of any damage or problems with the model within 30 days of receiving your airplane to be covered under warranty. If you wish to return this air- craft for any reason a 15% restock fee will be charged to the customer. In addition the cus- tomer is responsible for all return shipping cost and all prior shipping cost will not be re- funded.

  • Page 5: Kit Contents

    KIT CONTENTS (1) Pilot holes pre-drilled for tail wheel assembly 50cc ARF-QB Ultimate 20-300 (1) Top hatch cover for the engine box with AW logo Materials List installed by (4) T2.6x8mm PWA screws (2) Bottom wing fillet installed – Left and Right, BASIC AIRCRAFT PARTS: painted (1) Center cabane assembly installed...
  • Page 6 (14) pin point hinges glued (8) 6-32x10mm hex head bolts for the L steel Outer (2) Aileron servo string installed struts fittings (2) Pilot holes pre drilled for control horns mounting (2) 1/4x40mm Nylon Bolts for the bottom wing mounting Horizontal Stabilizer –1 Left 1 right with elevator as- sembly with (10) pin point hinges (glued)--- (4) 4-40 3”...
  • Page 7 #10: (24) 6.35mm aluminum engine stand offs. #11: (2) Aluminum stabilizer tubes – 383mm; 176mm anodized black (4) 4-40x16mm hex style head bolts for stab mount- (4) #6 bonded washers for stab mounting (4) Φ3mm split ring lock washers for stab mounting #12: (1) 300x300mm Pearl Blue Covering (1) 300x300mm Cub Yellow Covering...

  • Page 8: Items Needed To Complete

    ITEMS NEEDED TO COMPLETE Hardware • Allen wrenches US and Metric. • Dremel cutting disc and sanding drum tool • Electric drill and selection of bits • Razor saw • Flat head screwdriver • Hobby heat gun • Hobby iron and covering sock •...

  • Page 9: Tightening And Re-Shrinking The Covering

    TIGHTENING AND RE-SHRINKING THE COVERING 1. Remove the canopy before applying heat to the 3. Using your covering iron with a soft sock, gently covering. Excessive heat from covering irons or apply pressure and rub in the covering. If any heat guns can cause the canopy to melt or warp.
  • Page 10 5. Use your heat gun with extreme caution. Take care not to apply too much heat to one area for long periods of time. This may cause the trim colors to over shrink and pull away leaving un- sightly gaps on the color lines. The trim stripes are especially vulnerable to over shrinking.

  • Page 11: Check Seams And Overlaps For Good Seal

    It is the responsibility of the purchaser / operator to check the covering seams and overlaps for security and a good seal. Aeroworks is not responsible for failure of covering seams or overlaps during flight. Note: If covering continues to lift apply a small amount of thin CA underneath the covering.

  • Page 12: Wing Assembly

    (4) 6” Servo extension, (4) 1 1/4” Servo light tension. arms and (4) Aeroworks Safety Clips as shown below. Note: The ailerons have been pre-hinged and glued to the wing panels and are ready for flight. No other steps are necessary for hinging.
  • Page 13 Pull servo extension through wing and pro- Install servo with servo mounting screws. Re- vided exit holes in wing panel. peat servo installation process for all aileron servos. Install servo in servo well with the output arm toward the leading edge of the wing. Drill holes for servo mounting screws.
  • Page 14 Aileron Control Linkage Installation 3. Correct installation of ball link, flat washer and brass spacer to servo arm shown below. 1. Gather the aileron control linkage parts as shown below. 4 pushrod assemblies with ball links 8 4-40 Bolts and lock nuts 4 Washers 4 brass spacers 4 left and right side control horn...
  • Page 15 7. Tape the trailing edge of the aileron to the trail- 5. Use a drop of thick CA glue on each screw as ing edge of the wing in the neutral position. shown. Plug the servo into the receiver and turn radio on.
  • Page 16 Outer Strut Mounting Bracket Installation 1. Gather the (8) steel strut mounting brackets, (8) mounting bolts, and (8) washers as shown be- low. 2. Use loctite to prevent the strut mounting bolts from loosening. 3. Wing assembly is now complete. Note: Check mounting bolts are tight before each flying session.

  • Page 17: Inner Cabane Installation

    INNER CABANE INSTALLATION 1. Remove the rear inner cabane mounting bolts as Remove the rear cabane as shown below. shown. 2. Remove the 4-40 mounting bolt on the rear ca- 4. Slide the male end of a 6” extension through the bane as shown below.
  • Page 18 5. Route the extension into the fuse as shown be- low. Reinstall the rear cabane at this time. 6. Use blue loctite on the cabane mounting bolt as shown below. Reinstall the mounting bolts at this time. Note: We recommend removing all cabane mounting bolts and reinstall using loctite.

  • Page 19: Stab And Elevator Assembly

    STAB AND ELEVATOR ASSEMBLY Elevator Servo Installation Elevator Control Linkage Installation 1. The elevators have been pre-hinged and glued to the stabs and are ready for flight. No other steps are necessary for hinging. Clear covering has been provided for sealing of the hinge gaps if 1.
  • Page 20 3. Correct installation of ball link, flat washer and 5. Use tape to hold elevator in the neutral position. brass spacer to servo arm shown below. Plug the servo into the receiver and turn radio on. Ensure the servo trim and sub trim is cen- tered.

  • Page 21: Rudder And Rudder Servo Assembly

    RUDDER AND RUDDER SERVO INSTALLATION Mix epoxy in mixing cup and use a tapered Rudder Installation stick to apply the epoxy inside the pre-drilled holes in the trailing edge of the fin. Apply Gather the rudder, hinges, epoxy, Vaseline, epoxy to one side of each hinge and insert the stir sticks, mixing cup and alcohol as shown.
  • Page 22 Mix epoxy in mixing cup and use a tapered Ensure there is minimal to no gap between fin stick to apply the epoxy inside the pre-drilled and rudder. Allow epoxy to fully cure. holes in the leading edge of the rudder. Apply epoxy onto each hinge.
  • Page 23 2. Assemble the ball links between the control 4. Use thick CA on each screw prior to installing to horns as shown. Secure with nylon lock nut. lock screws in place Note: Mount ball link to bottom control horn hole Note: CA glues have a fast drying time.
  • Page 24 6. Feed the rudder cable through the pre installed 8. Pull the rudder cables from the fuse tail to the cable exit tube in the tail of the fuse toward the rudder servo tray. Take care not to cross the ca- front.
  • Page 25 12. Thread the brass swag tube onto the pull pull 10. Install the rudder servo with the output shaft fac- cable followed by the threaded coupler. ing forward as shown below. 11. Install the ball link onto the threaded coupler as 13.
  • Page 26 14. Loop the cable back through the brass swage 16. A drop of thin CA may be applied to the swage tube and pull tight as shown. tube to help secure the cable. 15. Crimp the brass tube with a crimping tool or pli- 17.
  • Page 27 18. Install the servo arm onto the rudder servo as 20. Tape the rudder balance tab to the top leading shown below. edge of the vertical fin in the neutral position as shown. This ensures the rudder is straight when the cables are attached.
  • Page 28 22. Finished pull pull installation shown below.

  • Page 29: Tail Wheel Assembly

    3. Place tail wheel steering tiller over the pre- Tail Wheel Installation drilled holes in the bottom of the rudder. 1. Tape the rudder balance tab to the top leading edge of the vertical fin in the neutral position as shown.
  • Page 30 5. Mount the tail wheel steering tiller using two 7. Place a drop of thick CA on tail wheel strut wood screws. mounting screws before inserting in the pre- drilled mounting holes on the bottom rear of the fuse. 8. Mount the tail wheel strut using three wood screws.
  • Page 31 10. Use pliers to twist spring ends closed around the 12. Repeat for opposite side tail wheel spring. Ad- rudder and tail wheel tillers. just length and spring tension so that tail wheel is centered when rudder is centered. 13. Tail wheel assembly is complete. 11.

  • Page 32: Main Landing Gear And Wheel Pant Assembly

    MAIN LANDING GEAR , AND WHEEL PANT INSTALLATION 3. Assemble the landing gear bolts with lock Main Landing Gear Installation washer and flat washer. Use a drop of blue Loc- tite on landing gear bolts before attaching the 1. Gather the landing gear parts as shown below. landing gear.
  • Page 33 5. Install the axle into the gear strut with nylon 7. Install the inner wheel collar on the axle. Use a lock nut. Only snug tighten at this time. drop of blue Loctite on the wheel collar set screw and tighten the wheel collar in place. 6.
  • Page 34 9. Secure the wheel pant using the supplied 4-40 mounting bolts, lock washers, and flat washers. Use blue Loctite on the mounting bolts. 10. Final gear assembly with wheel pants installed shown below.

  • Page 35: Engine/Throttle Installation

    ENGINE INSTALLATION 3. Locate the laser cut engine mounting template Engine Installation for the DA-50. 1. The 50cc Ultimate 20-300 will accept a wide Note: If other engines are used the templates may range of engine types. Illustrations for a DA-50 be modified to fit you engine selection.
  • Page 36 5. Remove the 4 Phillips head screws holding the 7. Engine installation is now complete. top hatch to the motor box. 6 5/8” Throttle Servo Installation 1. Gather the plywood four side throttle servo Using mounting bolts and flat fender washers mounting tray, the throttle servo and pushrod mount engine to firewall.
  • Page 37 2. Mark the location of the throttle pushrod on the 4. Assemble ball link to threaded end of pushrod. firewall. Note: Thread ball link half way onto pushrod to allow for proper adjustment during final installation. 3. Remove the engine and the upper right standoff. 5.
  • Page 38 6. Attach ball link to throttle arm of carburetor 8. Place the servo and tray inline with the throttle pushrod. 7. Place the throttle servo into the plywood servo 9. Position the throttle servo as shown below. With mounting tray as shown below. the servo output shaft facing the rear of the air- plane.
  • Page 39 13. Apply epoxy to the bottom of the servo mount- Mark the location of the plywood mounting tray ing tray as shown. Reinstall the servo mounting inside the fuse. tray in the fuse using the marks made in a previ- ous step.
  • Page 40 15. Assemble ball link and threaded coupler to servo 17. Gather the soldering tools as shown below. arm as shown below. Note: For best results we recommend a high quality Silver Solder like “Sta-Brite” silver solder. 16. With the servo arm centered and the throttle arm 18.
  • Page 41 19. Attach the throttle pushrod with the 4/40 ball links and secure. Power up the receiver and throttle servo and adjust pushrod for proper op- eration. Ensure the servo or rod does not bind or jam at closed or full open positions. 20.

  • Page 42: Ignition Installation

    IGNITION INSTALATION 1. Gather the ignition module, ignition battery, 3. Use a 1/4” drill bit to drill the nylon tie mount- regulator, switch, and mounting hardware as ing holes as shown. shown. 2. Position the ignition module outside the engine 4.
  • Page 43 Thread ignition connector through firewall and larger than the ignition module. connect ignition timing connectors with an Aeroworks Safety Clip. Ensure the connectors will not come apart from vibration or light ten- sion. 6. Install the ignition module and the foam pad 8.
  • Page 44 9. Install the ignition switch as shown below. Fol- low the switch manufacturers directions for spe- cific switch mounting instructions. 10. Install the ignition regulator as shown below. Follow the regulator manufacturers directions for specific regulator mounting instructions.

  • Page 45: Fuel Tank Installation

    FUEL TANK ASSEMBLY AND INSTALLATION 3. Assemble the fuel pick up line, rubber stopper Fuel Tank Assembly and metal end caps. As shown below. 1. Gather the fuel tank parts as shown below. A 750cc (26oz) fuel tank has been provided. 2.
  • Page 46 5. Final assembly of rubber fuel stopper with fuel 7. Install the fuel tubing and clunk. Secure the fuel pick up tube shown below. tubing with nylon ties to the pick-up tube and clunk. 6. Install air vent tube into rubber stopper and bend 8.
  • Page 47 Note: It is recommended you always use a fuel filter in the fuel line to the carburetor. Note: The fuel “T”, fuel filter and filler dot are not supplied, but are available through Aeroworks.
  • Page 48 6. Thread nylon ties under tank mounting plate and 4. Use nylon ties to secure fuel line. center in position. Note: Gasoline will cause the fuel line to swell over time. Always secure fuel lines with nylon ties to prevent them from pulling off during flight.
  • Page 49 8. Install the fuel tank with the vent line towards 10. Route the vent line on top of the fuel tank and the top of the fuse as shown below. secure with small nylon ties as shown. This will stop excess fuel from draining out the vent line during an extended down line or when lifting the tail.
  • Page 50 12. Attach the fuel line to the carburetor as shown. 14. Mark the location of the fuel filler dot. Use a small nylon tie to secure the hose to the carburetor. Note: The higher you mount the fuel fill dot the less fuel will siphon out when fueling.

  • Page 51: Radio Installation

    RADIO INSTALLATION 1. Gather the receiver, battery, switch, regulator 3. Install the receiver using the supplied Velcro ties and mounting hardware as shown below. and foam pad as shown below. Refer to receiver manufactures instructions for specific receiver mounting. 2. Install the receiver battery using the supplied 4.
  • Page 52 Y harness to the extension for the upper wing. Use an Aeroworks Note: Apply baby powder or corn starch to antenna safety clip. Ensure the plugs will not come apart wire to assist getting antenna into their guide from vibration or light tension.

  • Page 53: Cowl Installation

    COWL INSTALLATION 1. Gather the following material for making a cowl 3. Measure and mark a center line on bottom of cutout template. fuse as shown below. Hobby Knife, Ruler, Tape, Felt tip pen or marker Template material has been supplied. 2.
  • Page 54 5. Align centerline marks of template and fuse, 7. Using a hobby knife cut out template for cylin- align template with 3/16” reference mark on der head. Reattach the template and check to see fuse. Use masking tape to securely hold the tem- if the template lines up correctly.
  • Page 55 9. Trace around the muffler being careful to keep 11. Dry fit template and check to see if the template the template in the same location. lines up correctly. It may be necessary to make small adjustments to the cut out at this time. 10.
  • Page 56 Always check the operating temperature of your engine to prevent any damage from occurring. Aeroworks is not responsible for damages incurred from improper engine cooling. 14. Remove the template and use a rotary cutting tool and sanding drum to cut out the opening in the cowl.

  • Page 57: Manual Choke Installation

    Manual Choke Installation Manual Choke Installation 3. Finished choke installation shown below. 1. Gather the included choke pushrod, ball link assembly, large nylon tie, and (2) small nylon ties as shown below. Note: Manual choke assembly shown, for servo op- erated assembly please use the same method as described for the throttle servo Assemble the choke pushrod as shown below.

  • Page 58: Decal Installation

    DECAL INSTALLATION Decals Available through Aeroworks 1. Placement of optional decal package shown, in- 2. Placement of optional decal package shown, in- cluded decals will differ. cluded decals will differ.
  • Page 59 1. Decals supplied with the kit will vary from the 3. Remove backing from Clear transfer tape. photos below. Installation step are the same Gather supplied decals, transfer tape, ruler, scis- sors, hobby knife, plastic squeegee or credit card, Windex or Application fluid like Rapid Tac.
  • Page 60 5. Press transfer tape to top of decal. 7. Spray model surface with application fluid, Windex or soapy water solution. 6. Peel backing from decal. 8. Spray back side of decal with application fluid, Windex or soapy water solution.
  • Page 61 9. Position decal in proper location. Application 11. Pull transfer tape from top of decal. Take care fluid will allow decal to be moved slightly. not to pull away or damage decal. 10. Using a plastic squeegee or credit card. Spread 12.
  • Page 62 13. Repeat installation process of bottom decal for 15. Pull transfer tape from top of decal. Take care top decal installation. Use application fluid for not to pull away or damage decal. easier installation 14. Place top decal over bottom decal. Position 16.

  • Page 63: Dash Panel And Pilot Installation

    DASH AND PILOT INSTALLATION Available Through Aeroworks 1. If installing pilot or dash remove canopy mount- 3. Reattach canopy using mounting screws. ing screws. Dash panel pilot available from Note: Aeroworks 2. Glue or screw in dash panel and pilot figure ac-...

  • Page 64: Preflight Preparation

    2. Connect aileron extensions to aileron servos in bottom wing. Use an Aeroworks Safety Clip to ensure the plugs will not come apart from vibration or light tension.
  • Page 65 5. Gather the left and right cabanes, (8) Mounting 8. We recommend using Velcro hook and loop for bolts, (8) Lock Nuts, and (8) Washers as shown restraining the top wing aileron extension to the below. inner cabanes. This can be found at your local hardware, automotive or fabric stores.
  • Page 66 10. This will give you a simple and virtually invisi- ble method for connecting the top wing aileron servo to the servo extension wire to the re- ceiver.

  • Page 67: Center Of Gravity (C.g.)

    A tail heavy aircraft is uncontrollable and will likely crash. 2. Balance the 50cc Ultimate 20-300 ARF-QB without fuel in the tank with the batteries in- stalled and ready to fly. The engine, radio, ser- vos, and battery you use will determine the final weight and locations of equipment.

  • Page 68: Control Throws

    CONTROL THROWS 1. The amount of control throw should be adjusted 4. Measure the rudder deflection in inches from using mechanical means as much as possible and bottom of the rudder then electronically with the radio. The control throws are shown in degrees and inches of de- flection measured at the widest point of the con- trol surface for both low and high rates.
  • Page 69 Location for throw meter to measure Elevator throw in degrees.

  • Page 70: Control Throw Deflection Table

    Control Throw Deflection Table Preflight Checks Center of Gravity: Check CG is set properly. Low Rate High Rate 1” or 15˚ up 2” or 30˚ up Engine: The engine should run smoothly at all Aileron throttle settings with smooth transition from 1”...
  • Page 71 Aerobatics The 50cc Ultimate 20-300 ARF-QB is capable of any aerobatic maneuver. After you gain some con- fidence and little experience flying the airplane you can cut loose and perform any maneuver you can think of. Here is a list of some of the more popular aerobatic and 3D maneuvers you can try: •...
  • Page 72 50 cc Ultimate 20-300 ARF-QB NOTES ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ __________________________________________________________________________...

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