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BME Aircraft 37% Scale Ultimate Biplane Instruction Manual

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BME Aircraft
37% Scale Ultimate Biplane
BME 37% Ultimate Ver 1.0
3/15/2004
Page 1

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Summary of Contents for BME Aircraft 37% Scale Ultimate Biplane

  • Page 1 BME Aircraft 37% Scale Ultimate Biplane BME 37% Ultimate Ver 1.0 3/15/2004 Page 1...
  • Page 2 BME 37% Ultimate Ver 1.0 3/15/2004 Page 2...

  • Page 3: Specifications

    INTRODUCTION Congratulations! You have just purchased an outstanding aerobatic aircraft in the form of the BME Aircraft 37% Ultimate Biplane. The Ultimate has long enjoyed a reputation of being one of the best flying RC aerobatic designs in existence. This reputation was earned and well-proven over the years in what was perhaps the most prestigious RC event in the world –...
  • Page 4 ASSEMBLE CENTER CABANES 1. Refer to photos 1-3 and locate the 7 metal cabane pieces consisting of 2 long uprights, 2 short uprights, 2 diagonals and 1 center root rib. 2. Note that the two shorter uprights are installed towards the front of the fuselage while the longer uprights are installed towards the rear.
  • Page 5 MOUNT THE WHEELS AND WHEEL PANTS ( This part will be revised with new style ) 1. Refer to photos 4-8 and locate the landing gear, wheels, wheel pants, axles, wheel collars and wheel pant mounting screws as shown in photo 4. 2.
  • Page 6 7. Note, The landing gear on the Ultimate are swept rearwards. In other words, they slant towards the rear of the airplane when viewing from the side. Keeping this in mind identify the right and left gear legs and wheel pant assemblies.
  • Page 7 MOUNT THE LANDING GEAR TO THE FUSELAGE 1. Refer to photo 9 and locate the holes for the landing gear mounting screws underneath the covering. Pressing firmly with a finger will allow feeling the holes under the covering. 2. Using a sharp Exacto blade cut the covering from each hole.
  • Page 8 3. Test fit the tail wheel bracket into the hole. It may be necessary to remove the paint from the bracket and/or to radius the rear of the hole to accept the bracket. 4. Once the bracket fits all the way down into the hole secure it with the 2 formed straps and sheet metal screws as shown on photo 5.
  • Page 9 2. Locate the servo lead exit holes on the top of the bottom wing between the two strut mounting tabs. Cut the covering over the holes and use a trim iron to tuck the covering down into the holes as shown in photo 15.
  • Page 10 4. Locate the servo cut out and servo lead exit holes on the bottom of the top wing. Cut the covering over the holes and use a trim iron to tuck the covering down into the holes as shown in photo 18. 5.

  • Page 11: Install Flying Wires

    INSTALL FLYING WIRES 1. Refer to photo 20 and locate the flying Wire hardware consisting of steel cable, 12 angle brackets, 8 clevises, 8 rigging connectors and 16 ferrules. Note: the angle brackets are bent at 90 degrees at the factory. They should be un-bent some so that they align with the attach points as illustrated in subsequent photos 32, 33, 34.
  • Page 12 4. Locate the top right wing panel and the bottom right wing panel (the bottom wing panel has the plywood strut mounting tabs on the top/colored surface while the top panels have the tabs on the plain bottom surface). We are going to fasten the spar tubes into one top and one bottom wing panel.
  • Page 13 7. Using cap head screws and lock washers, fasten a flying wire bracket to each fuse side in the holes uncovered during a previous step. See photo 25. 8. Temporarily remove the cap head screw that was used to mount the rear of the metal rib to the cabanes.
  • Page 14 11. Using cap head screws and lock washers, attach flying wire brackets to the inside of the tops and bottoms of the struts. The brackets are towards the inside facing the fuselage. The screws also fasten the struts to the top and bottom wing panels. See photos 27 &...
  • Page 15 13. Crimp the ferule with a pair of pliers as shown in photo 30. 14. Thread clevis onto rigging connector until the threads of the clevis are fully occupied. See photo 31. 15. Attach the clevis to the forward bracket at the top of the right wing strut as shown in photo 32.
  • Page 16 16. Stretch the cable down to the bracket that is fastened to the fuse side and cut the cable to length to allow for going through the bracket and then back through the ferule. 17. Slip a ferule over the cable, thread the cable through the bracket and then back through the ferule.
  • Page 17 20. Now make up 2 more flying wires and attach them to the lower brackets on the right strut and connect the other end to the bracket attached the center cabanes as shown in photo 35. 21. Repeat steps 41-49 to assemble and install the 4 flying wires for the left wing panels and strut.
  • Page 18 INSTALL AILERON CONTROL HORNS AND LINKAGES 1. The builder may install the control horns of choice. We have used the Rocket City 4-40 HD ball links and 8-32 swivel links as illustrated in the photos. 2. With the servo arm pointed towards the wing tip and positioned at 90 degrees to the servo case, draw a line that is 90 degrees to the arm straight back onto the...
  • Page 19 CUT COVERING FROM SERVO MOUNTS IN THE HORIZONTAL STABILIZERS AND HINGE THE ELEVATORS 1. Locate the holes for the Elevator Servos underneath the covering on the bottom of the horizontal stabs. Trim the covering and use a trim iron to tuck the covering down into the servo holes as shown in photo 38.
  • Page 20 MOUNT ELEVATOR SERVOS AND INSTALL LINKAGES 1. Mount the elevator servos and bring the servo lead out of the hole in the stab root as shown in photo 41. Note that the servo arm points towards the stab tip. 2. With the servo arm pointed towards the stab tip and positioned at 90 degrees to the servo case, draw a line that is 90 degrees to the arm straight back onto the elevator.

  • Page 21: Mounting The Stabilizer Halves

    4. Assemble and install the 2 elevator linkages as shown in photo 44. MOUNTING THE STABILIZER HALVES 1. Locate the Left stab half and the two stab spar tubes. Note that the stab spar tubes are marked right/left and also note that the tubes have already been drilled for the 4- 40 retaining bolts.
  • Page 22 4. Locate the hole in the fuse for the elevator servo leads under the covering between the holes for the front and rear spar tubes. Cut the covering and tuck it into the hole using a trim iron as shown in Photo 47.
  • Page 23 INSTALL VERTICAL FIN 1. Insert the vertical fin into the slot in the rear of the fuse as shown in photo 49. Make sure it is resting on the platform and that it is pushed as far forward as it can go.
  • Page 24 INSTALL RUDDER HINGES 1. The Rudder hinge holes have already been drilled, however they probably do not fit all of the way into the rudder or fin yet. The hinge holes need to be made square because the hinge points have a square profile where they exit the rudder and fin (see photo 51).

  • Page 25: Prepare The Firewall

    PREPARE THE FIREWALL 1. Layout the firewall as shown in Photo 52a. Measure and draw a vertical Center Line on the firewall and label it CL. Draw another vertical line that is 7/32"" to the right of the center line and mark it as the Offset Line.
  • Page 26 3. Mount the bottom wing panels to the fuselage and put an incidence meter on the right wing panel inboard of the aileron. Block up the tail of the fuselage until the wing is at zero degrees – see photo 53. This provides a reference for setting the firewall up/down thrust to 0 degrees.
  • Page 27 6. Drill a 1 ¼" hole at the intersection of the Thrust Line and the Offset Line. This hole will be used along with a plywood engine spacer to locate the final position of the engine on the firewall. ASSEMBLE AN ENGINE SPACER/STANDOFF 1.
  • Page 28 2. Take another piece and draw 2 diagonals and also draw a horizontal and vertical center line as shown in photo 59. Set the engine on the piece and center the engine using the lines that have been drawn. Trace the outline of the engine mount, including the engine mounting holes onto the piece of AC ply.
  • Page 29 6. Attach the standoff to the firewall by holding the standoff on the front of the firewall with the hole in the center visible through the hole in the firewall (be sure to observe the standoff orientation as marked top previously). Now take the sheet metal screw and push it through the hole in the piece of scrap plywood, through the hole in the firewall, and then screw it into the...
  • Page 30 PREPARE THE COWL 1. Using a rotary tool remove the fiberglass from the cowl inlet areas. See Photo 65. Also locate the center of the cowl at the front where the spinner is to match up. The center may be located by using a compass to draw a circle on a piece if "...
  • Page 31 FINAL POSITION OF ENGINE AND STANDOFF 1. Slide the cowl onto the fuselage and mount the 4½”spinner back plate on the front of the engine. Check the fit of the cowl to the spinner back plate while keeping the front of the cowl against the wooden disc.
  • Page 32 PERMAMENTLY INSTALL THE FIREWALL 1. Locate the 3 pieces of hardwood triangle stock and note that two of them are cut at an angle on one end – these are the upright pieces. The third piece is cut square at the ends and it is located across the bottom of the firewall.
  • Page 33 LIGHTEN THE STANDOFF AND FIREWALL 1. Use a hole saw to bore a large hole through the center of the standoff to help reduce weight. If the hole saw does not remove enough material, additional lightening holes can be drilled on the back side –...

  • Page 34: Mount The Cowl

    MOUNT THE COWL 1. Locate some stiff paper or light cardboard (like from a manila folder) and cut 6 strips approximately ¾” wide and 2" long. 2. Make a clean hole at one end of each strip that is just big enough for a 4-40 screw to pass through.
  • Page 35 8. With the cowl firmly held in the correct position, mark the hole through one of the paper pieces on the top of the cowl. Drill a hole in the cowl at the mark just made that is just large enough for a 4-40 screw to pass through (#33 drill bit).
  • Page 36 CUT COWL CLEARANCE HOLES 1. There are many ways to locate where holes must be made in the cowl in order to provide clearance for mufflers. The example shown here utilizes a simple tool made from an old RC telescoping TX antenna and a block of wood.
  • Page 37 5. Remove the cowl again and mount the other muffler onto the engine. Use the locator tool to locate the cut out for this muffler. While you are at it, also locate the center of the carburetor on the bottom of the cowl.
  • Page 38 8. Now fabricate ducting inside the cowl to direct the airflow down behind the rear of the cylinders. Our example uses two pieces of .010” - .020” aluminum sheet that is fastened to the front of the engine box with scrap pieces of right-angle aluminum.
  • Page 39 INSTALL THE INSTRUMENT PANEL, PILOT AND CANOPY 1. The instrument panel (included) and pilot (not included) are optional. If they are to be installed, prepare the pilot as may be necessary (trimming, painting etc). Also carefully cut the instrument panel from the full size photo and test fit it to the dashboard area of the cockpit.
  • Page 40 6. Position the canopy on the ledge so that it is centered on the hatch and then draw lines on the sides of the hatch that follow the bottom edges of the canopy. Remove the covering at this line and cut/sand a slight ledge into the hatch sides so that the canopy fits flush with the outside of the hatch.
  • Page 41 INSTALL THE RUDDER PULL-PULL LINKAGE 1. Place a straight edge on the center of the rudder pull-pull cable exit slot and run the straight edge back onto the rudder in order to locate the height of the rudder linkage. See photo 94. 2.
  • Page 42 4. The pull-pull cables may be attached to a bell crank or may be attached directly to the servo – the choice is up to the builder. Photo 97 illustrates using a bell crank to relieve the servo of excessive side loads at the output shaft.
  • Page 43 TAIL WHEEL STEERING LINKAGE 1. Locate the aluminum tiller arm and 3 sheet metal screws. See photo 99. 2. The tiller is attached to the bottom of the rudder using the sheet metal screws. Its front edge is aligned with the rear of the bevel in the leading edge of the rudder.

  • Page 44: Center Of Gravity (Cg)

    3. Bend the right side of the tail wheel steering arm so that it is aligned with the tiller on the bottom of the rudder. See photo 102. Attach ball links and fabricate a pushrod. The pushrod in the photo is carbon fiber with 1”...