Pilot Communications 100-170cc Assembly Manual
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Pilot Communications 100-170cc Assembly Manual

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Assembly Manual For
100-170cc Planes
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Summary of Contents for Pilot Communications 100-170cc

  • Page 1 Assembly Manual For 100-170cc Planes www.pilot rc.com www.pilot rc.com...

  • Page 2: Introduction

    INTRODUCTION Thank you for purchasing a 100-170cc airplane. We strive to bring you the most complete and easy to build ARF kits in the market today. Assembly is quick with most of the major work already completed at our factory.

  • Page 3: Warranty

    ARRANTY ARRANTY ■ All Pilot-RC products are guaranteed against defects within 30 days of receiving your airplane. This warranty is limited to construction or production defects in both material and workmanship. It DOES NOT cover any components or parts damaged by misuse or modification.

  • Page 4: Attention

    ATTENTION ATTENTION You should not regard this plane as toy! ■ ■ To ensure safety, please read the instruction manual thoroughly before assembly. ■ Building and operating a model plane requires diligent practice and correct guidance. An inexperienced flyer can cause serious injury and property damage.

  • Page 5: Table Of Contents

    INDEX ……………… ….………..….…….…. Introduction …………………….……..… .…..……. Warranty …………….…………..… .……..……. Attention Landing Gear And Rudder Unit Rudder Assembly ………..……. …...…….. Rudder Control Horns …………..… …..Tail Wheel Installation ……. ……...….…….. Rudder Axis Installation Landing Gear Assembly ………….…..……. Main Landing Gear Installation …………..….………...

  • Page 6: Landing Gear And Rudder Unit

    Landing Gear and Rudder Unit Rudder Assembly 1. Remove the protective covering Rudder Control Horn from the horns and locking plates. Please refer to the 2. Trace around the locking plate HARDWARE LIST (download with a knife and remove the covering with instructions) to get the below to expose the pre-cut slots.
  • Page 7 Rudder Assembly 3. Scuff the middle of the horns 5. Fit the horns into the locking plate with sand paper to ensure a good and then insert them into the pre cut glue bond. slots. Wipe away excess glue with rubbing alcohol.

  • Page 8: Tail Wheel Installation

    Rudder Assembly 2. Use the tail wheel bracket as a Tail Wheel Installation template and drill holes for the mounting bolts. 3. Install the blind nuts through the 1. Draw a center line with a pencil opening in the rear of the fuselage. as shown Attach the tail wheel bracket and secure the bolts with Blue Loctite.
  • Page 9 Rudder Assembly 4.Install the hatch with 4 screws using the pre marked screw holes. 5. Install the tension spring using a self tapping screw and washer. Use the spring length with medium tension to determine where the screw should be located.

  • Page 10: Rudder Axis Installation

    Rudder Assembly 2. Fit the rudder by aligning the Rudder Hinge Installation hinges and inserting the hinge pin from the top of the rudder. This demountable rudder design could offer more room for you to ship and store 1. Insert the hinge pin into the hinges from the bottom of the rudder and push it right through to the top to locate the entry hole.

  • Page 11: Landing Gear Assembly

    Landing Gear Assembly 4. Fit the Teflon washer and tighten NOTE: the correct edge for mounting the collar set screw with 1.5mm hex wrench as shown. Taper to rear Straight edge to front of fuselage Main Landing Gear Installation...
  • Page 12 Landing Gear Assembly 1. Install the landing gear in the pre drilled holes with the supplied bolts 3. Lift the rear of fuselage parallel to and locking nuts. the ground as shown. Note: Don’t over tighten and crack the carbon fiber. 4.

  • Page 13: Pants Installation

    Landing Gear Assembly 5. Install the wheel and tighten the collar set screw using a drop of Blue 2. Drill the holes for the attachment Loctite. Make sure the wheel rotates bolts and install the blind nuts. freely. Wheel Pants Installation 3.

  • Page 14: Servo Unit

    Servo Unit Wing Servo Assembly Servo Arm Installation Servo Arm Installation 2. Position the servo arm 90 degrees Minimum Required Servo: Minimum Request Servo: to the servo as shown. Then mark and 180 in.oz / Metal Gear / Digital 180 in.zo / Metal Gear / Digital drill 2mm holes.

  • Page 15: Aileron Control Horns

    Wing Servo Assembly 1. Remove the protective covering Aileron Control Horns from the horns and locking plates.
  • Page 16 Wing Servo Assembly 4. Apply 30 minute epoxy inside the 2. Trace around the locking plate with a knife and remove the covering pre-cut slots, and coat the horn with below to expose the pre-cut slots. epoxy as shown. 5. Fit the horns in to the locking 3.

  • Page 17: Servo Installation

    Wing Servo Assembly 2. Use the provided safety clips to Servo Installation secure the servo and servo extension leads. 3. Tape the end of the servo 1. Carefully remove the covering from extension lead to the pre installed the servo location as shown. pull-string.
  • Page 18 Wing Servo Assembly 6. Install the servo arm facing 4. Pull the extension lead through toward the wing tip and adjust the to the root edge of the wing. push rod length to ensure the aileron and servo are in the neutral position. 5.

  • Page 19: Rudder Servo Assembly

    Rudder Servo Assembly Rudder servo Installation 2. Drill 2mm holes. Minimum Required Servos: 180 in.oz / Metal Gear / Digital 1. Turn on the transmitter (refer to wing 3. Attach servo arm with mounting servo installation) Align the servo arm screws and nuts as shown.
  • Page 20 Rudder Servo Assembly 4. Repeat the previous steps for 6. Cut off the excess horn as shown. the second rudder servo. Locate the coupler rods. 7. Attach the two rudder coupler rods 5. Drill 3mm holes in the servo arms. to both rudder servo arms.

  • Page 21: Servo Installation

    Rudder Servo Assembly Servo Installation 2. Tape the rudder panel to the top of the vertical fin to ensure it remains The rudder cables and couplers have in the neutral position. been pre installed as shown 1. Drill 1mm holes for the mounting 3.
  • Page 22 Rudder Servo Assembly 4. Turn on the transmitter. Make sure the servos are in the neutral position. Mount the pre-installed bolt link to the 5. Remove any slack in the cables servo arm without the locking nut. Use and crimp to secure as shown. two brass crimps on each cable and thread the cable through the end of the pull pull connector.
  • Page 23 Rudder Servo Assembly 7. Thread the connector in 2 – 4 9. Remove the ball links from the mm. Ensure the tension is the same rudder horn and secure the servo for both cables. arm ball links with locking nuts. 10.

  • Page 24: Elevator Servo Assembly

    Elevator Servo Assembly Servo arm Installation 2. Ensure the servo arm is 90 degrees to the servo as shown. Mark and drill 2mm holes. Minimum Required Servo: 180 in.oz / Metal Gear / Digital 1. Turn on the transmitter and plug 3.

  • Page 25: Elevator Control Horns

    Elevator Servo Assembly 2. Trace around the locking plate Elevator Control Horns with a knife and remove the covering below to expose the pre-cut slots. 1. Remove the protective covering 3. Scuff the horns with a piece of from the horns and locking plates. sand paper for a good glue bond.

  • Page 26: Servo Installation

    Elevator Servo Assembly 4. Apply the 30 minute epoxy inside Servo Installation the pre-cut slots, and coat the horn with epoxy as shown. 5. Fit the horns into the locking plate and then insert them into the 1. Carefully remove the covering pre cut slots.
  • Page 27 Elevator Servo Assembly 4. Use the provided safety clips to 2. Install servos as shown with the secure the servo and servo servo label facing toward the rear of extension lead. the fuselage. 3. Install the servo arm in the vertical position.
  • Page 28 Elevator Servo Assembly 7. Repeat the previous steps for the 6. Install the stab with mounting bolts and washers remaining stabilizer.

  • Page 29: Switch Assembly

    Switch Assembly Switch Installation 1. Carefully remove the covering over the switch cut out. Note: The switch mounting hole have been pre-cut for standard size 2. Mount the switch with the screws switches. and nuts provided with the switch.

  • Page 30: Engine Unit

    Engine Unit Firewall assembly steps are similar Firewall Assembly for both 50cc and 100cc engines. Move if necessary 1. Measure the length of the engine Note: The 2 degree right thrust from the firewall to the prop thrust have already been built in. Measure washer.
  • Page 31 Firewall Assembly 4. Epoxy the firewall with 30 minute 2. Drill the firewall according to the epoxy and use the mounting bolts and pre-set laser holes for DA engine lock nuts to fasten it immediately as installations. Otherwise measure your shown.

  • Page 32: Engine Assembly

    Engine Assembly Engine Installation Throttle servo Installation Not Include Remember: Use Blue Loctite on all 1. Install the engine throttle arm engine mounting screws. and secure the screws with Blue Loctite.
  • Page 33 Throttle servo Installation 2. Determine where on the engine 4. Measure and cut the throttle push box the throttle servo tray is to be rod and attach to the throttle body as mounted. The throttle push rod shown. Make a “Z” bend to connect requires a straight and direct the throttle pushrod to the servo arm.

  • Page 34: Ignition Module

    Ignition Module 2. Position the ignition outside the Ignition Module engine box to allow the spark plug lead to connect to the engine without excess tension. Secure with Nylon zip ties. 1. Tape foam rubber to the 3. Lock the connector leads with the bottom of the ignition safety cover provided safety clip to ensure the as shown.

  • Page 35: Hatch And Fuel Tank

    Hatch And Fuel Tank Fuel Tank and Dot Engine Box Hatch Fuel Fill Line Fuel line Epoxy the hatch in place and secure The fuel tank and fuel dot have with self-tapping screws been pre installed. Just tighten the Velcro ties that secure the fuel tank.

  • Page 36: Cowl Assembly

    Cowl Assembly 2. Use a fiber cutting tool to rough Cowl Assembly cut the cowl and finish with a round sander. 1. Use a paper template to 3. Ensure all corners in any cowl measure where the cowl will need cutouts are rounded.
  • Page 37 Cowl Assembly 6. Install the cowl into position NOTICE: using the bolts provided. There are Always check the engine two that mount from the rear of the temperature against the firewall on the top of the cowl and manufacturers recommendation. two that mount from the front of the cowl opening.

  • Page 38: Cg And Control Throws

    CG And Control Throws Center Of Gravity The First Flight set up The center of gravity is on the rear of the wing tube as shown. Adjust idle –full Throttle: Elevator: 40 Degrees on High rate 15 Degrees on Low rate Aileron: 30 Degrees on High rate 15 Degrees on Low rate...

  • Page 39: Flight Preparation

    Flight Preparation Make sure you have the right model programmed into your ■ transmitter Check the direction of each control surface during flight prep ■ and also right before you take off . Remember: “nothing wrong on the ground ever improves in ■...
  • Page 40 Pilot RC Control Horn Installation (50cc and larger have dual control horns & 30cc Aircraft have a single control horn) • Rubber/Latex Gloves. • Epoxy (30 Minute or Stronger) • Epoxy Mixing Cups • Epoxy Mixing Sticks (Any mixing stick that will fit into the slot) •...
  • Page 41 Then you will need to test fit your parts together before gluing in place. Please note that sometimes the slots need to be cleaned out a little bit and can be done with a dremel and a small drill bit or an x-acto knife. Force your epoxy into the slots.
  • Page 42 Install your horns. Make sure to clean off any epoxy that comes out from under the plate with a paper towel and alcohol.
  • Page 43 Pilot RC Wing & Elevator Servo Installation You will need: • Hobby Iron • X-Acto Knife • Thin CA “Super Glue” • Drill and Drill Bit First find the servo mounting hole and iron around to assure that the covering is stuck to the surrounding wood.
  • Page 44 Then press and iron excess covering down into the servo slot. Now you can pre fit the servo. Make sure your grommets are installed and drill the holes for the servo screws.
  • Page 45 Now apply a small amount of the CA to the already drilled servo screw holes and if need- ed run your extension wire through. (Don’t forget the safety clip!!) Now you can install the servo with your choice of screws and attach the linkage. Final adjustment of turnbuckles and it ready for servo adjustment.
  • Page 46 Pilot RC Optional Rudder Installation for 50-150cc Aircraft Shorten the rudder wire so that it will not pierce the covering at the top of the rudder and leave about 3/4” hanging out the bottom. Bend the bottom at a 90 degree angle, and then trace around the wire (See Photos).
  • Page 47 The Tail wheel bracket will lock it in to place. Make sure it overhangs the slot when you install the TW bracket.

  • Page 48: Center Of Gravity

    Center of gravity The CG list of Pilot-RC products This recommendation balance point is for PLANE CG location your first flight.The CG can be moved around to fit your personal taste. DECATHLON 107” 133mm/5.2inch DECATHLON 122’’ 145 mm/5.7inch DECATHLON 150’’ 182 mm/7.2inch Columbia 400 128’’...

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