Carf-Models Ultra Lightning Instruction Manual page 19

ly recommend. If your Ultra Lightning does not have these
installed in the factory please contact your Rep, or email
us directly on: info@carf-models.com and we will send
them to you immediately.
The inner hinge support should be glued up against the
inside edge of the wing root rib and flap root rib. Prepare
all surfaces properly by sanding and cleaning with alcohol
before gluing in place. Cut the small square holes (approx.
4mm x 5mm) through the elastic hinge for the knuckle and
3mm Ø aluminium hinge pins with a fine sharp knife and
file to size. It is important that the centre of the hinge pin is
exactly on the axis of the elastic hinge (P27 and right).
To fit the outer hinge support you need to mill 2 small holes in the fibreglass flap glove and ply-
wood false trailing edge of the wing, and also in the leading edge of the flap and flap glove, as
shown in the photo P28. It should be positioned just inside the balsa rib at the outboard end of
the flap. Assemble both hinges with the 3mm aluminium pins and E-clips, install and tack in
place with a drop of CA. Check alignment and flap operation carefully, and then secure with
plenty of slow epoxy and micro-balloons or milled fibre mixture. You can mill a small hole in the
flap outer rib for better glue access if needed.
Geardoors
The gear doors are very simple to fit, but need quite a lot of explanation. They are cnc milled
from a very strong carbon/fibreglass composite, combined with the wing servo cover, and
painted to match the underside of your wings. The hinging is simple and reliable, using a
length of 2mm wire and plastic tubes, combined with the milled phenolic hinge plates (right).
The opening in the wings for the LG and doors is already cut for you, needing only final adjust-
ment for your chosen wheels.
Inner Doors:
Sand the inner ends of the wheel wells right up to the edge
of the moulded lip, using the moulded edge as a guide to
keep it straight, and also notch the sides about 15mm long
to allow for the inner door to swing inside the wheel well.
(see photo @ bottom of page 17 for shape).
Separate the phenolic hinges from the sheet and prepare
with a light sanding. Separate the main (inner) door from
the rest of the milled sheet, and sand the edges for 0.75 -
1mm gap all round, and also on the inside surface where
the phenolic hinges and tubes will be glued. Clean careful-
ly. For each door cut 4 lengths of the supplied plastic tube 20mm long, and pieces of the 2mm
Ø wire 55mm long, and put a 90 degree bend in the ends of the wires, as shown. Scuff up the
outside surfaces of the plastic tube with 240 grit.
Position both the phenolic door hinges 13mm from the edge of the door (the front one has the
tab and hole for the door cylinder), and tack into position with a couple of drops of thin CA.
Tack glue 2 of the 20mm lengths of the plastic tube inside the hinges, using the wire for align-
ment with the milled holes. Slide the other 2 lengths of tube loose over the wire hinge pins
(photo P29).
The centre of the hinge pin must
be exactly on the hinge axis.
Milled phenolic hinges for main
and nosegear doors.
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