AirfoilZ Bearcat 32 Warbird Series Assembly Manual

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Warbird Series

Bearcat - 32

Assembly Manual

Specifications

Wing Span: 32 inches

Wing Area: 210 in

Fuselage Length: 26 inches

Weight (ready to fly): 11 to 13 oz.

Wing Loading: 7.5 to 8.9 oz/ft

Version 1.0a - 8/27/07

Table of Contents

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Summary of Contents for AirfoilZ Bearcat 32 Warbird Series

Page 1 Warbird Series Bearcat - 32 Assembly Manual Specifications Wing Span: 32 inches Wing Area: 210 in Fuselage Length: 26 inches Weight (ready to fly): 11 to 13 oz. Wing Loading: 7.5 to 8.9 oz/ft Designed by Jim Vigani Version 1.0a - 8/27/07...
Page 2 © Copyright 2007 all rights reserved Limited Warranty AirfoilZ takes pride in the care and attention given to the manufacture of the components in this kit. The company warrants replacement of any materials found to be defective for their intended...
Page 3: Recommended Power System
Introduction: Thank you for choosing the Bearcat - 32 airplane. We have taken great care to provide a design and kit components that, when properly assembled, will give you a high quality model with outstanding performance. While the assembly is not complicated, the quality and ultimate performance of your model will depend on the care you take while building.
Page 4: Kit Contents
Kit Contents: Before you start the assembly of this model, check to make sure that there are no missing parts and that none of the parts have been damaged during shipment. If you have any questions with the assembly or flying of this model, please contact us and we will be happy to assist you. If you need replacement parts please provide the model name.
Page 5 Making a Sanding Block: The leading edges of the elevator, the rudder, and both ailerons need to be beveled prior to installing the hinges. This is best performed by the use of a 2-inch wide by 12 inch long, 100 or 120 grit sanding block or sanding bar.
Page 6: Fuselage Assembly
alignment before applying any glue or epoxy. Keeping joints tight fitting will minimize the amount of glue required and will ensure a strong bond. When gluing foam to foam, or foam to wood, use only foam safe CA and foam safe kicker. There are two basic methods that can be used when gluing flat pieces of foam together such as when gluing the foam doublers to the fuselage skin.
Page 9 Step 1 Glue the wing root doubler in place with foam safe CA being careful to ensure the wing openings alignment. Tip: Before joining, apply CA to one part lightly spray kicker on the other part. Step 2 Using the plywood nose doubler as a guide, glue the top front doubler in place with foam safe CA.
Page 10 Step 3 Glue the lower rear doubler and the foam stab support in place with foam safe CA. NOTE: The lower rear doubler needs to be positioned 3 mm from the edge of the skin. An alignment tab is provided at the rear of the part to ensure proper alignment.
Page 11 Step 4 Dry assemble all the plywood crutch pieces and check for fit. The pieces should snap together and self align. If the fit is tight, lightly sand the notches for a snug fit. Note: the motor mount and motor mount support are very similar in appearance.
Page 12 Step 6 Test fit the skins on the crutch and check that the slot in the rear of the skin mates with the alignment tab on the rear of the crutch. Step 7 Glue the rudder and turtle deck former in place with medium foam safe CA .
Page 14 Step 8 Glue the crutch to one skin assembly from the nose to just behind the wing opening with medium foam safe CA. After the glue has set, glue the skin to the lower crutch member from the wing opening to the rear tab, making sure the rear alignment tab is...
Page 16 Step 11 Glue the front deck in position with medium foam safe CA. Step 12 Glue the canopy top skin and front top skin in place with medium foam safe CA. Tip: Before gluing, lightly score the backside of the top skin with a ballpoint pen to allow the foam to be bent around the nose without...
Page 18 Step 14 Cut the elevator servo mount supports to size and glue in place with medium foam safe CA. Space the supports to match your servo. The front servo mount is positioned directly over the crutch cross support. © Copyright 2007 all rights reserved...
Page 19 Step 15 Cap the servo mount supports with the plastic servo mounts. Step 16 Glue the bottom skins in position with medium foam safe Tip: Lightly score backside of the bottom skin with a ballpoint pen to allow the foam to be bent around the nose without cracking.
Page 20 Step 17 Epoxy the motor mount in position being careful to make sure it is square and flush to the motor mount support. Cut cooling air inlet holes in nose. Tip: we find it easier to pre-drill the motor mounting holes with a 1/32”...
Page 21 Step 18 Finish the fuselage by sanding and shaping the edges to a round shape. Be careful not to sand the surface of the fuselage as the sanding marks will affect the finish when painted. Step 19 Hinge the battery hatch at the front with packing tape.
Page 23: Wing Assembly And Installation
Wing Assembly and Installation Assembling the Spar: Step 20 Glue the spar sections together with thin being sure to match the bottom of the main spar sections with the bottom of the center doublers. Tip: Lightly sand the spar edges to help it slide into the wing.
Page 24 Wing Assembly: Step 21 Temporarily insert the 6 mm foam wing chord spacer to shape the wing airfoil. DO NOT GLUE IN PLACE! Locate spacer 2 3/8” from the wing leading edge. Tip: Recess spacer approximately 1/8” prevent it from moving while sanding the wing root dihedral angle.
Page 25 Step 22 Block up the wing tip 1- 1/8” and sand in the wing root dihedral angle with your sanding block. Remove the spacer after sanding. Make sure to make a LEFT and a RIGHT side version! Step 23 Mark the center of the spar and test fit it in the wings.
Page 26 Step 23a Glue the center seam with epoxy. Tip: Apply a small bead of glue on the top and bottom of 1/2 of the wing spar and slide into position in the wing. Repeat for the other wing making sure to align the root sections center seam.
Page 27 Wing/Fuselage Assembly: Step 25 Test fit the wing in the fuselage. FORCE! If the fit is tight, sand fuselage opening to fit. Make sure the wing is centered on fuselage and that there is equal amount of dihedral under each wing.
Page 28 Step 26 Permanently glue wing in place by forming a fillet from mixture of 15 or 30-minute epoxy and micro balloons. Tail Feather Assembly and Installation: Installing the Elevator Joiner: Step 27 Using the end of the 3/16” diameter wood elevator joiner, gently...
Page 29 Step 28 Secure the 3/16” diameter wood elevator joiner in place with epoxy. foam bridge behind the wood joiner, between elevator halves. Tip: For a lighter joint, a mixture of 15 minute epoxy and micro balloons can be used. © Copyright 2007 all rights reserved...
Page 30 Assembling and Installing the Horizontal Stabilizer and Elevator: Step 29 Using sanding block, bevel the leading edge of the elevator as shown allow movement elevator when hinged. Lightly round outside edges of the stabilizer and elevator with your sanding block. Step 30 Temporarily secure the elevator to the stabilizer...
Page 32 Step 31 Using your Exacto knife, carefully cut a slit along the centerline of both stabilizer elevator at each hinge location. Test fit the hinges into the slits. NOTE: Do not glue the hinges in place at this time. Step 32 Test fit the stabilizer in the fuselage and check that it fits square to the...
Page 33: Aileron Installation
Step 33 Epoxy the hinges in place. Aileron Installation: Step 34 Using the sanding block, bevel the leading edge of the ailerons as shown to allow for movement of the ailerons when hinged. Sand the trailing edge of the ailerons round using the sanding block.
Page 34 Step 35 Temporarily secure the ailerons to the wing with tape. Mark the position of the aileron hinges with strips ” wide painter’s tape. Use 4 hinges for each aileron. Cut the tape along the hinge line and remove the ailerons. Using your Exacto knife, carefully...
Page 35 Step 37 Test fit the servos in the holes. Mark the location plastic servo mounts and remove the servos. Glue the servo mounts place with foam safe CA. Drill a 1/32 inch diameter pilot hole in the servo mounts at each servo mounting lug location.
Page 36 Step 39 Sand the edges of the plastic control horn parts to remove the edge caused by laser cutting. Drill a 1/32” diameter hole in the horn to accept the push rod. Test components together. © Copyright 2007 all rights reserved...
Page 37 Step 40 Mark the location of the control horns on the control surface and cut a slit in the control surface with an Exacto knife to accept the control horn mounting tab. Step 41 Glue control horns in place with Medium foam safe ©...
Page 38: Painting The Airframe
Painting the airframe: All the Bearcat prototypes were painted with Krylon H2O paint. This paint is foam safe and provides a great looking surface finish. As a precaution, keep the spray nozzle at least 12” away from the foam to prevent possible damage from the propellant. Step 42 Mask the areas not to be painted with...
Page 39 Step 43 Apply several light coats of Krylon H2O paint being careful not to have the paint run. Remember, excess paint excess weight! When the paint is dry, remove masking tape and outline the canopy with 1/8” wide black auto pinstripe tape. Step 44a Apply the remaining graphics.
Page 42 Step 46 Secure the servos in place with the servo mounting screws provided with servos. Do not over- tighten the screws as you may strip the screw holes. Step 47 Route the aileron servo leads through the interior of the wing, and out through the exit hole.
Page 43 Step 48 Install elevator servo servo mounts inside fuselage. Pre-drill the screw holes with 1/32” drill before installing the screws. Do not over-tighten the screws as strip the screw holes. Push Rod Installation: Step 48 Install the 1/32” diameter wire aileron push rods securing at one end with a Z bend and the other end with a Dubro Mini EZ...
Page 44 Step 50 Cut a 1/32” wide exit slot for the pushrod in the fuselage side with an Exacto knife. Install the 1/32” diameter wire elevator push rod securing it at the servo end with a Dubro Mini E/Z Connector, and at the control horn end with a Dubro E/Z Link.
Page 45 Step 51 Position motor radial mount and mark position mounting holes. Drill 1/32” diameter pilot holes in the plywood motor mount for the mounting screws. Mount the motor using #2 wood screws and #2 washers. Check make sure the motor turns freely and there is interference between...
Page 46 Step 53 Mount Receiver with Velcro strips inside the fuselage on the lower wing surface as shown. Step 54 Mount the battery with Velcro strips inside the fuselage as shown. © Copyright 2007 all rights reserved...
Page 47: Preflight Checklist
Step 54a Velcro strips inside the fuselage on the crutch. Step 54b Velcro strip battery. Pre-flight checklist Balancing: We recommend that you perform initial flights with the CG at the spar location. (2 3/8 inches behind the leading edge, at the wing root). Adjust the CG to get the flight characteristics that suit your taste. Electrical Components: ©...
Page 48 Check that all electrical components are securely attached and the all plugs are fully seated. Secured any extra length on servo leads neatly within the fuselage or the wing. Avoid loose or dangling wires. We recommend the use of a micro antenna such as the Azarr, or the RC Direct Peel &...

AirfoilZ Bearcat 32 Warbird Series Assembly Manual

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Questions and answers

Related Manuals for AirfoilZ Bearcat 32 Warbird Series

Summary of Contents for AirfoilZ Bearcat 32 Warbird Series

Page 3: Recommended Power System

Page 4: Kit Contents

Page 6: Fuselage Assembly

Page 23: Wing Assembly And Installation

Page 33: Aileron Installation

Page 38: Painting The Airframe

Page 47: Preflight Checklist