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BTE SUPER FLYIN' KING Building Instructions
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BTE SUPER FLYIN' KING Building Instructions

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BUILDING INSTRUCTIONS FOR THE BTE
phone:
541-582-1708
orders:
800-557-4470
website:
www.btemodels.com
e-mail:
bruce@btemodels.com
Written by Bruce Tharpe
Wingspan: 132 inches
Wing Area: 3380 square inches
Length: 96 inches
Weight: 36 pounds (approximate)
Engine Range: 60cc - 80cc Gas
Manufactured by
B
T
RUCE
8622 E EVANS CREEK ROAD, ROGUE RIVER, OR 97537
E
HARPE
NGINEERING
June 2013

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Summary of Contents for BTE SUPER FLYIN' KING

  • Page 1 BUILDING INSTRUCTIONS FOR THE BTE Written by Bruce Tharpe June 2013 Wingspan: 132 inches Wing Area: 3380 square inches Length: 96 inches Weight: 36 pounds (approximate) Engine Range: 60cc - 80cc Gas Manufactured by RUCE HARPE NGINEERING 8622 E EVANS CREEK ROAD, ROGUE RIVER, OR 97537...
  • Page 2 " " " " TABLE OF CONTENTS !"# $! % & & !"# $! % & & !"* ! ! $% % $ !" !"# $! % ! .( ! !"# $! % ! $!2 % $# $ % 3 4 % 5 $ 4 !4 $!2 % $"...
  • Page 3 Cut at the dotted lines to connect the drill holes, front and rear W-2 and one W-4 " & " !! # ! * + , " # !/ !! ! " " # !/ " " Left Outer Wing Panel, Inboard End - Plywood W-2 rib is set at the proper dihedral angle using the 5/32"...
  • Page 4 !" % &' ( " % &* . (' . (% . (2 Center Wing Panel - Notice the screws holding the bottom main spar to the table. The front . (* . (' . (' screw needs to be removed before the shear web can be added.
  • Page 5 PAGE 4 WING JOINER INSTALLATION >  Prepare the wing joiners exactly as described in the Sig directions. Okay, maybe one exception: If you don't have numbered drill bits (like me), you can use a 7/64" drill for the 4-40 bolts (the mounting bolts, not the set screws) and a 9/64"...
  • Page 6 PAGE 5 WING JOINER INSTALLATION, CONTINUED...    Remove the outer panel and the webs. Drill at the marks (9/64’), put the webs back in the outer panel, then slide the outer panel into its final position against the center panel. Bolt the joiners to the webs with this hardware: Each Front Joiner - Three 6-32 x 1"...
  • Page 7 PAGE 6 WING SUBASSEMBLIES > Time for a bit of tedium here. Once these time-consuming tasks are done, you will be ready to take on the final assembly of the wing panels with minimal delay. Let's roll...  Sort the Balsa Sheets Go through the 3/32"...
  • Page 8 PAGE 7 WING SUBASSEMBLIES, CONTINUED...    Center Sheeting You'll need four 36" sheets to make two center sheets (one top, one bottom) for the wing center panel. If you look ahead, you will see that I got a little fancy with my Center Sheeting - Make 2 center and wing joint sheeting, adding curved edges to the 12"...
  • Page 9 PAGE 8 FINISH OUTER WING PANELS > Bevel full thickness of bottom trailing edge spar  Sand the back edge of the panel as shown in the diagram. Use a long sanding block and straightedge to be sure the trailing edge is straight along its entire length.
  • Page 10 PAGE 9 FINISH OUTER WING PANELS, Continued...  Unpin the TE, then pin or weight the panel down on the table, this time with the top spar against the table. Support the TE with a stick, then take a long careful look at the panel from all angles to be certain it is warp-free. This is your last chance to build a flat wing panel;...
  • Page 11 PAGE 10 FINISH CENTER WING PANEL > Check for excess epoxy near the aluminum channels and sand it away so it won't interfere with sheeting. Sand the back edge of the panel on each side of the long ribs, just like in the figure in Section 5. Sand the bottom trailing edge spar, just like the previous step, in the two outermost rib bays between the W-1 ribs.
  • Page 12 PAGE 1 1 FINISH CENTER WING PANEL, Continued... Flip upside down, pin the top TE sheeting flat to your table, and support the LE with wood. Cut and fit two more chunks of balsa laminate to fit between the W-1 ribs at the trailing edge spar.
  • Page 13 " " & ' ( Drill for Control Horn Bolt " Drawing is not to scale - ' . - ' . " Aileron - with the the bottom sheeting, spars, and ribs glued in place. Trailing edge still needs to be beveled to match the slope of the ribs.
  • Page 14 I glued in short Fin ready for final sanding. Note the hard points. Tail bracing is required on the Super Flyin' King. lengths of 1/2" dowel for my Sullivan Super Horns.

  • Page 15: Engine Installation

    PAGE 14 FUSELAGE DECISIONS > No construction here, but this deserves its own section because I literally spent days thinking about these items before starting on the fuselage. I'm the type that likes to plan way ahead when it comes to the engine and radio installation.

  • Page 16: Radio System

    1-3/4" Du-Bro tailwheel. The Graph Tech #304 assembly is a high-quality alternative (available from BTE). If you choose something else, be sure it's rated for at least a 35 lb. model. Tailwheel and Rudder Cables - I used Du-Bro 4-40 pull-pull cables on both the rudder and the tailwheel.
  • Page 17 " # $ % & " Engine Spacer built from 1/2" plywood. Total thickness is one inch. Carb must be installed after engine is bolted to spacer. " # $ % & # $ % & ( ) * # ./ 0 .- 0 F-1 shows carb cutout and four mounting holes for spacer.
  • Page 18 " # $ % & '( " " " " " " " # $ % & '+ & , " Fuselage Sides with Doublers shown here. 0 1 $ 2 " 4 5 6 " " " " '3 8 2 %1 .
  • Page 19 " " " " " + , 3 / , " # " " " # " " # " & " Fuselage Front End shows the stick and rubber " " band squeezing tool. I used a straight channel of aluminum taped to each side in the cabin area to "...
  • Page 20 " " Wing Saddle reinforced with 1/32" ply, indicated by arrow. Also note the balsa triangle stock at the front, sanded to con- form to the shape of the wing saddle. & The hardwood rails inside the cabin area below the windows were added to my model to support false floors which, of course, I've yet to finish..
  • Page 21 ! " % & & ( ( ! Fuselage Rear - I know, the gussets and diagonals are missing in this photo. The prototype wasn't built in exactly the same order & as the instructions. This photo does show the final result of the fin front "pocket".
  • Page 22 PHOTO 1 ! " # & PHOTO 2 & % - . ! 0 1 % * 3 & $ PHOTO 3 PHOTO 4 & ! "- # &...
  • Page 23 PHOTO 1 " $%& PHOTO 2 ( ) * + + ! ! $& " PHOTO 3 . ' & $ ' % & 2 3 PHOTO 4...
  • Page 24 PHOTO 5 " ) PHOTO 6 " 0 $%& PHOTO 7 " PHOTO 8 PHOTO 9...
  • Page 25 " , " PHOTO 10 PHOTO 11 " PHOTO 12 " 5; , < < > " " @...
  • Page 26 " " & " ( ) & PHOTO 1 " #$ % & & & PHOTO 2 & * #+ , PHOTO 3 Speaking of "Tail Braces" Here's a little safety feature that was built into the prototype. The eyelet isn't for towing banners, it's an attachment point for a rope to hold the model during starting.

  • Page 27: Control Throws

    BALANCE " " " % &' " ) " " " "" " " " " " " " " ." CONTROL THROWS " " " " " " " RECOMMENDED CONTROL THROWS AILERONS: 1-5/8" UP, 1" DOWN ELEVATOR: 1" UP, 1" DOWN RUDDER: 1-1/2"...
  • Page 28 ! " # $% & % * $+ , 0 12 $ " & " <...
  • Page 29 Sullivan Super Horn Set - This package contains all the heavy-duty control horns you will need; the same horns as used on the BTE prototype and shown throughout this book. Includes six Super Horns (for ailerons, flaps, and split BTE Price..$34.95 elevators), one Double Super Horn (for the rudder), and Sullivan 4-40 Gold-N-Clevises.
  • Page 30 BALSA STICKS WING JOINER SHEAR WEBS " # $ % # $ $ & " ' ( & ) * - . / & # $ % # $ % # & " ' ( ! ) * - . + # # 1 # 2 0 .