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3DAeroventures Super Chipmunk Build Manual

3d printed r/c aircraft
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Super Chipmunk
3D Printed R/C Aircraft
Build Guide
Wingspan: 1625mm (64")
www.3daeroventures.com
w�w�3�A�r�v�n�u�e�.�o�
3D
- 1 -
Aeroventures
N�v�r S�o� E�p�o�i�g� N�v�r S�o� Q�e�t�o�i�g� N�v�r S�o� P�a�i�g

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Summary of Contents for 3DAeroventures Super Chipmunk

  • Page 1 Super Chipmunk 3D Printed R/C Aircraft Build Guide Wingspan: 1625mm (64”) www.3daeroventures.com w�w�3�A�r�v�n�u�e�.�o� - 1 - Aeroventures N�v�r S�o� E�p�o�i�g� N�v�r S�o� Q�e�t�o�i�g� N�v�r S�o� P�a�i�g...
  • Page 2 Please Read A Note from the Designer: irst of all, thank you so much for your interest and support of 3DAeroventures. I can’t tell you how much joy I get out of designing and testing these aircraft, and the fact that you can now get joy out of my creations just makes this calling that much more special.
  • Page 3 4500g / 158.7 oz No. of Channels: 4 - Throttle, Aileron, Elevator, Rudder CG Location 75 - 85mm behind the Wing’s Leading Edge 75 - 85mm www.3daeroventures.com w�w�3�A�r�v�n�u�e�.�o� - 3 - Aeroventures N�v�r S�o� E�p�o�i�g� N�v�r S�o� Q�e�t�o�i�g� N�v�r S�o� P�a�i�g...

  • Page 4: Recommended Setup

    - Velcro strips with adhesive backing - Screwdriver and/or allen wrench for chosen screws/bolts - Needle Nose Pliers - Dremel/Rotary Tool for cutting carbon fiber tubes www.3daeroventures.com w�w�3�A�r�v�n�u�e�.�o� - 4 - Aeroventures N�v�r S�o� E�p�o�i�g� N�v�r S�o� Q�e�t�o�i�g� N�v�r S�o� P�a�i�g...

  • Page 5: Hardware Needed

    Wheel Collars to fit 5mm rod (main landing gear)..............Wheel Collar to fit 2mm rod (tailwheel)................... 4” servo extensions for aileron servos..................6” servo extensions for aileron ports in receiver..............www.3daeroventures.com w�w�3�A�r�v�n�u�e�.�o� - 5 - Aeroventures N�v�r S�o� E�p�o�i�g� N�v�r S�o� Q�e�t�o�i�g� N�v�r S�o� P�a�i�g...
  • Page 6 Estimated Part Weights by Material Type (Grams): Estimated Estimated Hybrid Recommended Material OPTIONAL Estimated PLA/LW-PLA PLA/PETG ABS/ASA Recommended Material for Hybrid PARTS Weights Weights Part Name Weights Weights Fuse 1 LW-PLA Tire TPU/TPE Tire Hub 1 PLA, ABS, ASA, or PETG Fuse 2 1 37 Fuse 3...
  • Page 7 Option 3: STL + Your Preferred Slicer If you prefer to use another slicer or create your own profiles in Simplify3D, use the included STL files and reference the included Recommended Slicer Settings PDF. www.3daeroventures.com w�w�3�A�r�v�n�u�e�.�o� - 7 - Aeroventures...

  • Page 8: Printing Tips

    We have experienced nice , clean outer surfaces when keeping the fan speed up to 20% without negatively affecting layer bonding. Experiment with fan speeds set between 0 - 20%. www.3daeroventures.com w�w�3�A�r�v�n�u�e�.�o� - 8 - Aeroventures N�v�r S�o� E�p�o�i�g� N�v�r S�o� Q�e�t�o�i�g� N�v�r S�o� P�a�i�g...
  • Page 9 A small amount of elephant’s foot is okay but too much will interfere with the designed alignment aids. www.3daeroventures.com w�w�3�A�r�v�n�u�e�.�o� - 9 - Aeroventures...

  • Page 10: Step 2. Fuselage Assembly

    Fuse 3 (PLA) Fuse Tray 3 (PLA) Fuse 2 (PLA) Fuse Tray 2 (PLA) Canopy Latch Fuse 1 Fuse Tray 1 (PLA) Canopy Latch Cover www.3daeroventures.com w�w�3�A�r�v�n�u�e�.�o� - 1� - Aeroventures N�v�r S�o� E�p�o�i�g� N�v�r S�o� Q�e�t�o�i�g� N�v�r S�o� P�a�i�g...
  • Page 11 Fuse 6 and Fuse 7. Print out the drawing of the tailwheel wire on the following page to aid in bending a 1.8mm - 2mm diameter steel wire to the proper shape. Set aside for a later step. www.3daeroventures.com w�w�3�A�r�v�n�u�e�.�o� - 1� - Aeroventures N�v�r S�o�...
  • Page 12 Tailwheel Wire 1.8mm - 2mm Diameter Wire Scale 1:1 Front View Side View www.3daeroventures.com w�w�3�A�r�v�n�u�e�.�o� - 1� - Aeroventures N�v�r S�o� E�p�o�i�g� N�v�r S�o� Q�e�t�o�i�g� N�v�r S�o� P�a�i�g...
  • Page 13 2.3.1 Once the epoxy has dried, use a soldering iron to sink qty. 4, M3 x 0.5mm Thread Heat-Set Inserts in place in the cowl mounting holes, which are located on the sides of Fuse 1. Place M3 Heat-Set Inserts Here www.3daeroventures.com w�w�3�A�r�v�n�u�e�.�o� - 1� - Aeroventures N�v�r S�o� E�p�o�i�g� N�v�r S�o� Q�e�t�o�i�g� N�v�r S�o� P�a�i�g...
  • Page 14 You will find most of the stringing comes off quite easily. www.3daeroventures.com w�w�3�A�r�v�n�u�e�.�o� - 1� - Aeroventures N�v�r S�o�...
  • Page 15 Fuse Tray parts slide into rails located in the Fuse parts. The Trays overlap the seams of the Fuse parts and make for a very strong, rigid fuselage. DO NOT GLUE ALL OF THE FUSE PARTS TOGETHER WITHOUT THE FUSE TRAY PARTS IN PLACE! www.3daeroventures.com w�w�3�A�r�v�n�u�e�.�o� - 1� - Aeroventures...
  • Page 16 Fuse 2 before applying CA Accelerator to secure the bond. Ensure the tray is fully seated into the rail behind the firewall before applying accelerator The Tray slides into these three rails www.3daeroventures.com w�w�3�A�r�v�n�u�e�.�o� - 1� - Aeroventures N�v�r S�o� E�p�o�i�g� N�v�r S�o� Q�e�t�o�i�g� N�v�r S�o� P�a�i�g...
  • Page 17 2.5.3 Now glue part Fuse Tray 2 into your assembly just as you did with Fuse Tray 1. Apply the CA glue to the rails inside Fuse 2 and slide Fuse Tray 2 in place until fully seated before applying accelerator. www.3daeroventures.com w�w�3�A�r�v�n�u�e�.�o� - 1� - Aeroventures N�v�r S�o�...
  • Page 18 Fuse 6 Fuse 5 Fuse Tray 5 (PLA) Fuse 4 Fuse Tray 4 (PLA) Fuse 3 (PLA) Fuse Tray 3 (PLA) www.3daeroventures.com w�w�3�A�r�v�n�u�e�.�o� - 1� - Aeroventures N�v�r S�o� E�p�o�i�g� N�v�r S�o� Q�e�t�o�i�g� N�v�r S�o� P�a�i�g...
  • Page 19 90 degree bend that is at the top of the tailwheel wire should stick out the back as shown in the figures below. This is the portion of the wire that will engage with the rudder during final assembly. www.3daeroventures.com w�w�3�A�r�v�n�u�e�.�o� - 1� - Aeroventures N�v�r S�o�...
  • Page 20 Step-by-Step Build Guide (cont’d) 2.5.6 Using a hot knife or soldering iron, follow the molded in line/guide to cut away the sacrificial support located on Fuse 2 and Fuse 3. www.3daeroventures.com w�w�3�A�r�v�n�u�e�.�o� - 2� - Aeroventures N�v�r S�o� E�p�o�i�g� N�v�r S�o� Q�e�t�o�i�g� N�v�r S�o� P�a�i�g...
  • Page 21 Use qty. 3 , 3mm diameter x 10mm long dowel pins cut from scrap wood dowels or carbon fiber rods to align Canopy 3 to Canopy 2 and glue together. You may need to clear out the dowel pin holes with a 3mm or 1/8” drill bit. www.3daeroventures.com w�w�3�A�r�v�n�u�e�.�o� - 2� - Aeroventures N�v�r S�o�...
  • Page 22 Canopy 3. This will keep the spring slightly compressed. BE EXTRA CAREFUL NOT TO GLUE THE CANOPY LATCH PART IN PLACE AND IT IS FREE TO SLIDE BACK AND FORTH. Canopy Latch Cover www.3daeroventures.com w�w�3�A�r�v�n�u�e�.�o� - 2� - Aeroventures...

  • Page 23: Step 3. Tail Section Assembly

    Horiz Stab R2 Horiz Stab R1 Elev Control Horn L (PLA, ABS/ASA, or PETG) Horiz Stab L1 Elev L4 Horiz Stab L2 Horiz Stab L3 www.3daeroventures.com w�w�3�A�r�v�n�u�e�.�o� - 2� - Aeroventures N�v�r S�o� E�p�o�i�g� N�v�r S�o� Q�e�t�o�i�g� N�v�r S�o� P�a�i�g...
  • Page 24 3.2.1 Prior to gluing the Stab parts together, make sure your carbon fiber hinge rod fits in the hinge hole on each part. If needed, clear out the hinge holes with a 1.2 to 1.7mm drill bit, depending on what size hinge rod you are using. www.3daeroventures.com w�w�3�A�r�v�n�u�e�.�o� - 2� - Aeroventures N�v�r S�o�...
  • Page 25 3.2.3 Using the 6mm O.D. x 220mm long carbon fiber tube, test fit the Vert Stab assembly to the fuselage to ensure it fully seats and your carbon fiber tube is cut to the proper length. If all looks good, glue the Vert Stab assembly to the fuselage. www.3daeroventures.com w�w�3�A�r�v�n�u�e�.�o� - 2� - Aeroventures...
  • Page 26 Note the labels on some of the Right and Left Parts 3.2.5 Repeat Step 3.2.4 for the Left Horiz Stab Parts. www.3daeroventures.com w�w�3�A�r�v�n�u�e�.�o� - 2� - Aeroventures N�v�r S�o� E�p�o�i�g� N�v�r S�o� Q�e�t�o�i�g� N�v�r S�o� P�a�i�g...
  • Page 27 3.2.6 Using the 6mm O.D. x 500mm long carbon fiber tube, test fit the Horiz Stab assemblies to the fuselage to ensure they fully seat and the carbon fiber tube is cut to the proper length. If all looks good, glue the Horiz Stab assemblies to the fuselage. www.3daeroventures.com w�w�3�A�r�v�n�u�e�.�o� - 2� - Aeroventures...
  • Page 28 The parts can also be laid on a flat surface while gluing to ensure a perfectly flat assemby. Set the Rudder aside for the Final Assembly steps later. www.3daeroventures.com w�w�3�A�r�v�n�u�e�.�o� - 2� - Aeroventures N�v�r S�o� E�p�o�i�g� N�v�r S�o� Q�e�t�o�i�g� N�v�r S�o� P�a�i�g...
  • Page 29 The parts can also be laid on a flat surface while gluing to ensure a perfectly flat assembly. 3.3.5 Repeat Step 3.3.4 for the Left Elev parts and set the elevators aside for the Final Assembly Steps later. www.3daeroventures.com w�w�3�A�r�v�n�u�e�.�o� - 2� - Aeroventures...
  • Page 30 Aileron L2 Wing R3 Aileron L3 Wing R2 Aileron L4 Wing R1 (PLA) Wing L1 (PLA) Wing L2 Wing L3 Wing L4 Wing L5 Wingtip L www.3daeroventures.com w�w�3�A�r�v�n�u�e�.�o� - 3� - Aeroventures N�v�r S�o� E�p�o�i�g� N�v�r S�o� Q�e�t�o�i�g� N�v�r S�o� P�a�i�g...
  • Page 31 You will find most of the stringing comes off quite easily. www.3daeroventures.com w�w�3�A�r�v�n�u�e�.�o� - 3� - Aeroventures N�v�r S�o�...
  • Page 32 6mm O.D. x 600mm (24”) Long Carbon Fiber Tube Glued in place prior to Wingtip R assembling Wing R1 Wing R5 Wing R4 Wing R3 Wing R2 www.3daeroventures.com w�w�3�A�r�v�n�u�e�.�o� - 3� - Aeroventures N�v�r S�o� E�p�o�i�g� N�v�r S�o� Q�e�t�o�i�g� N�v�r S�o� P�a�i�g...
  • Page 33 Wing Trailing Edge R slides into a slot located on the back of Wing R1 Wing R1 Wing Trailing Edge R www.3daeroventures.com w�w�3�A�r�v�n�u�e�.�o� - 3� - Aeroventures N�v�r S�o� E�p�o�i�g� N�v�r S�o� Q�e�t�o�i�g� N�v�r S�o� P�a�i�g...
  • Page 34 Wing R1 and Wing R2 Place M3 Heat-Set Inserts Here 4.3.5 Repeat Steps 4.3.1 thru 4.3.4 to assemble the Left Wing www.3daeroventures.com w�w�3�A�r�v�n�u�e�.�o� - 3� - Aeroventures N�v�r S�o� E�p�o�i�g� N�v�r S�o� Q�e�t�o�i�g� N�v�r S�o� P�a�i�g...
  • Page 35 Right side and Left side Aileron parts, notice each individual part is labeled with it’s name. Aileron R4 and Aileron L4 are labeled inside the hollow portion of the parts. www.3daeroventures.com w�w�3�A�r�v�n�u�e�.�o� - 3� - Aeroventures N�v�r S�o� E�p�o�i�g� N�v�r S�o� Q�e�t�o�i�g� N�v�r S�o� P�a�i�g...
  • Page 36 The parts can also be laid on a flat surface while gluing to ensure perfectly flat assembly. 4.4.4 Repeat steps 4.4.1 thru 4.4.3 to assemble the Left Aileron. www.3daeroventures.com w�w�3�A�r�v�n�u�e�.�o� - 3� - Aeroventures N�v�r S�o�...
  • Page 37 Landing Gear L3 (PLA, ABS/ASA, Tire Hub 1 (x2) or PETG) (PLA, ABS/ASA, or PETG) Tire (x2) Tire Hub 2 (x2) (TPU/TPE) (PLA, ABS/ASA, or PETG) www.3daeroventures.com w�w�3�A�r�v�n�u�e�.�o� - 3� - Aeroventures N�v�r S�o� E�p�o�i�g� N�v�r S�o� Q�e�t�o�i�g� N�v�r S�o� P�a�i�g...
  • Page 38 5.1.2 Use qty. 4 , 3mm diameter x 10mm long dowel pins cut from scrap wood dowels or carbon fiber rods to align Cowling 1 to Cowling 2 and glue together. You may need to clear out the dowel pin holes with a 3mm or 1/8” drill bit. www.3daeroventures.com w�w�3�A�r�v�n�u�e�.�o� - 3� - Aeroventures...
  • Page 39 Landing Gear R1 Landing Gear R2 - No Wheel Pants Landing Gear R1 - No Wheel Pants 5.2.3 Repeat step 5.2.2 to assemble the Left landing gear parts. www.3daeroventures.com w�w�3�A�r�v�n�u�e�.�o� - 3� - Aeroventures N�v�r S�o� E�p�o�i�g� N�v�r S�o� Q�e�t�o�i�g� N�v�r S�o� P�a�i�g...
  • Page 40 Secure the 5mm wheel collar on the other side of the wheel Wheel Collar for 5mm Shaft M5 x 0.8mm Thread Lock Nut M5 Steel Washer M5 x 0.8mm Thread x 40mm Long Screw www.3daeroventures.com w�w�3�A�r�v�n�u�e�.�o� - 4� - Aeroventures N�v�r S�o� E�p�o�i�g� N�v�r S�o� Q�e�t�o�i�g� N�v�r S�o� P�a�i�g...
  • Page 41 Then sand the parts with 220 grit, followed by 400 grit sandpaper to further smooth the parts. 6.1.2 Lightly wipe down all parts with isopropyl alcohol to remove any residual dust from sanding. www.3daeroventures.com w�w�3�A�r�v�n�u�e�.�o� - 4� - Aeroventures...
  • Page 42 We used 3mm or 1/8” wide pinstripe tape. 6.3.2 Mask off larger areas with standard masking/painter’s tape 6.3.3 Mask off the largest areas with kitchen plastic wrap or newspaper www.3daeroventures.com w�w�3�A�r�v�n�u�e�.�o� - 4� - Aeroventures...
  • Page 43 I used scale decals purchased in the United States from www.callie-graphics.com After applying decals, give the model a final light clear coat with a clear spray paint. www.3daeroventures.com w�w�3�A�r�v�n�u�e�.�o� - 4� - Aeroventures N�v�r S�o� E�p�o�i�g� N�v�r S�o� Q�e�t�o�i�g� N�v�r S�o� P�a�i�g...

  • Page 44: Step 7. Final Assembly

    Tailwheel Hub 1 Tailwheel Tire Printed Parts Needed: Tailwheel Hub 2 Motor Mount - Leopard 5065 Motor Mount - Leopard 5055 Motor Mount - Turnigy SK3 5055 www.3daeroventures.com w�w�3�A�r�v�n�u�e�.�o� - 4� - Aeroventures N�v�r S�o� E�p�o�i�g� N�v�r S�o� Q�e�t�o�i�g� N�v�r S�o� P�a�i�g...

  • Page 45: Step 7.1 Install Landing Gear

    2 and spray with accelerator to speed up the bond. Place the tailwheel on the tailwheel wire and secure with the 2mm wheel collar. Tailwheel Hub 1 Tailwheel Tire Tailwheel Hub 2 www.3daeroventures.com w�w�3�A�r�v�n�u�e�.�o� - 4� - Aeroventures N�v�r S�o� E�p�o�i�g� N�v�r S�o� Q�e�t�o�i�g� N�v�r S�o� P�a�i�g...
  • Page 46 Make sure the arrow that is on the face of the motor mount is facing up. Ensure the arrow on the face of the motor mount is facing up when mounted. www.3daeroventures.com w�w�3�A�r�v�n�u�e�.�o� - 4� - Aeroventures...
  • Page 47 Place a drop of CA glue in the rod entry holes to prevent the rod from sliding out. 7.3.2 Repeat step 7.3.1 to attach the Left Aileron to the Left Wing www.3daeroventures.com w�w�3�A�r�v�n�u�e�.�o� - 4� - Aeroventures N�v�r S�o�...
  • Page 48 2, 275mm long rods. Insert one rod through Elev R4 and one through Elev L4 until they meet in the middle. Place a drop of CA glue in the rod entry holes to prevent the rod from sliding out. www.3daeroventures.com w�w�3�A�r�v�n�u�e�.�o� - 4� - Aeroventures N�v�r S�o�...
  • Page 49 - 4” Servo Extensions for aileron servos (x2) and 6” Servo Extensions for Receiver (x2) Printed Parts Needed: Wing Servo Cover R Wing Servo Cover L Spinner 2 www.3daeroventures.com w�w�3�A�r�v�n�u�e�.�o� - 4� - Aeroventures N�v�r S�o� E�p�o�i�g� N�v�r S�o� Q�e�t�o�i�g� N�v�r S�o� P�a�i�g...

  • Page 50: Step 8.1 Install Servos

    8.1.3 Install the servo control arms and attach the pushrods to the servos with a z-bend or with a pushrod connector. 8.1.4 Screw the nylon or steel kwik-links onto the threaded ends of the rudder and elevator pushrods and attach them to the control surfaces. www.3daeroventures.com w�w�3�A�r�v�n�u�e�.�o� - 5� - Aeroventures...
  • Page 51 2mm (or 2-56) Diameter Wire with Threaded End Scale 1:1 Side View Qty. 2 required Rudder Pushrod 2mm (or 2-56) Diameter Wire with Threaded End Scale 1:1 Side View www.3daeroventures.com w�w�3�A�r�v�n�u�e�.�o� - 5� - Aeroventures N�v�r S�o� E�p�o�i�g� N�v�r S�o� Q�e�t�o�i�g� N�v�r S�o� P�a�i�g...
  • Page 52 8.1.7 Cut the 12” aileron pushrods to the proper length and screw a nylon or steel kwik-link into the threaded end. Attach the pushrods to the servo control arms with a z-bend or with a pushrod connector, then attach the kwik-links to the ailerons. www.3daeroventures.com w�w�3�A�r�v�n�u�e�.�o� - 5� - Aeroventures...
  • Page 53 You will also need a Y-harness and a servo reversing lead for one of the elevator servos if you can not mix the two elevator servos together. www.3daeroventures.com w�w�3�A�r�v�n�u�e�.�o� - 5� - Aeroventures N�v�r S�o� E�p�o�i�g� N�v�r S�o� Q�e�t�o�i�g� N�v�r S�o� P�a�i�g...
  • Page 54 Be sure to use the two 6mm diameter carbon fiber wing tubes when bolting on your wings. Be sure to plug your aileron servos in as well, in preperation for setting the control surface throws and exponential. www.3daeroventures.com w�w�3�A�r�v�n�u�e�.�o� - 5� - Aeroventures...
  • Page 55 8.2.5 Once you are happy with where the battery is located for balancing, attach a long strip of velcro with adhesive backing to the fuselage tray and the battery, and use two velcro straps to hold the batter in place during flight. www.3daeroventures.com w�w�3�A�r�v�n�u�e�.�o� - 5� - Aeroventures N�v�r S�o�...
  • Page 56 Low Rate High Rate 18mm 10mm Exponential: 15% Exponential: 30% 10mm 18mm Elevator Low Rate High Rate 25mm 15mm Exponential: 15% Exponential: 30% 15mm 25mm www.3daeroventures.com w�w�3�A�r�v�n�u�e�.�o� - 5� - Aeroventures N�v�r S�o� E�p�o�i�g� N�v�r S�o� Q�e�t�o�i�g� N�v�r S�o� P�a�i�g...
  • Page 57 Step-by-Step Build Guide (cont’d) Recommended Rates and Exponential: Rudder (Measured at the Front of the Rudder) Low Rate High Rate 40mm 25mm Exponential: 15% Exponential: 30% 25mm 40mm www.3daeroventures.com w�w�3�A�r�v�n�u�e�.�o� - 5� - Aeroventures N�v�r S�o� E�p�o�i�g� N�v�r S�o� Q�e�t�o�i�g� N�v�r S�o� P�a�i�g...
  • Page 58 Tips For Your First Flight Weather: Due to the larger size of the Super Chipmunk, it can handle mild to moderate winds. But It is recommended to fly on calm days, with winds between 0 - 10 mph. With any R/C aircraft, always ensure you are taking off...
  • Page 59 Alliance, to connect with other Aeroventurers, to share your builds, and to troubleshoot any issues with us and the community. - With any questions or feedback on 3DAeroventures’ designs or content, you mailto: eric@3daeroventures.com can email Eric directly at eric@3daeroventures.com N�v�r S�o�...