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Carf-Models BOLD Instruction Manual

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Introduction:
Thanks for trusting us with your purchase of this latest top of the line Sport Jet from CARF-
Models. You will see, you have purchased an all composite, all carbon pane, very special, very
high end. A jet with a lot of new and unconventional construction techniques - which CARF-
Models has become known for and is proud of. Thus it is especially important to read this manual
a few times BEFORE starting the build and then follow it step by step.
A few special features of our BOLT! will be highlighted here at the beginning of this manual:
1. We tried to make things work without servo hatches. The cleaner the better, we say. So it
might be a little different to install most of the servos in your BOLT!, but it will be much less
work than you might initially think, if you have the right screws and the right tools. Therefore,
we have included in the kit the screws which work best for this purpose, and a specially
extended allen key, which makes servo installation a breeze.
2. The CARF-Models BOLT! is consequently designed with full gear doors. It's a little more
complex, more sophisticated than without. Although some love the simplicity of not having to
deal with gear doors - the open wheel wells and nose gear cutouts will always be kind of
"rough". So it depends on how the gear doors are designed, how successful and reliable their
operation will be. As a consequence we use magnetic help to keep the doors shut at highest
speeds, place gear door servos on strategic positions and supply linkages stiff enough to
safely do the task.
3. We decisively opted for a fully ducted engine installation. Not so much of advantage for a
slower flying 3D jet, but absolutely crucial for a fast sport jet. The full ducting is going to
enhance the performance of the plane significantly. Again, a lot more work to do for the
manufacturer, and also considerable potential to do things wrong, but we've put a lot of effort
in calculating airflow based on the constant area rule, creating intakes with rounded lips, and
designing a carbon bypass which fits around the common 220-260 N engines like a glove.
Instruction Manual

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Summary of Contents for Carf-Models BOLD

  • Page 1 2. The CARF-Models BOLT! is consequently designed with full gear doors. It's a little more complex, more sophisticated than without. Although some love the simplicity of not having to deal with gear doors - the open wheel wells and nose gear cutouts will always be kind of “rough”.
  • Page 2 Boredom is not on the agenda when building a CARF-Models BOLT! Follow this manual, do not change things, simply go with our advice and our recommended equipment and accessories and you will have a blast building this airplane to the highest standards of what is possible today.
  • Page 3 successfully! There are some simple and straight forward CARF planes where we only put very little emphasis on a build manual… but this BOLT! is definitely not one of them. READ and FOLLOW the instructions, please! Let’s get started, now, component for component. Begin the wings, then stab and fin, then the nose area.
  • Page 4 Flap Servos: Following the aileron servo procedure, prepare the flap linkages the same way and also install the servos using the supplied hex cap self tapping screws. You should use a short metal servo arm with 1” / 25mm. Use the strongest servo you can get, we recommend 35-40 kg torque.
  • Page 5 Main Gear Installation: The Electron BOLT! gear set has been developed by Electron to fit the CARF-Models BOLT! perfectly. Assemble the gear, strut, wheel and brake following the Electron manual. The mains will drop in and can be mounted with the 4 self tapping screws immediately.
  • Page 6 important that the washers touch the magnets in the correct flat angle, otherwise the magnetic force will not be fully utilized. The correct procedure is to glue the washers at the exactly right position to the door first, then click the magnets on to the washers, close the gear doors and so sink the magnets into the recesses/holes prepared for them and glue them with Hysol in place.
  • Page 7 Main Gear Update! After extensive test flights and successive move of the CG further back we have found that the BOLT! gets pretty light on the nose gear. In order to get a little more load on the nose gear, it is recommended to have the trialing link struts “trail”...
  • Page 8 Stab: Elevator Servos: In the BOLT! stab there is no servo hatch either. The servos are screwed into the servo ribs in reversed direction. That means, the servo screws are inserted into the rubber grommets from the bottom side and the servo gets screwed in place reversed.

  • Page 9: Front End

    deflection of approx. 50 mm (2”) right and left, measured at the root. The linkage should not hit or bind with the fin tube. You should set the neutral position of the servo arm not 90 deg to the servo, but 90 degree to the linkage, which is in an angle.
  • Page 10 That keeps the load on the servo to a minimum and applies the highest holding power to the gear door. Because of the over-kneeing of the servo arm and linkage a single sided ball link must be used on the servo arm, so even here a metal arm is a must.
  • Page 11 forward, away from the gear unit, otherwise it will rub or squash the wire when retracting. Also we strongly recommend to grind a flat spot in the gear pin, where the control arm is clamped. This arm has only ONE grab screw and this should have a flat spot.
  • Page 12 Nose Hatch Fixture: The very special design of the CARF-Models BOLT! is that completely removable nose section. It’s a nice feature, but requires the installation of one servo connection into that joint. Even though it is possible to make it with a regular servo connector, it would be much more rigid to use some stronger 3-pin connector.

  • Page 13: First Assembly

    If you have a few instruments or side panels lying around, they would for sure enhance the looks of the cockpit. We have decided that the CARF-Models BOLT! looks too good to not boast a clear canopy and a cockpit, so that little extra work is well invested and you will love the result.
  • Page 14 Engine, bypass, thrust tube and fuel tanks: General: Now comes the next specialty of the CARF-Models BOLT: The installation of the engine. It’s a fact that you won’t find an aerodynamically cleaner engine installation in any large sport jet on the market, no matter where you look.
  • Page 15 A fully ducted engine installation, together with a sleek fuselage, poses also a great challenge for placing the fuel. The CARF-Models BOLT! has 2 saddle tanks with 5.6 Liter volume installed which, due to the geometry of the factory installed intake ducts, are placed exactly in the CG.
  • Page 16 edge of the bypass cover to allow the wires to go through. We recommend to only notch the front edge of the cover, instead of drilling holes and feeding the wires through these holes to plug them into the engine, simply because in the tight space it is easier to put the bypass cover on AFTER the connectors are plugged in to the engine.
  • Page 17 Fuel tanks: Plumb the saddle tanks now. We only use 2 lines (one in, one out). The out line is the clunk line. Put a brass tube in the baffle area so that the baffle cannot damage the fuel line. The in-line will be bent so that the tube reaches the top corner of the fuel tank.
  • Page 18 second pair of hands available, to channel the unit through the openings in the formers and then place it on the mounting rails. Once you are confident that you do not need to access the area inside the fuselage behind the engine formers anymore, bolt the integrated engine unit tight.
  • Page 19 min 5 mm max 10 mm Congratulations: You now completed the most complex part of your BOLT! build: The installation of the propulsion system. cut out for cable...
  • Page 20 Smoke System Plumb the smoke tank the same way you were plumbing the fuel saddle tanks. Fix the smoke tank with a strap of double sided velcro in the V of the intake ducts on top of the equipment board. We are using two balsa spacers to elevate the smoke tank about 20 mm above that equipment board, which makes it easier to access the M4 bolts and to handle the removable part of the equipment board.
  • Page 21 RC-Equipment All equipment can be installed on the removable part of the equipment board. Rubber grommets should be used to protect wires from rubbing against the carbon fibre edges. All wires can be routed hidden below the board, creating an unbelievably clean way to install all electronic equipment.

  • Page 22: Final Setting

    Final Setting Center of Gravity: Initially we hook a wire loop around the wing fixing bolts. That position is slightly nose heavy. To reach this point (using a KingTech 260 G2 engine, 2x 3000 mAh LiPo receiver packs and 1x 3700 mAh 3S LiFe turbine battery) you might have to add 250-300 g of lead in the nose.