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FLIGHTORY STALLION User Manual

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USER MANUAL

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  • Page 1 USER MANUAL...
  • Page 2 Socials Join Flightory Tech group on Facebook and create community with us. Share progress of your builds. Any suggestions or questions welcome. www.facebook.com/groups/flightory Join our Discord server as well, where the discussions are organized by topics, and the interaction between users is lively.
  • Page 3 General Aircraft Data General data Wingspan 1340mm Wing area 26.5 dm² Lenght 990mm Center of Gravity 60mm from leading edge (at wing root) 1500-3000g Optimal Cruise Speed 60-70 km/h Airfoil Eppler E205 Root Chord 255mm 211mm Aspect Ratio Wing load 55 - 115 g / dm²...
  • Page 4 Changes in V2 The Stallion has been updated. Files for both V1 and the latest V2 are included in the package. While the overall geometry and dimensions remain unchanged, several technical improvements have been made. Wing Mounting Change – Replaced M3 screws with a snap-fit joints with torsion springs.
  • Page 5 General Aircraft Data The aircraft is configured with 2 tractor motors, a single tail boom, and a V-Tail configuration. It is designed for optimal performance and compactness. Geometry has been carefully designed and optimized using CFD and real test flights. The airframe is designed with modularity in mind. The nose of the aircraft is fully detachable, allowing for adaptation to various types of payloads.
  • Page 6 CFD Analysis The geometry has been designed and optimized to achieve maximum efficiency while maintaining the stability of the aircraft. The airfoil used is Eppler E205. With the correct center of gravity set at a distance of 60mm from the leading edge (measured at the wing root), the aircraft maintains a longitudinal stability margin and zero pitching moment at zero angle of attack.

  • Page 7: Exploded View

    Exploded View USER MANUAL...
  • Page 8 Reccomended RC Equipment Reccomended electronics Motors T- Motor F60 1750KV / T- Motor F90 1300KV Propellers 7x4 / 7x5 / 7x6 (one CW, one CCW) Flight Controller Speedybee F405 Wing or any other Mavlink FC Matek M10Q or similar GPS with compass Servos EMAX ES08 MAII Metal Gear or similar 2x BlHeliS 30-40A...

  • Page 9: Required Accessories

    Required Accessories ITEM QUANTITY 10x800mm Carbon Tube (MAIN SPAR) 8x600mm Carbon Tube (SECONDARY SPAR) 6x435mm Carbon Tube (WING SPAR) 16x430mm Carbon Tube (TAIL BOOM) 2x260mm Carbon Tube (V TAIL SPAR) 2x250mm Carbon Tube (V TAIL SPAR) Thick + Thin CA Glue 20g tube CA Activator 1 (optional but useful)
  • Page 10 Parts List - Fuselage PART MATERIAL FUS 1 L/R LW-PLA FUS 2 L/R LW-PLA FUS 3 L/R LW-PLA FUS 4 L/R LW-PLA FUS 5 L/R LW-PLA HATCH FRONT 1 LW-PLA HATCH FRONT 2 LW-PLA HATCH REAR 1 LW-PLA HATCH REAR 2 LW-PLA NOSE CLEAN LW-PLA...
  • Page 11 Parts List - Wings PART MATERIAL WING 1 L/R LW-PLA WING 2 L/R LW-PLA WING 3 / WING 3 NO LED L/R LW-PLA WINGTIP LED / WINGTIP NO LED L/R LW-PLA WING LED COVER L/R LW-PLA AILERON 1 / AILERON 2 L/R LW-PLA WING LOCK BASE PETG...
  • Page 12 Parts List - Tail PART MATERIAL TAIL 1 LW-PLA TAIL 2 LW-PLA TAIL 3 LW-PLA V TAIL 1 L/R LW-PLA V TAIL 2 L/R LW-PLA V TAIL TIP L/R LW-PLA RUDDER 1 L/R LW-PLA RUDDER 2 L/R LW-PLA BOOM FUS INSERT PETG BOOM KNOB PETG...
  • Page 13 STEP Files List PART AILERON FRONT HATCH REAR HATCH NOSE NOSE GIMBAL NOSE SOLID FUS 4 FUS 5 RUDDER SERVO COVER TAIL 1 TAIL 2 TAIL 3 V TAIL 1 MOTOR MOUNT F60 MOTOR MOUNT F90 WING LED COVER SOLID USER MANUAL...

  • Page 14: Print Setting

    Print Setting The recommended slicer to use is Ultimaker Cura. All LW-PLA parts, print using the recommended settings detailed on the Flightory website under Print Settings tab. Whether you are using prefoamed or active foaming LW-PLA, you will find settings for both of these filaments there.
  • Page 15 Print Settings Print Setting All parts are suitable for printing on any standard printer with a small working area. Printing was done on a 220 x 220 mm area. The settings provided serve as a base and can be modified and adjusted as needed. The following pages contain recommended infill settings for each part.
  • Page 16 Parts Orientation Parts Orientation Important thing is the correct orientation of the printed parts to avoid overhangs. Below is the recommended orientation of parts and infill settings. FUS 1 - 3% gyroid infill FUS 2 - 3% gyroid infill USER MANUAL...
  • Page 17 Parts Orientation Parts Orientation FUS 3 - 3% gyroid infill FUS 4 - 3% gyroid infill USER MANUAL...
  • Page 18 Parts Orientation Parts Orientation FUS 5 - 3% gyroid infill NOSE - 3% gyroid infill + 2 walls USER MANUAL...
  • Page 19 Parts Orientation Parts Orientation NOSE TOP - 3% gyroid infill + 2 walls HATCH FRONT 1 - 3% gyroid infill USER MANUAL...
  • Page 20 Parts Orientation Parts Orientation HATCH FRONT 2 - 3% gyroid infill HATCH REAR 1 - 3% gyroid infill USER MANUAL...
  • Page 21 Parts Orientation Parts Orientation HATCH REAR 2 - 3% gyroid infill WING 1 - 3% cubic subdivision infill USER MANUAL...
  • Page 22 Parts Orientation Parts Orientation WING 2 - 3% cubic subdivision infill WING 3 - 3% cubic subdivision infill USER MANUAL...
  • Page 23 Parts Orientation Parts Orientation WINGTIP- 3% cubic subdivision infill AIL 1 / 2- 4% gyroid infill USER MANUAL...
  • Page 24 Parts Orientation Parts Orientation TAIL 1 / 2 / 3 - 3% gyroid infill + 2 walls USER MANUAL...
  • Page 25 Parts Orientation Parts Orientation VTAIL 1 / 2 / TIP - 4% gyroid infill USER MANUAL...
  • Page 26 Parts Orientation Parts Orientation RUDDER 1- 4% gyroid infill RUDDER 2- 4% gyroid infill USER MANUAL...
  • Page 27 Parts Orientation Parts Orientation LOCK 1 / 2 / SPRING - 20% grid infill + 3 walls USER MANUAL...
  • Page 28 Parts Orientation Parts Orientation WING / FUS ROOT - 20% grid infill + 3 walls NOSE / NOSE TOP GIMBAL - 20% grid infill + 3 walls USER MANUAL...
  • Page 29 Parts Orientation Parts Orientation BOOM FUS MOUNT / INSERT- 20% grid infill + 3 walls BOOM KNOB / TAIL MOUNT - 20% grid infill + 3 walls USER MANUAL...
  • Page 30 Parts Orientation Parts Orientation WING LOCK BASE / FRONT / REAR - 20% grid infill + 3 walls FRONT REINFORCEMENT / BAT PAD - 20% grid infill + 3 walls USER MANUAL...
  • Page 31 Parts Orientation Parts Orientation MOTOR MOUNT / SERVO COVER - 20% grid infill + 3 walls WING LED COVER – thin single wall print + transparent filament USER MANUAL...
  • Page 32 NOSE VARIANTS Nose Variants There are 2 variants of the nose. You can choose version with a VTX mounted inside and a 19x19mm FPV camera, or the version adapted for the GM3 Walksnail gimbal (or others with a similar design). The VTX mounts on a "shelf" and the available space is sufficient to accommodate any VTX.
  • Page 33 WINGLET VARIANTS Wingtip Variant There are also 2 versions of wingtips. One with a space for 2812 ARM LED and a cover printed from transparent material, or a regular version without a navigation light. USER MANUAL...
  • Page 34 NOSE VARIANTS Nose Variants In addition to the ready-made nose versions described earlier, there is also a CLEAN version of the nose available. This is a solid model in STEP format, ready for any modifications to accommodate a custom payload. USER MANUAL...
  • Page 35 STEP FILES STEP Files All files are available in STL format. In addition, some important elements are available in STEP format, which allows easier editing and customization. Check the full list of STEP files in the STEP FILES LIST section. You can find these files in folders labeled STEP USER MANUAL...

  • Page 36: Fuselage Assembly

    Fuselage Assembly Fuselage Assembly Aligments Pins Fuselage segments are available in both a split version (left and right halves) and a single-piece version, allowing for selection based on preference. Each segment includes small 2mm alignment holes to facilitate precise positioning during assembly. Short fragments of filament can be inserted into these holes to aid in alignment and bonding.
  • Page 37 Fuselage Assembly Fuselage Assembly Prepare all fuselage segments. Before gluing, you can gently sand the surface of all elements, especially the gluing surfaces. It’s best to use thick CA glue. If you printed the fuselage segments divided to left and right side, simply glue them together also.
  • Page 38 Fuselage Assembly Fuselage Assembly Prepare parts printed with PET-G or other hard material. Take the BATTERY PAD and paste it in the designated place in the front of the fuselage. Take FUS ROOT and glue with CA to the fuselage in the corresponding places. It’s best to use thick CA glue.
  • Page 39 Fuselage Assembly Fuselage Assembly Take the TAIL BOOM MOUNT printed with PETG or another rigid material and paste it into the designated slot. This component features a designed "guide" that ensures the correct orientation within the fuselage, allowing for smooth and precise tail assembly.
  • Page 40 Fuselage Assembly Fuselage Assembly Now take M3 threaded inserts with an outer diameter of 5mm. Insert them into the designated places in the front part of the fuselage. You can use a slightly heated soldering iron for this. Then glue NOSE REINFORCEMENT printed with PETG or other hard material.

  • Page 41: Tail Assembly

    Tail Assembly Tail Assembly Take the tail components in order: TAIL 1, 2, 3 and glue them together into a single piece. It’s best to use thick CA glue. USER MANUAL...
  • Page 42 Tail Boom Drilling Tail Assembly Prepare the Tailboom components printed from PETG or another rigid material. Take the Tailboom, which is a 16mm diameter carbon tube cut to a length of 430mm. Slide the BOOM FUS INSERT, BOOM KNOB, and BOOM TAIL INSERT onto the tube as shown in the diagram.
  • Page 43 Tail Assembly Tail Assembly Place the servos in the designated mounting points in the tail. Insert the cables through the dedicated opening and route them outside. The servos should be secured with screws, which are always included in the servo set. To further reinforce the mounting, a small amount of hot glue can be applied to the bottom of the servo.
  • Page 44 Tail Assembly Tail Assembly At this stage, the previously prepared tailboom should be glued into the tail. Before gluing, insert the cables and route them outside the tube. It is recommended to use epoxy glue with a longer curing time for this process. While inserting the tailboom into the tail, the glue may spill, so it should be applied carefully and in a thin layer.
  • Page 45 Tail Assembly Tail Assembly Prepare the V-tail components. Take carbon tubes with a diameter of 4mm cut to approximately 260mm. Insert the tubes into the designated slots. Note that the tubes are not parallel to each other. To facilitate easy assembly, insert one tube first, then fit stabilizer, and glue it in place to tail base.
  • Page 46 Hatches Hatches Prepare the locks, consisting of 3 elements: LOCK 1, LOCK LOCK SPRING. Assemble them as shown in the diagram. USER MANUAL...
  • Page 47 Hatches Hatches Prepare the front and rear hatch. Assembled locks paste into the designated places. Glue locks into the hatches using CA, but carefully so that the glue does not spill and block the lock. USER MANUAL...
  • Page 48 Nose Mount Nose Mount Now you can mount the nose with short M3 screws. If you are using version with VTX, you can put your VTX on the "shelf" and cover it with NOSE TOP and secure the antennas. USER MANUAL...
  • Page 49 Nose Mount Nose Mount The assembly of the nose with the gimbal is similar. The GM3 gimbal is mounted to the shelf from below using 4 M2 screws included with the gimbal set. Gimbals from other manufacturers with a similar design, also compatible with the DJI system, follow the same structure.
  • Page 50 Tail Assembly Tail Assembly At this stage, the tail can be mounted to the fuselage. Slide the tailboom into the fuselage, ensuring the servo cables are routed inside. Once this is done, the threads will align and connect. Finally, tighten the knob, which will fully secure the tail.

  • Page 51: Wings Assembly

    Wings Assembly Wings Assembly Glue all the wing segments together into a single piece. Decide which wingtip you want to use, with or without navigation lights. Insert the 6mm carbon tube, cut to a length of 435mm, into the designated slot. The tube does not need to be glued.
  • Page 52 Wings Assembly Wings Assembly Prepare the servo cover along with the servo. The design is adapted for securing the servo with screws in the designated spot. Optionally, a small amount of hot glue can be added to further strengthen the mounting.
  • Page 53 Wings Assembly Wings Assembly Install the M3 threaded inserts in the designated spots on the wing and secure the servo cover along with the servo, ensuring the cable is routed through the designed slot leading to the wing root. In this case, servo extensions wires may also be necessary.
  • Page 54 Wings Assembly Wings Assembly Prepare the motor and the motor mount printed in PETG. There are two versions available for T MOTOR F60 and F90 motors. The assembly is secured to the wing using two M3 screws, one from the top and one from the bottom. To do this, attach M3 threaded inserts to the motor mount.
  • Page 55 Wings Assembly Wings Assembly If you have chosen the version of the winglet with an LED, place it in the designated area. LEDs 2812 ARM work well for this purpose, and you can attach them, with strong double-sided foam tape. Inside the winglet, there is a channel through which the wire should be routed.
  • Page 56 Wings Assembly Wings Assembly Prepare the wing locks, printed from PETG or another rigid material. The lock consists of a bottom base and top part. The base is identical for all four locks, while the top part differ depending on whether they are for the front or rear.
  • Page 57 Wings Assembly Wings Assembly The prepared locks should be glued into the designated spots in the wing roots. Apply the glue carefully and in a small amount to avoid restricting the movement of the locks. Before final gluing, it is recommended to fit the wing to the fuselage and insert the locks without glue to ensure their exact positioning.
  • Page 58 Wings Assembly Wings Assembly Insert the 10x800mm and 8x600mm carbon tubes, serving as the main spars, into the fuselage. Then, slide the prepared wings into place, guiding the motor and servo cables inside the fuselage. USER MANUAL...

  • Page 59: Equipment Layout

    Finishing Build Equipment layout The fuselage interior offers ample space for flexible equipment placement and can accommodate a large battery. The front section is dedicated to the battery, with a battery pad designed to secure it using Velcro straps threaded through designated slots. Behind the battery, a flat area is accessible through the rear hatch, providing space for additional components.
  • Page 60 Finishing Build Finishing Build The rest of the equipment should be organized accordingly. The Battery Pad accommodates large batteries, including 4S6P Li-Ion. While this is the largest battery pack that fits, smaller and lighter batteries are advised, especially for the first flights. Using the recommended motors ensures optimal performance and long flight times.

  • Page 61: Wiring Diagram

    Finishing Build Wiring Diagram The diagram illustrates an example wiring and equipment layout, including suggested channel assignments for the servos and motors. Only the essential equipment is shown in the schematic. Optional components, such as the FPV camera, VTX, receiver, and additional sensors, are not included, as their implementation can vary depending on the chosen hardware.
  • Page 62 All information, as well as the firmware, is available onthe ArduPilot website. It is also recommended to review the user manual of the flight controller for configuration. https://ardupilot.org/plane/docs/common-speedybeef405wing.html The document is available for free download from the Flightory Discord server in the #free-files channel. USER MANUAL...

  • Page 63: Before Flight

    Before Flight Before Flight The model is ready to fly. Before flying, take care of the correct balance, which is 60 mm from the leading edge (at wing root). Check the correct operation of the ailerons and rudders and the direction of propeller rotation.
  • Page 64 USER MANUAL...

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