AirfoilZ EXTRA 300NX Assembly Manual

Nx profile series airplanes

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NX Profile Series

Assembly Manual

Version 2.0 – 10/12/09

EXTRA 300NX

EDGE 540NX

YAK 54NX

KATANA NX

Table of Contents

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Summary of Contents for AirfoilZ EXTRA 300NX

Page 1 NX Profile Series Assembly Manual Designed by Jim Vigani Version 2.0 – 10/12/09 EXTRA 300NX EDGE 540NX YAK 54NX KATANA NX...
Page 2 © Copyright 2009 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 one of the AirfoilZ NX Profile Series airplanes. 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 Figure: General Comments on Assembly: While not difficult to assemble, the AirfoilZ NX Profile Series kits are intended for persons with some building experience. As such, the instructions are presented as a simple sequence that, when followed, will help ensure that the airframe turns out straight and light. Improperly aligned surfaces and unnecessary weight will only hinder its performance.
Page 6: Fuselage Assembly
Avoid scratching the surface of the Depron foam. Graphics: The AirfoilZ NX Profile Series kits come with printed vinyl graphics. Extra care in cutting out and applying the vinyl panels will result in a professional look for your plane. Some people prefer to lightly mist the surface with “Frebreze”...
Page 8 Step 1 Glue the two 1/8”x 1/2”x 24” balsa spars together to form a single spar measuring 1/4"x 1/2"x 24”. Check that the spar edges are straight. slightly bent, lightly sand edges required to eliminate the bend. Step 2 Test fit the carbon tube and balsa spar in their respective groves.
Page 9 Step 3 Glue the fuselage spars and skins together using 30 minute epoxy or a very thin layer of Gorilla glue. NOTE: Place the glued assembly on a flat building surface and weigh down to ensure the assembly dries flat and true.
Page 10 Step 5 Glue one of the plastic landing gear mount doublers to the side of the fuselage with foam- safe CA. Epoxy the landing gear block and other plastic landing gear mount doubler in place with 5 minute epoxy. Tip: Sand the surface of the plastic landing gear mount doublers that mate to...
Page 11 Step 6 Glue the plastic nose doublers in place with foam-safe CA making sure to align the edges of the doubler with the opening in the fuselage. Tip: Sand the surface of plastic nose doublers that mates to the fuselage for better bonding of the epoxy.
Page 12 Cut the balsa tri-stock motor mount supports to the proper length and check their fit behind motor mount. Epoxy the motor mount and balsa tri-stock rear supports place making sure that the motor mount is square to the fuselage. Tip: lightly sand the plastic doubler better...
Page 13: Wing Assembly And Installation
Wing Assembly and Installation Assembling the Spar: Step 8 Glue the spar web to the center of the bottom spar cap with thin CA being sure to keep the spar web perpendicular to the spar cap. © Copyright 2009 all rights reserved...
Page 14 Step 9 Repeat for the top spar cap forming the “I beam” shape. Tip: When completed, lightly sand the spar edges to help it slide into the wing. Wing Assembly: © Copyright 2009 all rights reserved...
Page 15 Place another mark behind the leading edge each wing root. Model: Tip Distance: Wing Root Distance: Extra 300NX 2 1/8” 3 1/8” Edge 540NX 2” 2” Yak 54NX 2 1/8” 3 1/8” Katana NX 2 1/8”...
Page 16 Step 12 Mark the center of the spar and test fit it in the wings. Glue the spar into place with Gorilla Glue or 15-minute epoxy. Align the spar with the spar location marks on the wing panels. Step 13 Repeat for the other wing making sure to align the root...
Page 18 Step 15 Carefully sand the wing tip profile and spar end to remove any irregularities. Glue the wing tip caps onto the wing using foam safe CA and foam safe kicker. For curved wing tips, carefully bend the wing tip caps around the bend.
Page 20 Wing/Fuselage Assembly: Step 17 Test fit the wing in the fuselage. FORCE! If the fit is tight, gently sand the fuselage opening to fit. Make sure the wing is centered on, and square to the fuselage. With wing properly aligned, tack glue it in place with medium foam safe CA.
Page 21 Step 18 Permanently glue wing in place by forming a fillet from mixture of 15 or 30-minute epoxy and micro balloons. for KATANA NX ONLY KATANA ONLY Step 18a With the wing properly aligned, tack glue it in place with medium foam safe CA.
Page 22 KATANA ONLY Step 18b Tack glue the aileron fairing in place with medium foam safe CA. Step 18c Permanently glue wing and aileron fairing in place by forming a fillet from mixture of 15 or 30-minute epoxy and micro balloons. ©...
Page 23 Tail Feather Assembly and Installation: Installing the Elevator Joiner: Step 19 Using the end of the 3/16” diameter carbon elevator joiner, gently create a shallow grove in the elevator joiner cutout. Step 20 Secure 3/16” diameter carbon elevator joiner in place with epoxy.
Page 24 Step 21 Cut out the foam bridge behind the wood joiner, between the elevator halves. Installing the Horizontal Stabilizer Spar: Step 22 Glue the ¼”x¼” balsa horizontal stabilizer spar to the rear of the horizontal stabilizer © Copyright 2009 all rights reserved...
Page 25 Step 23 Using the sanding block, bevel the leading edge of the elevator as shown to allow for movement of the elevator when hinged. Step 24 Temporarily secure the elevator to the stabilizer with tape. Mark the position of the elevator hinges with strips of ”...
Page 26 Step 25 Cut the tape along the hinge line and remove the elevator. Step 26 Using your Exacto knife, carefully cut a slit along centerline of both the stabilizer and elevator at each hinge location. Test fit the hinges into the slits.
Page 29 Step 28 Test fit the horizontal and vertical stabilizer assembly in the fuselage and check that it fits square to the fuselage and wing. Glue the stabilizer in place with medium foam safe CA. Step 29 Install the elevator and epoxy the hinges in place.
Page 30: Rudder Installation
Rudder Installation: Step 30 Glue the rudder post in position using foam safe CA. Sand the rudder post flush with the top of the vertical stabilizer and with the bottom of the fuselage. Trim the back of the fuselage at an angle to match the rudder post using your Exacto knife.
Page 31: Aileron Installation
Aileron Installation: Step 32 Using the sanding block, bevel the leading edge of the ailerons as shown to allow for movement of the ailerons when hinged. © Copyright 2009 all rights reserved...
Page 32 Step 33 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. Note: To minimize aileron flexing, position centerline of the second hinge approximately 5½“...
Page 33 Aileron Servo Mount Installation: Step 35 Mark wing servo locations on the bottom surface of the wings. The recommend servo location using Hitec HS- 55 or HS 65 servos is shown. Cut the hole in the wing skin for the servo using your Exacto knife.
Page 34 Typical Control Horn Installation: Step 37 Sand the edges of the plastic control horn parts remove edge caused laser cutting. Test fit the pieces together Step 38 Mark the location of the control horns on the control surface and cut a slit in the control surface with an Exacto knife...
Page 35: Landing Gear Installation
Step 39 Glue the control horns in place with medium foam safe CA or Epoxy. Landing Gear Installation: Step 40 Solder a #2 washer on the landing gear. as an inner wheel retainer Tip: Drill a 3/32” hole in a scrap block of wood to use as an alignment tool.
Page 36 Step 41 Place a scrap piece of thin plywood cardboard over wheel as a spacer and slide a #2 washer on the axel. Solder in place. Use only enough heat to ensure good solder flow. Excess heat may melt the wheel hub. Completed wheel installation ©...
Page 37 Step 42 landing gear wires into the slots in the landing gear mount and secure in place with a small electrical tie. Fit the tie into the grove on bottom landing gear mount. Tip: Round the corners of the slots so that the wires fit flush to the mount surface.
Page 39 Motor, ESC, Servo, Receiver and Battery installation: Aileron Servo Installation: Step 45 Secure the wing servos in place with the servo mounting screws provided with servos. Route aileron servo leads through the interior of wing, through the exit hole. Do not over-tighten the screws as you may strip the screw holes.
Page 40 Elevator and Rudder Servo Installation: Step 47 Securely glue elevator and rudder servo mounts in place with medium foam safe CA. Step 48 Insert threaded rod into the end of the carbon fiber tube and glue with thin CA or JB Weld.
Page 41 Step 49 Install elevator and rudder push rod securing at both ends with nylon clevises provided. Bend the rod ends as appropriate maintain torsion free geometry. Motor, ESC, Receiver and Battery installation Step 50 Mount the motor using #2 wood screws washers.
Page 43: Preflight Checklist
Step 52 Mount the battery with Velcro strips on the right the fuselage as shown. Velcro strap through the slots in the lower crutch to secure the battery in place. Pre-flight checklist Balancing: We recommend that you perform initial flights with the CG 3½ to 4 inches behind the leading edge at the wing root.
Page 44 Controls: Check that all the control surfaces move in the correct direction. For 3D flying adjust the servos and pushrod locations to give 45 of control surface travel. If you radio has a dual rate function set the low rates to suit your taste. We recommend 30-40% expo to start. Prior to each day’s flying, always perform range check of your equipment in accordance with the manufactures instructions.

This manual is also suitable for:

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