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Diamond Dust CW Kit Assembly Manual

Model aircraft diamond dust cw kit
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Diamond Dust CW Kit
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Specifications
Wingspan: .................. 29.75 in (755.65mm)
Length: ....................... 24.50 in (622.30mm)
Wing Area: ................. 468 sq in (30.19 sq dm)
Weight: ..................... 2.25 – 3.0lbs (1020g–1360g)
ASSEMBLY MANUAL
________________
Engine size: ..................... .25 - .40 2 cycle
Wing Loading ........................ 12oz/SF
Radio: ..................... 4-channel w/3 servos

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Summary of Contents for Diamond Dust CW Kit

  • Page 1 Diamond Dust CW Kit _________________ ASSEMBLY MANUAL ________________ Specifications Wingspan: ……………… 29.75 in (755.65mm) Engine size: ………………… .25 - .40 2 cycle Length: .…………………. 24.50 in (622.30mm) Wing Loading …………………… 12oz/SF Wing Area: ……….……. 468 sq in (30.19 sq dm) Weight: …………………...

  • Page 2: Table Of Contents

    Section 10: Balancing the Diamond Dust........

  • Page 3: Introduction

    You can also check on the Diamond Dust RC website for any updates to this manual at www.diamonddustrc.com. Also there are a number of steps in the assembly of the Diamond Dust and Diamond Dust Clipped Wing version that are identical. For practicality and efficiency reasons, some pictures in this manual may show the Stock Diamond Dust in the illustrations.

  • Page 4: Warranty Information

    Warranty Information Tetracam, Inc. and Diamond Dust RC, guarantees this kit to be free from defects in both material and workmanship at the date of purchase. This warranty does not cover any component parts damaged by use or modification. In no case shall the liability to Tetracam, Inc.

  • Page 5: Contents Of Kit

    Contents of Kit – Diamond Dust CW Main Box Qty Description Qty Description 1/8” x 1/8” Bass wood coving stock (For Leading Edge) Assembly manual 6oz Fuel tank with hardware Blueprint / Plan .005” Carbon fiber Strip (1/4”x34”) 14 ¼” Main wing spars (Front &...

  • Page 6: Required Radio And Engine

    Required Radio and Engine Radio Equipment (Recommended Items) • 4-channel radio system (minimum) SERVOS • 2 High torque digital servos (JR9411 recommended or equivalent) Throttle: JR: 331Micro or 3121 Mini • 1 HS 85MG or equivalent mini servo Hitec: HS-85MG Mini servo Elevon .28 and under: Engine / Power System JR: DS537...

  • Page 7: Additional Required Tools And Adhesives

    Additional Required Tools and Adhesives Tools Adhesives • Drill • Thin CA Glue (Cyanoacrylate) • Drill bits: 32”, 7 64”, 1 16” 8” • Thick CA Glue (Cyanoacrylate) • Hobby Knife • CA Accelerator • Razor saw or hacksaw • CA Remover / Debonder •...

  • Page 8: Section 1: Framing Of The Airframe

    Section 1: Framing of the Airframe Step 1 Step 2 Locate all parts listed in materials list, and Assemble the rear spar by locating the tubes take inventory of all parts. This will help you labeled “Rear Spar” and “Spar extenders”. familiarize yourself with the various Insert the spar extenders into each end of the components.
  • Page 9 Section 1: Framing of the Airframe – Cont. Step 3 Step 4 Lay the assembled spar on the print to see Find the ¼” x 3/8” x 36” balsa stick trailing how far the tubes should fit into one another. edge (T.E) and cut it the same length as Adjust both sides so the center main spar is shown on the plan.
  • Page 10 Section 1: Framing of the Airframe – Cont. Step 5 Step 6 Install one #19 rubber band (included) over Take the two center ribs (rib #1) and locate each rear spar half and one rubber band the square 1/4 x 1/4 servo rail holes. Note: over each forward spar half, as shown the square holes are closest to the top below.
  • Page 11 Step 7 Step 8 Take the 1/16” x 1-3/4” x 4” balsa fuel tank Place the engine mount in between the two and lay it ompartment rear bulkhead #1 ribs. You will first have to insert the front vertically against the front of the front spar part of the #1 ribs into the front part of the between the #1 ribs.
  • Page 12 Section 1: Framing of the Airframe – Cont. Step 9 Step 10 Center the forward spar with the alignment Take the trailing edge assembly from step 4 hole in the #2 rib (centered top and bottom), of this section and slide it through the four and insert one of the 1/8”...
  • Page 13 Section 1: Framing of the Airframe – Cont. Step 11 Step 12 Square up and center the #3 rib on the T.E NOTE: be careful not to glue the and the rear spar extender. Next, insert the temporary spacers at the spars or the wood tab through the #3 rib into the rear rubber bands.
  • Page 14 Section 1: Framing of the Airframe – Cont. Step 13 Next you will be installing the leading edges on the airframe. Find the two tubes labeled “L.E. Tubes” and slide each one through the double rubber bands attached to the forward spar halves.
  • Page 15 Section 1: Framing of the Airframe – Cont. Step 15 Next glue the triangle gussets, that are positioned behind the L.E. and on the outside Locate the triangle gussets from the parts of the #2 ribs, with thick CA. bag. The first ones are installed behind the leading edge at the motor mount.
  • Page 16 Section 1: Framing of the Airframe – Cont. Step 16 Place a drop of thin CA on the spar tube and lay the tip of the Kevlar thread in the glue drop and allow it to dry. This will hold the Locate the two p recut 1/4”x1-1/2”...
  • Page 17 Section 1: Framing of the Airframe – Cont. Step 17 – Cont. Step 18 Trim the .300 E glass tube flush with the Next, thread the Kevlar through one of the wing tip (Hack saw, razor saw,9+ or band small laser cut holes found on the motor saw works well for this;...
  • Page 18 Section 1: Framing of the Airframe – Cont. Step 19 When you have finished shaping both sides of the T.E., glue the cap strips down to the tapered T.E assembly on both sides of the Now separate the unglued portions of the airframe.
  • Page 19 Section 1: Framing of the Airframe – Cont. Step 20 Step 21 Apply cap strips to both top and bottom of the #3 ribs on both sides of the airframe. Next, locate the leading edge hardwood coving stock and apply one piece to each of leading edge tubes with thick CA.
  • Page 20 Section 1: Framing of the Airframe – Cont. Step 21 – Cont. Step 22 Now cap strip the outer edge of both the balsa wing tips from the L.E tubes back to the T.E. Leave a little extra at both ends for shaping.
  • Page 21 Section 1: Framing of the Airframe – Cont. Step 22 – Cont. Step 23 The taper should be strait and consistent towards the T.E. Install a 1/16” x ½” cap strip to the top and bottom of the #2 ribs using thick CA. Next, sand the cap strip over the #3 rib so it flares around the L.E tube assembly.
  • Page 22 Section 1: Framing of the Airframe – Cont. Step 24 Glue the servo rails in first using a drop of thin CA between each servo rail and each #1 NOTE: when installing the hardwood rails, rib. Note: Center the rails so you leave pay close attention to the direction of the approximately ¼”...
  • Page 23 Section 1: Framing of the Airframe – Cont. Step 24 – cont. Step 25 Next find the 4” x 4-5/8” x 1/16” Balsa sheet with precut slots and glue it at the Once you have both servo rails glued in, you trailing edge of the aircraft on the topside will need to pre-drill your servo mounting of the airframe using thick CA.
  • Page 24 Section 1: Framing of the Airframe – Cont. Step 25 – cont. Step 26 With the airframe bottom side up, The antenna tube will be inserted in install the center the four precut 3/32” holes found on both of 4” x 4-5/8” x 1/16” balsa sheeting, beginning at the TE and going the main ribs.
  • Page 25 Section 1: Framing of the Airframe – Cont. Step 26 – cont. Step 27 Continue to apply the rest of the cross grain sheeting on the bottom of the airframe. The Leave approximately ¼” to ½” of the tubing last piece should stop at the firewall (it will protruding through the #1 ribs.
  • Page 26 Section 1: Framing of the Airframe – Cont. Step 28 With a hobby knife, trim the triangle stock to Next you will cut pieces of ¼” x ¼” triangle match the #1 rib profile. stock to fit on the inside area of the motor mount plate.
  • Page 27 Section 1: Framing of the Airframe – Cont. Step 29 Step 30 Locate the two ¼” x ¼” x 7/8” Locate the 1/8” x 3-7/8” x 1-3/4” plywood hardwood throttle servo rails. Pre-mount the switch plate and apply thick CA to the sides throttle servo to the short servo rails (this will and front part of the switch plate.
  • Page 28 Section 1: Framing of the Airframe – Cont. Step 30 – cont. Locate the nsert 1/16” balsa partial rib and i it between the firewall and the fuel tank rear Once you have determined which side the bulk head, while pressing it up against the throttle servo will be mounted, cut a small ¼”...
  • Page 29 Section 1: Framing of the Airframe – Cont. Step 31 Step 32 Cut-to-fit two 1/16” x ½” cap strips to fit over both #1 ribs, between the newly Locate a piece of 4” x 4-5/8” x 1/16” balsa covered switch plate and the cross grain cross grain sheeting and cut it to match the sheet where the elevon servos are mounted.
  • Page 30 Section 1: Framing of the Airframe – Cont. Step 32 – cont. NOTE:!!! The next step is determined by what size engine you will be using. If your engine is a .28 or smaller you will place the fuel tank against the rear bulkhead of the fuel compartment.
  • Page 31 Section 1: Framing of the Airframe – Cont. Step 32 – cont. Add another piece of 1/16” cap strip to the partial rib in the fuel tank compartment. Next apply 1/16” cap strips to both #1 ribs Remember to apply all cap strips with thick between the switch plate and firewall.
  • Page 32 Section 1: Framing of the Airframe – Cont. Step 32 – cont. Also, don’t forget to seal any spaces found Sand all the cap strips at the LE, and any around the cap strip and the motor mount/ rough edges, being careful not to sand firewall area.

  • Page 33: Section 2: Elevon Construction

    Section 2: Elevon Construction Step 1 Step 2 – cont. Locate the two precut balsa elevons from the box. Please take note that the Glue the triangle stock, first using thick CA elevon stock is NOT symmetrical. and then applying thin CA Make sure to orient both elevons with the 90 deg.
  • Page 34 Section 2: Elevon Construction – Cont. Step 3 Step 4 With the airframe and elevons on the print, mark all hinge locations on both the elevons Next, sand both ends of the elevon and airframe with a pencil, as indicated on triangle stock flush with the ends of the the plans.
  • Page 35 Section 2: Elevon Construction – Cont. Step 5 With the airframe lying on the table, soak Bend each elevon to full deflection (about 90 each CA hinge with thin CA. Allow your first deg.). Be careful to not bend so far as to pull glue application to dry, then apply glue to the elevons and trailing edge apart.
  • Page 36 Section 2: Elevon Construction – Cont. Step 5 NOTE: Be sure to match the taper of the Next, while using a sanding block or file, balsa wingtips as closely as possible. taper both outside elevon ends to match the Taper the elevons only in the tapered tapered wing tips.

  • Page 37: Section 3: Vertical Fin Assembly

    Section 3: Vertical Fin Assembly Step 1 Step 2 Next, locate one of the 1/8” x 1/8” x 4” balsa fin offset fin cap strips. Install them Cover a clean flat surface with wax paper or to the top of the fin as a cross grain cap parchment paper and then glue the front and strip.
  • Page 38 Section 3: Vertical Fin Assembly – Cont. Step 4 First, apply the ¼” x 6 ¼” carbon strip along the seam where the front and rear fin In this step you will be cutting and applying halves are joined using thick CA carbon fiber strips to add strength to the vertical fins.
  • Page 39 Section 3: Vertical Fin Assembly – Cont. Step 5 - cont. We have included a few photos of the hatch we have constructed using left over 1/16” Install the ¼” x 6” strip across the bottom of cap strip and cross grain sheeting. the fins above the fin insert tab, again using thick CA.

  • Page 40: Section 4: Installing The Control Horns And Elevon Linkage

    Section 4: Installing the Control Horns and Elevon Linkage Step 1 Once properly aligned, mark and drill four holes in the elevons using a 1/8” drill bit. Locate the two control horns along with Install the 4-40 x 1” cap screws and (8) 4-40 x 1”...
  • Page 41 Section 4: Installing the Control Horns and Elevon Linkage – Cont. Step 2 - cont. Next, install the 4/40 ball links as shown To determine the correct hole to drill, place a below on both control horns. servo arm against the control horn and use the closest hole to match the length of the servo arm and control horn with a ratio of 1:1.
  • Page 42 Section 4: Installing the Control Horns and Elevon Linkage – Cont. Step 3 Next, place a drop of thin CA at the tip of the stiffener tube and wrap about 6 wraps of Locate the two push rods and the two Kevlar thread around the tube.

  • Page 43: Fuel Tank Assembly

    Section 4: Installing the Control Horns and Elevon Linkage – Cont. Step 4 Screw the pushrods on to the ball links Note: You must power on your radio system on each elevon about halfway to start. in order to properly center your servos at their true center.

  • Page 44: Section 5: Equipment Placement And Pre-Balancing

    Section 5: Equipment Placement and Pre-Balancing Step 1 Gather the receiver, receiver battery, power switch harness, fuel tank, throttle servo, vertical fins and engine with prop. Insert the two vertical fins in the rear slots. Place the fuel tank in the fuel tank compartment and Install the throttle servo. Center the engine on the motor mount plate so it can be moved forward or aft later.

  • Page 45: Section 6: Covering The Aircraft

    Section 6: Covering the Aircraft. Step 1 Step 2 Now locate the 1” wide roll of Solartex from the parts bag and with a med to hot Fuel proofing: Apply a layer of Stix-it on the covering iron, apply a strip across the bottom wood portion of the airframe where the of the airframe above the forward and rear covering will contact the wood parts of the...
  • Page 46 TIGHTEN COVERING WITH IRON OR recommend using Hangar 9 Ultracote or HEAT GUN AT THIS TIME! Iron the Solartex to cover the Diamond Dust. These covering into the crevice between the coverings have proven to be more resilient elevon and trailing edge and entire elevon, and will not shatter as easily with age.
  • Page 47 ½”. different color. This will help with orientation when the Diamond Dust is in the air. Make sure you overlap the first layer of covering over the #2 ribs.
  • Page 48 Section 6: Covering the Aircraft - Cont. Step 8 Step 7 Cover both vertical fins with covering. Make Look at the aircraft from a frontal view and sure to not cover the bottom of the fin or the determine if both wingtips are even with fin insert tab.
  • Page 49 Section 6: Covering the Aircraft - Cont. Step 8 Step 7 When installing the fins, use the fin gage. Use thick CA on the fin insert where it Insert a vertical fin in the fin insert slot and makes contact with the offset spacer and the mark with a pencil where the fin makes bottom cross grain sheeting.

  • Page 50: Section 7: Fuel Tank Installation

    Section 7: Fuel Tank Installation Step 1 Step 3 Install the fuel tank and latch the Velcro strap Locate the Velcro strap from the kit and place around the fuel tank. it in the middle of the fuel tank compartment and glue with thin CA.

  • Page 51: Section 8: Final Equipment Installation

    Both servos pull forward Some radios offer a delta wing configuration Tip: Because of the amount of force placed on the Diamond Dust’s control surfaces, plastic geared servos can fail prematurely. Therefore we strongly suggest the use of metal geared servos like the JR DS9411, DS8611A or Hitec HS-5625MG.
  • Page 52 Section 8: Final Equipment Installation – Cont. Step 3 Step 5 After you have established proper servo movement and centering, Install your elevon Pull the short semi-cut section back to open servos in the servo/ radio compartment and the tube so you can insert the end of the attach the control linkage to the elevons.
  • Page 53 Section 8: Final Equipment Installation – Cont. Step 7 Step 9 Continue pulling the pull tube until the antenna exits the other side of the guide NOTE: Due to battery size, type, and weight, tubing.. It will be up to the end user to determine the location and manner in which the battery will be attached to the airframe.

  • Page 54: Section 9: Final Inspection/Control Throws

    Section 9: Final Inspection/Control Throws Step 1 Control Throws: Give the aircraft a complete check over and make sure the airframe and all control surfaces are straight. Also make sure that with up and down elevator your elevons stay equal through their range of motion.

  • Page 55: Section 10: Balancing The Diamond Dust

    An important part of preparing the aircraft for flight is properly balancing the model. The recommended Center of Gravity (CG) for the Diamond Dust is at the high point of the main ribs to ½” in front of the high point.

  • Page 56: Section 11: Pre-Flight & At The Flying Field

    Section 11: Pre-Flight & At the Flying Field Step 1 Preflight check: Step 3 Charge both the transmitter and main battery Initial Instructions for Takeoff pack for your airplane. Use the Have an assistant hold the aircraft from recommended charger supplied with your behind with one hand over the leading edge particular radio system, following the of each wing tip.
  • Page 57 Section 11: Pre-Flight & At the Flying Field – Cont. Step 4 LANDING: NOTE: Landings are usually done on soft grass. Dirt or sand is not recommended. (A) Get into a high approach and shut off engine. (B) While at high altitude slow the aircraft down by bringing it to nose high attitude and get the feel of its low speed glide characteristics..
  • Page 60 www.diamonddustrc.com © 2007 Tetracam, Inc 21601 Devonshire Street Suite 310 Chatsworth, California 91311 www.tetracam.com Sales - (818) 718 -2119 Tech Support – (352) 871-7301...

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