FlyingFoam Nurf General Assembly Instructions

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These instructions apply to the Nurf, an all EPP forward swept flying wing available from

FlyingFoam.com.

Building and operating a remote controlled aircraft involves risk. By building and flying

this kit you are accepting said risks. We assume a basic level of model aviation

knowledge in both building and operating our aircraft. Please seek experienced help

when required. We make every effort to ensure our kits are of the highest quality, and

any documentation is as accurate as we can make it at the time of writing. Due to the

flexible nature of our designs there are many ways to successfully build our kits. We

document what we feel is the best method for general-purpose use. Please refer to

www.flyingfoam.com for further details.

Requirements:

 Radio/receiver with elevon mixing

 2 mini servos (We like the Hitec 82MG)

 Motor: 300+ watt electric power (we like 75 watts per pound of flying weight for

average performance)

 Battery: 5000 mAhr 3S lipo or 4350+ mAhr 4s lipo (Nurf has flown with as much

as a 9000mAhr 3S)

 Electronic Speed Control: Match to your motor (40+ amps would not hurt)

 Prop: 9" for ground clearance (12" max to clear vertical stabilizer, but you might

want a folder or add landing gear for ground clearance)

 Options: Folding prop and spinner

Included:

• 1.3# EPP fuselage core (cut in half for easy access)

 1.9# EPP wing cores (with spar slots)

 (6) .188" carbon fiber tube spars

 (4) Steel joiners (pre-bent)

 (12ft) 5 mil lamination film (to cover the wing and fuse)

 (3ft) 1.7 mil lamination film (to cover/hinge the elevons)

 (1) 4mm coroplast vertical stab (top/bottom)

 (2) 2-56 Threaded rods and nylon clevis

 (2) Nylon control horns

 (2) 2-56 quick connectors

 (2) 1/4" Balsa elevons

 (1) 3/32" birch ply firewall

 (1) Mylar hatch

Rev 2.0 10/21/13

FlyingFoam Nurf

General Assembly Instructions

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Summary of Contents for FlyingFoam Nurf

Page 1  Motor: 300+ watt electric power (we like 75 watts per pound of flying weight for average performance)  Battery: 5000 mAhr 3S lipo or 4350+ mAhr 4s lipo (Nurf has flown with as much as a 9000mAhr 3S)  Electronic Speed Control: Match to your motor (40+ amps would not hurt) ...
Page 2  .188 carbon fiber tail pin  3” wide fiberglass tape  (2) Bamboo Skewers  Recommended Tools/Supplies:  Hobby knife with #11 blades  Snap-blade knife  Sanding block with medium grit (120-150) paper  5 minute epoxy  CA – Medium and Thick ...
Page 3 Spar Installation 7. The carbon fiber spars are joined at the wing panel joints with the pre-bent joiner wires that are found in the small parts bag. The spars will also be wrapped at the joint with ~1.5” of the 3” wide fiberglass tape. Start by dry fitting the joiners and spars; de- burr the ends of the joiners/spars with sandpaper if required.
Page 4 spar. This will be the outboard edge of your servo pocket. You can now mark the outlines of your servo using this mark as a guide. Make sure you keep the servo pocket behind the spar so you do not cut into it while creating the pocket. Your servo pockets should be a snug fit in the foam to ensure you minimize any excess play.
Page 5 NOTE: Do not use too much pressure with the sanding block or you risk tearing instead of sanding. 15. Perform a final sanding of the entire wing with a sanding block and 120-150 grit sand paper. This sanding will help remove the thin layer of heat-affected EPP from the hotwire process, which will help the lamination film better adhere to the surface of the foam.
Page 6 23. Once the elevons are hinged you can cut out access holes for the servo control arms; plug in the servos; and allow the arms to center. 24. The control rods should run perpendicular to the hinge line. Use a fine tip marker to mark the holes for the horns and a small drill bit to make the holes for the screws.
Page 7 31. You can now position your battery and reposition other components until the Nurf balances on your pin. 32. Once you are happy with the balance of the Nurf you can mark the locations of the components for reference during pocketing. You can now remove the tape and components and begin the pocketing process.
Page 8 Final Fuselage Prep 35. You can now use your sanding block with 120-150 grit to round the edges of the fuselage and lightly sand the surface. 36. Once sanding is complete it is time again to vacuum the cores and your bench to prepare for covering of the fuse.
Page 9 Tail Fin Installation 42. Temporarily place the wing in the saddle with the top and bottom fin in position. Once you are happy with the fit of the both the bottom and top fin, mark the bottom fin with a pencil along the fuselage outline. Remove the bottom fin and scuff the bottom fin inside these lines.
Page 10 NOTE: Since the Nurf is a flying wing it has a fairly tight CG range and it is much easier to maiden with the CG at the leading edge of the wing. You can slowly move the CG back as you get comfortable with the plane.
Page 11 NOTE. The Nurf has 4 degrees of thrust line built into the motor mount and we have found it works well with several different motors and payload configurations. However, to get best performance it is good to check your configuration. Even if you plan to fly with an IMU our other auto stabilization method there is no substitute for a well- balanced and trimmed aircraft.