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FlatfoilZ EXTRA 300 Assembly Manual

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FlatfoilZ Assembly Guide
EXTRA 300, EDGE 540, LEK-TRICK & STALKER
Version 1.0
10-27-11

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Summary of Contents for FlatfoilZ EXTRA 300

  • Page 1 FlatfoilZ Assembly Guide EXTRA 300, EDGE 540, LEK-TRICK & STALKER Version 1.0 10-27-11...
  • Page 2 Limited Warranty FlatfoilZ 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 use prior to their use in the construction of the model, provided the purchaser requests such replacement within a one year period from the date of purchase, and the part is returned, if so requested by the Company.

  • Page 3: Fuselage Assembly

    Fuselage Assembly: The fuselage assembly on the FlatfoilZ NX Profile Series kits consists of a 6 mm depron laser cut core, over which are laminated 3 mm depron skins. A 6 mm carbon tube is embedded in the 6mm core piece.
  • Page 4 Completed Fuselage Assembly Follow the steps in the order outlined below to ensure accurate alignment of the components. © Copyright 2011 all rights reserved`...
  • Page 5 Step 1 Apply thinned 15 min epoxy to one side of the 6mm fuselage core and position the core on the 3mm fuselage skin . Step 2 Apply epoxy into the center slot fuselage core and insert the 6mm carbon tube spar into slot.
  • Page 6 Step 5 Glue the 3mm depron nose doublers on both sides of the fuselage. Step 6 Test fit the ply motor mount in the fuselage opening. © Copyright 2011 all rights reserved`...
  • Page 7 Step 7 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. If you would like to finish the edges of the fuselage, use your sanding block to smooth and either bevel or round the edges approximately inch.

  • Page 8: Wing Assembly And Installation

    Wing Assembly and Installation The fuselage assembly on the FlatfoilZ NX Profile Series kits consists of a 6 mm depron laser cut core, over which are laminated 3 mm depron leading edge skins. A 6 mm carbon tube is embedded in the 6mm core piece.
  • Page 9 Completed Wing Assembly Wing Assembly: Step 8 Join the two wing cores together using 5 minute epoxy. © Copyright 2011 all rights reserved`...
  • Page 10 Step 9 Cut the spar slot through the center joint. © Copyright 2011 all rights reserved`...
  • Page 11 Step 10 Apply thinned 15 min epoxy to the bottom side of the 6mm wing core and position the core on bottom skins. NOTE: Test fit the bottom LE skins on the wing core lightly mark where the rear edge is located on the wing core.
  • Page 12 Step 13 Place the glued assembly on a flat building surface weigh down ensure assembly dries flat and true. Step 14 After the epoxy has cured, sand the wing LE round. © Copyright 2011 all rights reserved`...
  • Page 13 Wing/Fuselage Assembly: Step 15 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 14 Step 17 Secure 3/16” diameter carbon elevator joiner in place with epoxy. Tip: For a lighter joint, a mixture of 15 minute epoxy and micro balloons can be used. Step 18 Cut out the foam bridge behind the wood joiner, between elevator halves.
  • Page 15 Installing the Horizontal Stabilizer Spar: (Note: Not required on the Stalker) Step 19 Glue the 1/8” x 1/4” balsa horizontal stabilizer spar to the rear of the horizontal stabilizer Step 20 Test fit the horizontal stabilizer in the fuselage and check that it fits square to the fuselage and wing.
  • Page 16 Step 22 Glue the 1/8” x 1/4” 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. (Not required on Stalker) Step 23 Trim the back of the fuselage at an angle to match the rudder post...

  • Page 17: Control Surface Hinging

    Control Surface Hinging: All the control surfaces on the prototypes were hinged with tape. Any number of schemes can be used. However, we prefer the Over/Under method outlined below. Making Over/Under Tape Hinges: Step 24 Using a sanding block, bevel the edge of the both mating surfaces along the hinge line.
  • Page 18 Step 24a Hinges are made by overlapping 2 pieces of tape together along the hinge line. One side goes on top of one surface and the other side goes on the bottom of the mating surface. Step 24b Attach the 2 pieces of tape together before...
  • Page 19 Typical Control Horn Installation: Step 25 Sand the edges of the plastic control horn parts remove edge caused laser cutting. Test fit pieces together. Note: The control horn with the short mounting tab is for the elevator. Step 26 Mark the location of the control horn control surface and cut...

  • Page 20: Servo And Pushrod Installation

    Step 27 Glue the control horns in place with medium foam safe CA or Epoxy. Servo and Pushrod Installation: Servo Installation: Step 28 Test fit the servos in their mounting holes. Install the plastic servo mounts using medium foam safe CA. Secure the servos in place with servo mounting...
  • Page 21 Pushrod Assembly and Installation: Note: The Stalker uses solid wire pushrods attached with Z bends. Support the Stalker elevator pushrod with the plastic support provided. Step 29a Cut the pushrod wire into 3” long sections and form a Z bend on one end.
  • Page 22 Step 29c Heat shrink a section of heat shrink tubing onto the end of the carbon fiber tube. Wick thin CA into the joint between the heat shrink and the tube. Step 30 Attach the pushrod to control horn then attach a section of Z bent wire into the servo arm.
  • Page 23 Motor, ESC, Receiver and Battery installation Step 31 Mount the motor using #2 wood screws washers. Check to make sure motor turns freely and there is no interference between the rotating motor components fuselage. Tip: Right thrust adjustments can be made placing washers under the left...

  • Page 24: Preflight Checklist

    We recommend that you perform initial flights with the CG located behind the leading edge at the wing root as shown below. Adjust the CG to get the flight characteristics that suit your taste. Stalker 3” to 3¼” Extra 300 3½” to 3¾” Edge 540 3” to 3¼”...
  • Page 25 Electrical Components: Check that all electrical components are securely attached and the all plugs are fully seated. Secured any extra length on servo leads neatly within the fuselage or taped to the wing. Avoid loose or dangling wires. 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.

This manual is also suitable for:

StalkerLek-trickEdge 540

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