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TufFlight Tuf-Yak Manual

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The Toughest R/C Planes Ever!
46"
Wingspan:
Length:
48"
4.5 - 4.75 lbs
Weight:
Engine:
.63-.82 four stroke
Radio:
4 channels
5
Servos:
670 sq in
Wing Area:
Hello, and thanks for buying the Tuf Yak! Our version
of the popular profile Yak 55SP represents a quantum
leap in flying excellence PLUS unprecedented Durabil-
ity for intermediate to advanced 3D pilots.
Caution: The Tuf Yak is not intended as an R/C trainer airplane. This plane is a very agile aerobatic performer
that is capable of quick rolls, hovering flight and many tricks appealing to the "3D" flyer.
While you may be tempted to fly close to yourself, please practice in a safe manner.
Always obey safety rules and exercise good judgement when learning new maneuvers.
Please read and understand the instructions before starting to build. We recommend joining the AMA and follow-
ing the AMA safety code. Call 1 (800) I- FLY-AMA for more details.
We assume no responsibility for how you use your plane. That said, let's get started!
Items Included in kit:
Foam:
CNC sliced EPP "block"
CNC sliced fuselage core pieces
Wood:
(3) 1/32" x 2-1/4" x 24" ply
(12) 1/16" x 3" x 24" balsa sheet
(4) 5/16" sq x 24" balsa sticks
(2) 1/2"x 18" balsa tri stock
(3) 1/4" x 5/8" x 18" balsa
(1) 5/8" x 3/4" x 18" balsa
(1) 5/16" x 3" x 8-7/8" balsa
(1) 1/4" 5/8" x 4" bass
(2) 1/32" x 6" x 8" ply
(2) 5/16" x 6" dowels
(1) 5/16" x 2-1/2" dowel
(1) 1/2" x 5/8" x 22" pine
Plastic:
(4) G10 joiner pieces
Rev 1.3
5376 Amalfi Drive,
.40 - .53 two stroke,
The CG location is 3/4" behind the spar.
Clay, NY 13041
www.tufflight.com
Tuf-Yak
(4) 1/16" clear plastic control horns
(1) 3/16"" x 4" x 7" white engine plate
(1) 1/16" x 2-1/4" x 15" spacer
(2) 2.5 degree wedges
Hardware:
(8) 10-24 x 1.5" nylon bolts
(8) 10-24 nuts
(8) 6-32 x 3/8" nylon bolts
(2) 1/4" washers
(1) 1/4-20 x 2" nylon bolt
(4) 6-32 nuts
(2) 6-32 x 1-1/4" bolts
(1) 1/4-20 nut
(4) #64 rubber band
(1) roll hinge tape - Frost King # T94
(15) Robart Hinge points
(1) 7" x 1/16" tail skid wire
(1) 21" pre-drilled carbon tube elevator axle
Graph Tech profile landing gear
This Instruction Manual
Full Size Plans
Page 1

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Summary of Contents for TufFlight Tuf-Yak

  • Page 1 5376 Amalfi Drive, Clay, NY 13041 www.tufflight.com Tuf-Yak The Toughest R/C Planes Ever! 46" Wingspan: Length: 48" 4.5 - 4.75 lbs Weight: .40 - .53 two stroke, Engine: .63-.82 four stroke Radio: 4 channels Servos: 670 sq in Wing Area:...

  • Page 2: Items Needed To Complete

    Helpful Tools: Items needed to complete: 40 grit sandpaper on block (available at auto finishing stores and Sears) Equipment: hobby knife / utility knife .46-.53 two stroke engine square or .63-.82 four stroke X-acto knife with # 26 blade radio receiver (2.25 inches long, great for cutting (2) 18”...
  • Page 3 Pacer Zap-a-Dap-a-Goo, PFM or “Shoe Goo”. Goop is fuel proof and flexible. . Other TufFlight kits rely heavily on this glue for many critical high strength joints. Goop is relatively heavy, so use sparingly. May substi- tute Goop for Sumo glue when gluing clear plastic parts if Sumo glue not available.
  • Page 4 Prepare Foam Parts Don’t discard You’ll need : Pre Sliced foam block any other 40 grit sandpaper on a block pieces! They straight edge at least 24” long will be used medium viscosity CA (not foam safe) later CA Accelerator Step 1: Gather parts and tools.
  • Page 5 It helps to skip ahead to see what you’re working toward during these steps Step 11: Open the “hinge” as shown and Step 16: Mark two of the spar pieces 2” sand/clean these surfaces too as shown. from one end of each piece Place on a Make cuts table edge to...
  • Page 6 Step 21: Cut on the lines to make the 3” points Step 26: Mark the center line on the 6” as shown (do one end only on both pieces) double tapered spar piece as shown Step 22: Mark the unused spar piece 6” Step 27: Apply medium viscosity CA to half from each end as shown of the tapered piece to the tip as shown...
  • Page 7 Note, half of this 2” piece should “overhang” and not be glued to anything at this point Step 31: Apply the 2” piece as shown Step 36: Cut the white plastic to match the wood spar’s 6” tapered point (Note, your white plastic piece will probably be...
  • Page 8 Glue wing parts together Bottom of wing is up with Leading Edge of You’ll need : Assembled spar pieces wing facing down 1/16” plastic spacers Wood piece faces Gorilla Glue “forward” (nearest LE) water spray bottle masking tape Insure both lines even popsicle stick with foam edge Step 41: Gather supplies...
  • Page 9 Make foam tail feathers You’ll need : 5/16” foam sheet, medium CA, kicker ruler, pencil, hobby knife, 3M77 balsa tri stock, carbon elevator tube Robart hinges, template sheet hand drill 1/16”, 1/8” and 5/32” bits Step 51: Open the right wing and apply Step 56: Gather parts and tools.
  • Page 10 Step 61: Here are the foam parts cut out. Step 66: Sand the balsa triangle corners off so the balsa is even with the foam surface. Step 62: Cut the balsa triangle stock to the Step 67: Here is the rudder sanded flat. length as shown for the rudder hinge line.
  • Page 11 Step 71: Use a hobby knife to carve out the Step 76: Use a hinge in the tube to see which balsa so a hinge will fit inside. side will be glued to the foam elevators Only elevator plans shown for clarity Repeat process for all rudder...
  • Page 12 It’s often wiser to cut a little long, and slowly sand to the correct length and angle Step 81: Kick the CA taking care to keep Step 86: Cut the sticks to the correct length. the tube centered and aligned to the foam. Step 82: Glue other half to match the first Step 87: Lay the sticks over the plan in the half (lay on table to help alignment)
  • Page 13 Center the stab within the elevator assembly (gaps on sides should be equal) Step 91: Make the vertical stab in similar Step 96: Use the elevator assembly to mark fashion. the horiz stab hinge locations at each hole. Apply tri stock ONLY to the horiz stab for now! (Vertical stab will...
  • Page 14 Hinge pivot point center should be aligned with tri stock point, and free to move up and down as shown. Step 101: Test fit hinge. Trim with knife as Step 106: Using 40 grit sandpaper, sand the needed. wing bottom spar areas flush with surface a gap of 1/16”...
  • Page 15 Be sure this is the RIGHT WING Aileron servos will BOTTOM! sit directly in front of the spar with the The Throttle Servo will wire pointing to the sit directly in front of root edge as shown the spar with the wire pointing to the root edge as shown Step 111: Trace around and cut the outline...
  • Page 16 Step 121: Pull the foam out 1/2” and trace Step 126: Sand both foam tips to make the the outline again as shown surfaces flat and even using 40 grit. Watch your fingers! We want to break it free of the poly-u glue that may have expanded into the groove...
  • Page 17 Step 131: Re-insert the white plastic spacer Step 136: Remove masking tape from piece the way it was before. servos Cover wing halves and make / hinge ailerons Cut covering to have about 2” extra all You’ll need : wing assemblies, hinges, old credit cards around 3M77, covering iron, masking tape sandpaper, pliers, ruler, toothpick...
  • Page 18 iron temperature Set Iron should be about temperature to 250 degrees F ~300 deg F Step 141: Iron around the servo spline to Step 146: Iron all surfaces to minimize minimize wrinkles wrinkles. Step 142: Once wrinkles are minimized, iron Step 147: Remove white plastic pieces edges and trim leaving about 1/4”...
  • Page 19 Step 151: Trim root, tip and trailing edges of Step 156: Use full size plans to transfer ailerons with sharp hobby knife hinge locations to wing and aileron as shown be sure to hold aileron STRAIGHT during this step (check leading edge with another ruler) Step 152: Use a ruler to trim the trailing...
  • Page 20 Step 161: Insert dowel and test fit hinge Step 166: Fit the aileron onto the hinges as near root edge of wing as shown shown taking care to center hinge in gap Step 167: Tape the aileron to the wing Step 162: Trim 2 hinges to so they won’t leaving a 1/16”...
  • Page 21 Step 171: Cut the sticks even with the foam as Step 176: Glue the rearward basswood shown. stick as shown with foam safe CA Leave about 3/32” gap on each side of servo to basswood (mark foam at correct size for the cavity) Step 172: Glue the sticks in place with foam Step 177: Use elevator servo and basswood...
  • Page 22 The horizontal stab will sit directly to the rear of this piece Step 181: Refer to the full size plans to Step 186: Using the full sized plans, fit and locate the 5/16” stick and cut as shown. cut the front fuse pieces and place as shown Step 182: Glue the stick in place Step 187: Using 3 scraps of 1/32”...
  • Page 23 Step 191: Position and glue the remaining Step 196: Take the remaining 5/16” piece foam and pine landing gear block as shown and mark a line 1-1/2” as shown Step 192: Remove spacers Step 197: Make a 1-1/2” x 5/8” thick square block by cutting and doubling where shown Right hand side of fuse front shown...
  • Page 24 Step 201: Insert the balsa block and glue in Step 206: Make 4 sheets of sheeting from place joining 3 at a time as shown. Leave about 1/4” to 1/2” extra sheeting around the edges. Save the trimmings, you need them to extend the sheet in the next step Step 202: Sand both sides fuselage parts so...
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  • Page 29 Step 211: Make 2 identical sheets for the Step 216: Apply the sheeting, flip the piece rear fuse pieces and sand both sides. over and apply glue to the other side Step 212: Vacuum the fuse assembly and Step 217: Wipe away any glue that has balsa sheets gotten into the channel.
  • Page 30 Step 221: Clean the hinge area with acetone Step 226: Press the tape into the hinge crevice with a credit card as shown. DO NOT touch the tape to the wing yet! (wing shown for measuring purposes) Step 222: Unroll and cut enough tape to Step 227: Blot away excess water.
  • Page 31 Step 231: When hinge has dried, repeat Step 236: Apply medium CA to the balsa in process for other side of both aileron hinges. front of the marked line and apply plywood Finish crafting fuselage assemblies You’ll need : Sheeted fuselage pieces hobby knife, sanding block, pencil, pin Fuse joiners, Right wing, pliers Drill with 1/8”, 3/16”...
  • Page 32 The spar fit should not be too tight. Step 241: Mark the center of the pine beam Step 246: Test fit the right wing spar through and transfer to the top surface. the slot and clear the slot as needed. This is the location for the front dowel hole...
  • Page 33 THIS STEP IS OPTIONAL Step 251: Draw an oval between these two Step 254: Glue 1/16” scrap balsa with foam marks as shown. safe CA to the perimeter to “cap” the edge THIS STEP IS OPTIONAL Try to be neat, but it’s not absolutely let glue dry, remove critical.
  • Page 34 Be careful not to make slots too large at this stage-- better to make them smaller and file open later Step 257: Locate the 4 joiner pieces, trm Step 262: Cut out the joiner slots with band and lighten by drilling them as shown / scroll saw or other cutting tool.
  • Page 35 A Saito .82 is shown on the template. Modify engine width and lug hole spacing to fit your motor if different Step 267: Trim wood from channel opening Step 272: Cut the center of the “U” with (if necessary) band saw or coping saw. Clear the opening to the channel as required...
  • Page 36 Step 277: A 5/16” dowel and rubber bands Step 282: Test fit the stab into the groove provide bottom “shock absorber:” The wheels run on 6-32 bolt axles held to the gear with 2 nuts-- one on either side of the gear.
  • Page 37 Step 287: Apply Gorilla glue into the slot as Step 292: Remove covering from the holes shown and glue vertical stab in place. in both elevator and stab with a knife Step 288: Test the fit of the horizontal stab Step 293: Apply Gorilla glue to the hinges and sand the slot if needed for a good fit and install...
  • Page 38 Step 297: Transfer the rudder hinge loca- Step 302: Drill a 1/16 hole slightly off center tions to the vertical stab as shown so it doesn’t hit the hinge Step 298: Install hinges in similar fashion to Step 303: File a groove into the end of the the elevator procedure 1/16”...
  • Page 39 Step 307: Start by covering the vertical stab Step 312: Cover the sides one at a time and top fuselage area as shown Step 308: Let the covering overlap the fuse Step 313: Use covering from the sides to sides by about 1/8” overlap the straight perimeter areas as shown It’s easier and looks better if you do these...
  • Page 40 Step 317: Test fit the joiners into the slots Step 326: Glue in place with gorilla glue or epoxy. Make sure fuse is straight! A 36” long 4” wide carpenter’s level makes a good straight tool for Work quickly so you this step.
  • Page 41 Do for both sides of stab (top and bottom) Step 331: Use a hobby knife to gently score Step 336: Double check your center and peel covering from this area as shown. measurement and adjust if needed Step 332: Glue the stab inside the fuselage Step 337: Once satisfied, weight down and with Sumo Glue allow to cure...
  • Page 42 Step 341: Move elevators to insure there is no Step 346: Glue the balsa piece in place as interference and make clearance as needed. shown Step 342: Insert 5/16” balsa into the slot as Step 347: When glue has cured, sand/trim shown and trace around fuselage even with fuselage sides.
  • Page 43 Install Control Horns and Linkages You’ll need :Rear Fuselage, Wings, Sumo Glue clear plastic control horns, push rods hobby knife, drafting square, pliers elevator and rudder servos, servo arms 24” long thin wire or similar drill matching clevis pin and push rod diameters Step 351: Gather parts and tools.
  • Page 44 Step 361: Trace location of elevator horn as Step 366: Make a slot and glue the horn like shown similar to how you installed the elevator horn. Make the slice perpendicular to the elevator surface DO NOT cut all the way through the elevator! Step 362: Carefully slice into elevator to...
  • Page 45 Step 371: Install aileron servo arm and mark Step 376: Install push rod with Z bend as perpendicular location on aileron as shown shown. Glue wings to fuselage You’ll need :Wings, Sumo Glue, Gorilla Glue drafting square, dowels, masking tape 2(2) 18”...
  • Page 46 Step 381: Mark a stick 3-1/2” from one Step 386: Use a dremel tool or hobby knife end as shown to create the hole where marked Use enough glue to smear around the inside at the 3-1/2” depth as shown Step 382: Use the stick to help spread Step 387: Tape the wire extensions stag- Sumo Glue inside the perimeter at this depth...
  • Page 47 Step 391: Insert the wire through the rear as Step 396: Apply glue inside the spar shown “pocket” Be sure to coat all This is a TEST FIT mating WOOD and ONLY exposed foam surfaces well with Gorilla Glue If there is any binding, find and correct the (no need to apply glue issue so the wires will...
  • Page 48 Masking tape can help correct any “dihedral” or “anhedral” (The wing should be perfectly straight) Step 401: Apply Gorilla Glue to the left wing Step 406: Insure both wings are square to spar and dowel holes the fuselage and set aside to cure. Install Mount motor, tank and gear You’ll need :Wing / Fuse assemblies, screwdrivers engine mounting hardware, push rod ends...
  • Page 49 Step 411: Drill the angled blocks for your Step 416: The front of the plane should look engine mount bolts like this Step 412: step removed Step 417: Install the tank with rubber bands and 1/2” thick latex foam as shown The thickest part of the blocks should go to the FRONT of the motor...
  • Page 50 Four stroke oil line The boundary is 1” can be affixed using a from the fuselage, 1” wire tie clamped from the wing front, 1” between the landing from the spar and is 2- gear and fuselage as 1/2” wide shown Step 421: Mount landing gear using 10-24 Step 426: Measure and mark the hatch...
  • Page 51 50% expo is highly recommended for 3D throws Step 431: Make small slit for the battery Step 436: We recommend 50 degrees each lead to protrude from inside the hatch. way for the elevator. Adjust to your taste. Step 434: Pull the battery lead out and plug Step 438: We recommend 35 degrees of it into the battery to turn the plane “on”...
  • Page 52 Also look for these from TufFlight: The 4D-Lite: Our first ELECTRIC powered kit. Indoor/outdoor super lightweight and durable. Fly an entire 3D airshow in your front yard. One day build time. Fully 3D capable deluxe kit versions available so you supply only your radio RX.