AirfoilZ YAK 54 Assembly Manual

Full fuselage

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Specifications

Wing Span: 40 inches

Wing Area: 350 in

Fuselage Length: 35.5 inches

Weight (ready to fly): 19 to 23 oz.

Wing Loading: 7.8 to 9.5 oz/ft

YAK 54 - Full Fuselage

Assembly Manual

Version 1.0 – 3/24/08

Table of Contents

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Summary of Contents for AirfoilZ YAK 54

Page 1 YAK 54 - Full Fuselage Assembly Manual Specifications Wing Span: 40 inches Wing Area: 350 in Fuselage Length: 35.5 inches Weight (ready to fly): 19 to 23 oz. Wing Loading: 7.8 to 9.5 oz/ft Designed by Jim Vigani Version 1.0 – 3/24/08...
Page 2 © Copyright 2008 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 the YAK 54 airplane. 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 YAK 54 kit is 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.
Page 6: Fuselage Assembly
Depron foam. Graphics: The YAK 54 comes with printed vinyl graphics. Extra care in cutting out and applying the vinyl panels will result in a painted look for your plane. Some people prefer to lightly mist the surface with “Frebreze” before applying the vinyl. This allows the vinyl to be repositioned while applying them.
Page 8 Step 1 Glue wing root doubler in place with foam safe being careful to ensure the wing openings are in perfect alignment. Tip: Apply CA to the doubler, carefully position on the skin, then lightly spray kicker along the edges of the doubler.
Page 9 Step 3 Glue the lower rear doubler in place with foam safe CA. NOTE: The lower rear doubler needs to be positioned 3 mm from the edge of the skin. An alignment tab is provided at the rear of the part to ensure proper alignment.
Page 11 Step 6 Trim off the top front doubler alignment tab flush with the upper rear doubler. Repeat Steps 1 to 3 for the other skin assembly making sure to make a LEFT and a RIGHT side version! Step 7 Dry assemble all the plywood crutch pieces and check for fit.
Page 12 Step 8 Glue the plywood crutch parts and landing gear mount parts together with medium CA. Insert foam formers and glue in place with medium foam safe CA. TIP: tack glue the plywood pieces in place with thin CA then re-glue with medium CA.
Page 13 Glue the landing gear wire support in place with medium CA making sure that the holes in the landing gear mount align with the opening in the landing gear wire support. Glue the landing gear wire torsion support in place with medium CA making sure the slot in the support aligns with the hole in the landing...
Page 15 Step 9 Test fit the rudder servo in the crutch. Trim the opening as necessary to match the servo. Step 10 Test fit the skins on the crutch and check that the slot in the rear of the skin mates with alignment tab on the rear of the crutch.
Page 16 Step 11 Glue the crutch to one skin assembly from the nose to just behind the wing opening with medium foam safe CA. After the glue has set, glue the skin to the lower crutch member from the wing opening to the rear tab, making sure the rear alignment tab is properly seated in...
Page 17 Step 13 Epoxy the motor mount in place making sure it is flush and square with the motor mount support. TIP: Mark the motor mounting hole locations before gluing the motor mount in place. Step 14 Test fit the turtle deck filler piece and glue in place with medium foam safe CA.
Page 18 Step 15 Test fit the canopy filler piece and glue in place with medium foam safe CA. Step 16 Glue the top cowl skin in place with medium foam safe CA. Tip: Before gluing, lightly score the backside of the top skin with an old ballpoint pen to allow the foam to be bent around the nose without...
Page 20 Step 18 Glue the bottom cowl skin in place with medium foam safe CA. Tip: Before gluing, lightly score the backside of the bottom skin with an old ballpoint pen to allow the foam to be bent around the nose without cracking.
Page 21 Step 20 Cut a 2” piece off the front of the fuselage lower skin. Save the piece. This front piece will be glued in place after the rudder pull-pull system has been installed. Step 21 Glue the lower fuselage skin in position with medium foam safe CA.
Page 23: Wing Assembly And Installation
Wing Assembly and Installation Assembling the Spar: Step 24 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 2008 all rights reserved...
Page 24 Step 25 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 2008 all rights reserved...
Page 25 Step 26 Place a mark 2 ” behind the leading edge at each wing tip. Place another mark 3 ” behind the leading edge each wing root. Step 27 Glue the 3 mm foam wing alignment tabs in place on the left wing using foam safe CA staying sufficiently away from the spar location mark to...
Page 26 Step 28 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 29 Repeat for the other wing making sure to align the root...
Page 27 Step 30 Push the wing center joint together making sure the wing root airfoil profile both wings match at the center. Step 31 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.
Page 28 Step 32 Trim and sand the wing tip to final shape. Step 33 Cut a ½” diameter hole in the lower wing skin along the wing centerline, just behind the spar for use as an exit for the servo leads. Wing/Fuselage Assembly: ©...
Page 29 Step 34 Test fit the wing in the fuselage. FORCE! If the fit is tight, sand fuselage opening to fit. Make sure the wing is centered on, square fuselage. With the wing properly aligned, tack glue it in place with medium foam safe CA.
Page 30 Step 36 Using the end of the 3/16” diameter carbon elevator joiner, gently create a shallow grove in the elevator joiner cutout. Step 37 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.
Page 31 Step 38 Cut out the foam bridge behind the wood joiner, between the elevator halves. Installing the Horizontal Stabilizer Spar: Step 39 Glue the ¼”x¼” balsa horizontal stabilizer spar to the rear of the horizontal stabilizer Assembling and Installing the Horizontal Stabilizer and Elevator: ©...
Page 32 Step 40 Using sanding block, bevel leading edge of the elevator as shown to allow for movement of elevator when hinged. Step 41 Temporarily secure the elevator to the stabilizer with tape. Mark the position of the elevator hinges with strips of ”...
Page 33 Step 42 Cut the tape along the hinge line and remove the elevator. Step 43 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 34 Step 44 Test fit the stabilizer in fuselage check that fits square to the fuselage and wing. Glue the stabilizer in place with medium foam safe CA. Epoxy the hinges in place Step 45 Trim the tail post at rear horizontal stab slot.
Page 35: Rudder Installation
Step 46 Install the elevator and epoxy the the hinges in place. Rudder Installation: Step 47 Bevel the leading edge of the rudder and install using the same method as with the other control surfaces. Use 3 hinges. Remember leave approximately ”...
Page 36 Step 48 Using the sanding block, bevel the leading edge of the ailerons as shown to allow for movement of the ailerons when hinged. Step 49 Temporarily secure the ailerons to the wing with tape. Mark the position of the aileron hinges with strips ”...
Page 37 Step 50 Cut the tape along the hinge line and remove the ailerons. Using your Exacto knife, carefully slit along centerline of both the aileron wing trailing edge each hinge location and glue the hinges in place NOTE: that the wing has a glue seam along the centerline of the trailing edge.
Page 38 Step 52 Test fit the servos in the holes. Mark the location plywood servo mounts and remove the servos. Glue the servo mounts in place with foam safe CA. Drill a 1/32 inch diameter pilot hole in the servo mounts each servo mounting lug location.
Page 40 Step 54 Mark the location of the control horns on the control surface and cut a slit in the control surface with an Exacto knife accept control horn mounting tab. © Copyright 2008 all rights reserved...
Page 42: Landing Gear Installation
Landing Gear Installation: Step 56 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. Lightly sand the axel washer ensure good bonding of the solder.
Page 43 Step 57 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 44 Step 58 landing gear wires into the slots in the landing gear mount. Tip: Round the corners of the slots so that the wires fit flush to the mount surface. Step 59 Secure the landing gear mount cover in place with screws provided.
Page 45 Step 60 Tie the wire tailskid to the plywood mount with unwaxed dental floss or thin wire. Secure with CA. Attach the plywood tailskid mount to the rear fuselage using foam safe CA or epoxy. Motor, ESC, Servo, Receiver and Battery installation: Aileron Servo Installation: Step 61 Secure the wing servos...
Page 46 Step 62 Route the aileron servo leads through the interior of the wing, and out through the exit hole. Step 63 Install the 2-56 threaded rod aileron push rods, securing at both ends with the nylon clevises provided. Bend the rod as appropriate to maintain torsion free geometry.
Page 47 Elevator Servo Installation: Step 64 Securely glue elevator servo mounts in place with medium foam safe CA. Step 65 Install elevator servo servo mounts outside fuselage. Pre-drill the screw holes with 1/32” drill before installing the screws. Do not over-tighten the screws strip the screw holes.
Page 48 Step 66 Install the 2-56 threaded elevator push securing at both ends with the nylon clevises provided. Bend the rod appropriate maintain torsion free geometry. Rudder Pull-Pull System Installation: Step 67 Cut 1/8” wide exit slots for the pull-pull rudder control wire in the fuselage sides ©...
Page 49 Step 68 Secure the rudder pull-pull cord on the rudder servo control horn using provided metal sleeves. TIP: Slip the control line through the tubing, then through the control horn, and back through the tube. Squeeze tube with some pliers to flatten it, and then add a drop of thin CA at the end of the tube away from the control horn.
Page 50 Step 69 Install the rudder servo and route pull-pull wire through the slots in the fuselage. Step 70 Connect the pull-pull wires to the eyebolts provided and secure to the rudder control horn using clevises provided. © Copyright 2008 all rights reserved...
Page 51 Step 71 Install the 2” section of the fuse bottom that trimmed off in Step 20. TIP: An access hole can be cut for access to the servo horn if desired. Step 72 Mount the motor using #2 wood screws washers.
Page 53 Step 75 Mount the battery with Velcro strips inside the fuselage as shown. Loop a Velcro strap through the slots in the lower crutch to secure the battery in place. Step 75a Velcro strips inside the fuselage on the bottom crutch.
Page 55: Preflight Checklist
Step 77 Fit the hatch in place and secure with the retention tabs. Trim as necessary clear fuselage crutch bottom support. Pre-flight checklist Balancing: We recommend that you perform initial flights with the CG 3¾ to 4 inches behind the leading edge at the wing root.
Page 56 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 the wing. Avoid loose or dangling wires. For 72 MHz systems, we recommend the use of a micro antenna such as the Azarr, or the Berg Peel &...

AirfoilZ YAK 54 Assembly Manual

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Related Manuals for AirfoilZ YAK 54

Summary of Contents for AirfoilZ YAK 54

Page 3: Recommended Power System

Page 4: Kit Contents

Page 6: Fuselage Assembly

Page 23: Wing Assembly And Installation

Page 35: Rudder Installation

Page 42: Landing Gear Installation

Page 55: Preflight Checklist