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TufFlight Big Bouncer Assembly Instruction Manual

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BIG Bouncer
55"
Wingspan:
58"
Length:
831 sq in
Wing Area:
Flying Weight: 4.5 lbs
Hello, and thanks for buying the Big Bouncer! Whether you've just entered the exciting world of radio control and
3D flying, or you're a seasoned veteran, the Bouncer is the perfect combination of agility, durability, versatility and value
for the schoolyard, park or front yard 3D flyer.
Caution: The Bouncer can be a very agile performer, and requires care in setup and operation. Please obey
manufacturer's safety rules for your motor, propeller and battery. Lithium polymer (lipo) batteries are ideal for
this plane. Charge lipo batteries ONLY with a lithium capable charger according to battery instructions.
While you may be tempted to fly close to yourself, please practice in a safe manner.
Please read and understand the instructions before starting to build. We recommend joining the AMA and
following 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 Parts:
(1) right/left EPP wing cores in shucks
(2) EPP tail feathers sheets in shucks with wings
(1) EPP front fuselage piece
(1) EPP rear fuselage piece
Misc:
(2) 0.038" control horn clear plastic sheet
(1) 0.005" 1" x 8" clear mylar rudder hinge
(1) 0.003" 3" clear mylar hinge material
(1) 1/32" x 1/2" G10 strip
(1) 1/32" x 12" G10 sheet
(1) 1/16" G10 sheet
(1) 3/8" white plastic motor mount sheet
(2) 1/16" x 3/4" fiberglass LG struts
(6) 1/16" x 72" fiberglass rod
(1) 0.188" x 18.5" carbon tube
(2) 1/4" x 3.75" fiberglass rod
(2) 1/8" x 1-3/8" fiberglass rod
Rev 1.0
5376 Amalfi Drive,
The Toughest R/C Planes Ever!
Motor:
Radio:
Servos:
Excellent 3D capability -plus- Outstanding Durability
The CG location is 6-3/4" from the wing leading edge at the root.
Clay, NY 13041
~800 W
4 channels
4 HS 65 or equivalent aileron
2 HS 85 or equivalent elevator
1 HS 225 or equivalent rudder
Hardware:
(4) Dubro mini EZ connectors
(3) Dubro 2-56 x 12" threaded rod
(3) Dubro 2-56 nylon clevis
(2) main wheels
(1) tailwheel
(8) 4-40 x 5/16" nylon bolts
(2) 6-32 x 3/8" nylon bolts
(2) 6-32 x 1-1/4" steel bolts
(6) 6-32 nuts
(1) 0.039" x 18" wire
(1) 1/16" x 7" wire
(2) zip ties
(8) O-rings #017
(2) Velcro strap
(4) #64 rubber bands
Template / Plans Packet
This Instruction Manual
www.tufflight.com
Page 1

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Summary of Contents for TufFlight Big Bouncer

  • Page 1 Excellent 3D capability -plus- Outstanding Durability Hello, and thanks for buying the Big Bouncer! Whether you’ve just entered the exciting world of radio control and 3D flying, or you’re a seasoned veteran, the Bouncer is the perfect combination of agility, durability, versatility and value for the schoolyard, park or front yard 3D flyer.
  • Page 2: Items Needed To Complete

    We welcome any feedback you may have on this or ruler/straight edge other TufFlight products. metal file scissors, heavy duty and tin snips Please feel free to contact us: clamps scrap wood...
  • Page 3 Assemble Wings You’ll need : Foam wing pieces, mylar hinge sheet, medium and thin CA, kicker, hobby knife, scissors, razor blade, ruler, cutting board, scrap wood, scrap EPP / 40 grit sanding block Step 1: Gather parts and tools. Step 6: Ailerons should be identical DON”T DISCARD the sheets in the...
  • Page 4 A weight or ruler helps to keep the hinge/foam joint together Step 11: Glue razor blade to scrap wood as Step 16: Apply kicker to hinge. shown Work carefully and press all parts to the bench when slicing Step 12: Slice the aileron LE and wing TE with Step 17: Trim hinge at angle as shown to aid tool as shown.
  • Page 5 Assemble Fuselage You’ll need : Foam fuselage pieces, ruler, white gorilla glue or quick grip glue, scrap EPP / 40 grit sanding block, sharp knife, 1/16” fiberglass rods, ruler dremel tool /cutoff wheel, 2 large blocks Step 21: Gather parts and tools. Step 26: Lay fiberglass rod into groove and press down so it’s flush with surface.
  • Page 6 Do for both top and bottom wing surfaces (on both sides of fuselage also) Step 31: With wing LE in position, transfer Step 36: Poke and slice carefully through to wing spar locations to fuselage as shown the other side as shown You’ll use these guides later for alignment of wing...
  • Page 7 The styrofoam packaging from your radio transmitter may work well (At least 6” tall) Step 41: Obtain two identical large blocks Step 46: Work Spars into slots being careful to use as supports during next steps to center them along the span (other half too) Repeat for all wing spars...
  • Page 8 Take care to insure fuse is perpendicular to wing and things look square and symmetrical Step 51: Apply weights while glue cures as Step 56: Drill central 1/2” hole where shown. indicated. Make Motor Mount You’ll need : scissors, white motor mount plastic paper templates, 3M77, drill, motor Step 52: Gather parts and tools.
  • Page 9 Step 61: Deburr corners of holes Step 66: Cut two elevators using the same template. Note wires route on left side of fuselage Step 62: Test fit motor to “H” mount and Step 67:Glue the horizontal stab halves to- adjust holes if needed. gether as shown.
  • Page 10 Step 71: Slice the rear fuselage for the Step 76: Glue the spar into the horizontal hinge also stab as shown Step 72: Bevel the rudder, stab and elevator Step 77: Tape the joint to clamp it while the to allow desired deflection glue dries.
  • Page 11 position elevator horns 1.5” from center as shown Step 81: Cut out the control horn templates Step 86: Select the “bottom” surface and measure location for elevator horns 3M77 is easily removed with mineral spirits Step 82: Apply templates to plastic with Step 87: Slice the foam as shown for the 3M77 horns (cut all the way to the top surface)
  • Page 12 Make and Apply Fuse Reinforcements You’ll need : scissors, thick and thin G10 material paper templates, 3M77, scrap wood white gorilla glue or quick grip, tin snips front fuse/wing assembly, plastic wrap, clamps, sanding block, nylon screws, 1/4” fiberglass rods, CA and kicker Step 91: Place fuse vertical on table and Step 96: Gather parts and tools.
  • Page 13 Step 101: Cut out fuse motor mount/dowel Step 106: Repeat for bottom rod holes paper template as shown. Step 102: Align template to nose and mark Step 107: Glue G10 reinforcements to other hole locations as shown with pen. side as shown. The Motor mount “H”...
  • Page 14 Use plenty of glue for this step See template drawings for guidance Step 111: Apply glue to joiner doublers/ Step 116: Glue assembled joiners to fuse- spacers as shown lage as shown See template drawings for guidance Step 112: Glue joiner doubler/spacers Step 117: Apply wood and clamps so joint together as shown appears as shown...
  • Page 15 A dremel We recommend a tool with 3300mAH 4S lipo drum pack for best sander results. works well after slicing the outline Step 121: Obtain your battery and charge it. Step 126: Slice servo outlines with sharp hobby knife and clear foam to make cavity as shown Plane LEFT BOTTOM side...
  • Page 16 Step 131: Glue both elevator servos together Step 136: Feed the wires through channels as shown slice servo cavity all the way through the fuselage Step 132: Locate and cut elevator servo cavity Step 137: Tuck the wires into channel and tape under stab LE as shown in place as shown Step 133: Extend and route servo wires to...
  • Page 17 Note shape of Elevator and rudder use control horn-- the 2-56 rods and clevises point at the front will inset Clevises go into control perfectly with horn end point of the (z bends give better aileron at the clearance at servo end) hinge line Step 141: Use control horn to mark location Step 146: Install clevis then make Z bend in...
  • Page 18 join sanded sides together Step 151: Laminate LG struts together using Step 156: Assemble LG parts as shown. medium CA as shown Install nylon bolt and nut for main LG pivot. Step 152: Apply LG strut template as shown Step 157: Insert carbon tube to locate support with 3M77 inserts as shown Be careful not to...
  • Page 19 mark both sides of support Step 161: Repeat for other gear assembly Step 166: Use LG assembly to mark location (make left and right gear legs) for supports. Align hole to scribe as shown. Step 162: Mark the wing bottoms 6” from Step 167: With a sharp hobby knife, slice each root edge as shown (left and right) the borders for the LG supports as shown.
  • Page 20 If you reverse the angles of your slices and clear Quick grip shown out the foam, the spar will be more eastily White gorilla glue does trapped in the groove a better job of filling any gaps in the foam (think of reverse but either may be used “pumpkin lid carving)
  • Page 21 Final Assembly Refer to template You’ll need : pen, hobby knife, Dremel tool, ruler, pages for tailwheel “H” motor mount, rubber bands/O rings, bending guide. battery, velcro strap, 4-40 nylon bolts Scrap wood, G10 or plastic (ie credit card thickness, zip ties, scrap 1/16”...
  • Page 22 Step 191: Mount motor to “H” mount with Step 196: Mount secured as shown. Re- bolts, washers and loc tite as shown. peat for all 4 corners of “H” mount. Make 2 slices -- one above, one below Step 192: Insert motor assembly as shown. Step 197: Slice through fuse to poke zip tie around G10 reinforcements as shown.
  • Page 23 Step 201: Mark CG location 6-3/4” from LE Step 206: Slice through fuselage above and at wing root below battery edge locations as shown. Step 202: Place battery on wing top left side Step 207: Insert (two linked) velcro straps and move to balance on the marks.
  • Page 24 Optional Items This helps to give the foam a You’ll need : pen, hobby knife, covering iron, mylar, protective skin to drill, scrap 1/16” rod, resist tearing. quick grip, clear plastic wing root joiner , airbrush, paint, 1/8” drill, socket Step 211: Gather parts and tools.