AeroWorks BD-5B ELECTRIC ARF Assembly Manual

BD-5B ELECTRIC ARF

ASSEMBLY MANUAL

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TABLE OF CONTENTS

Page

Aeroworks Contact Information …………………………………………………………........ 3

Introduction …………………………………………………………………………………….. 4

Kit Contents……………………………………………………………………………………... 5

Items needed to complete ……………………………………………………………………… 7

Covering……………..………………………………………………………………………….. 8

Wing Assembly………………………………………………………………….……………… 9

Stab and Elevator Assembly…………………………………………………………………… 17

Rudder, Nose Gear, Servos, and Motor Installation ………………………………………… 21

Radio Installation ……………………………………………………………………………….. 28

Finishing and Preflight Preparation …………………………………………………………… 31

401 Laredo Unit “D”

Aurora, CO 80011

Phone: (303) 366-4205

Fax: (303) 366-4203

Website:

www.aero-works.net

E-mail:

[email protected]

Thank you for choosing the Aeroworks BD-5B Electric ARF. We put great effort into

making this plane the best model you will ever build and fly. We provide you with the

highest quality and performance possible. We wish you great success in the assembly and

flying of your new Aeroworks BD-5B Electric ARF.

WARNING

An R/C aircraft is not a toy! If misused, it can cause serious bodily harm and property

damage. Fly only in open areas, and AMA (Academy of Model Aeronautics) approved

flying sites. Follow all instructions included with your plane, radio, and motor.

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INTRODUCTION

Your new BD-5B Electric ARF is a highly maneuverable electric powered sport airplane. It is

capable of gentle and stable slow flight to full out jet like sport flying. We hope you enjoy building and

flying your BD-5B. This aircraft builds easily, quickly, and accurately due to the CAD design and

LASER cutting technology. The wing, stab and fuse are pre-assembled and covered requiring only a

minimum amount of gluing or drilling.

The BD-5B Electric ARF can be transported completely assembled. This totally eliminates

assembly time when you get to the flying field. The battery installs easily with Velcro to get you into the

air quickly to enjoy high performance jet like sport flying.

A Himax 2815 brushless motor is shown in the assembly instructions. The aircraft was tested with

this motor, a 3 cell 2000mah LiPoly battery, and a Castle Creation 25amp speed control. These

components provided excellent performance. The final choice of motor, battery, and speed control is left

up to the builder. A minimum four channels in the radio are required to allow the pilot to take full

advantage of the capabilities of this aerobatic aircraft.

Before starting the assembly of your new BD-5B, please inventory and inspect all parts and

hardware for imperfections or damage. Notify AEROWORKS immediately if there are missing or

damaged parts.

IMPORTANT! Please read through the assembly manual carefully before starting assembly.

Follow the order of assembly in the manual. This will help save time and eliminate any chances of

building errors.

INTENDED USE

This plane should not be regarded as a toy. This is high performance plane and is recommended for pilots

who are beyond the trainer-stage and are comfortable with flying a high performance sport plane.

WARRANTY

It is important to notify Aeroworks of any damage or problems with the model within 30 days of

receiving your plane to be covered under warranty. If you wish to return this aircraft for any reason a 15%

restock fee will be charged to the customer. In addition the customer is responsible for all return shipping

cost and all prior shipping cost will not be refunded. Parts will be exchanged or replaced once the original

item is returned at the owner’s expense. If you have any problems, please contact Aeroworks.

Aeroworks cannot ensure the skill of the modeler and cannot influence the builder during the

construction or use of this aircraft. Therefore, Aeroworks will not be accountable for any property

damage, bodily injury, or death caused by this aircraft.

The purchaser/operator accepts all responsibility of any and all structural or

mechanical failures.

KIT CONTENTS

BD-5B Electric ARF Parts List

1. Left Wing assembled and covered

• Aileron in place with CA hinges not glued

• Torque rods and nylon control horn installed

• Wing bolt holes pre-drilled

2. Right Wing assembled and covered

• Aileron in place with CA hinges not glued

• Torque rods and nylon control horn installed

• Wing bolt holes pre-drilled

3. Horizontal Stabilizer and Elevator covered

• Elevator in place with CA hinges not glued

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• Control horn holes pre-drilled

4. Fuselage assembled and covered

• Canopy installed

• Nose gear mount installed

• Wing mounting blind nuts installed

• Rudder in place and hinges not glued

• Rudder pushrod installed connected to rudder

• Elevator pushrod installed with nylon keeper

• Motor hatch installed

• Battery hold down Velcro strap installed

• Plastic belly pan

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5. Landing gear parts

• Main landing gear painted and pre-drilled

• 2 main wheels

• 2 axle bolts with 2 nuts and 2 lock nuts

• 2 sheet metal mounting screws

• 1 wire nose gear strut

• 1 nose wheel

• 1 nose wheel steering tiller with set screw

• 2 wheel collars

6. Control system parts

• 2 wire aileron pushrods

• 4 pushrod easy links

• 1 nylon elevator control horn

7. Misc. assembly parts

• Plywood dihedral brace

• Plywood aileron servo mount

• Wood wing mounting dowel

• 2 Wing mounting bolts

• White covering patch for rudder linkage hole

• 2 Velcro adhesive patches for battery

• Aluminum spinner kit

8. Decal Sheet

• Self adhesive decals and logos

Items needed to complete:

Hardware:

• Himax 2815 motor with mounting screws

and 18” leads

• 7-5” APC-E propeller

• Castle Creation 25 amp speed control

• Battery – 3 cell 1500-2000mah Li-Poly for

motor and receiver

• 4 Ch receiver, feather or micro size

• 1 x aileron mini servo – Recommend Hitec

HS-55

• 1 x rudder mini servo – Recommend Hitec

HS-55

• 1 x elevator mini servo – Recommend Hitec

HS-55

• 1 x 6” servo extension

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Tools:

• Modeling knife

• Electric drill and selection of bits

• Phillips screwdriver

• Needle nose pliers

• Allen wrenches US and Metric.

• Scissors

• Tweezers

• Wire Cutters

• T pins

• Medium sandpaper

• Ruler and tape measure

• Pen, pencil or felt tipped marker

• Rubbing alcohol

• Paper towels

• Masking tape

• Waxed paper

• Hobby iron

• Hobby heat gun

Adhesives:

• 15-30 Minute epoxy

• Thin CA

• CA kicker (optional)

• Blue Lock Tite (optional)

• Epoxy mixing cups, sticks

• Double sided foam mounting tape

COVERING

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1. Open your kit slowly and take care not to damage

any parts of the kit. Remove all parts from their

plastic protective covers for inspection. Before

doing any assembly or installation of any decals

it is very important to re-shrink or re-tighten the

factory applied covering. Due to shipping, heat

and humidity changes from different climates,

the covering may become lose and wrinkle in the

sun. If you take the time to re-tighten the

covering, you will be rewarded with a long

lasting beautifully covered model.

2. Using your covering iron with a soft sock, gently

apply pressure and rub in the covering. If any

bubbles occur, your iron may be to hot. Reduce

heat and work slowly. If bubbles persist, use a

small pin to punch holes in the bubble to relieve

trapped air and reheat.

3.

Warning! If you use a heat gun, do so with

extreme caution. Take care not to apply too

much heat to any area for long periods of time.

This may cause the trim colors to over shrink and

pull away leaving unsightly gaps on the color

lines. The red and blue lines are especially

vulnerable to over heating and over shrinking.

WING ASSEMBLY

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1. Gather the left wing, right wing, wing dowel,

plywood dihedral brace, plywood aileron servo

mount parts, thin CA, epoxy for the following

steps.

2. Remove the aileron from the wing. Remove each

CA hinge and push a T-pin through the center of

each CA hinge. Reinstall each hinge in the

trailing edge of the wing and push the hinge half

way in so the T-pin is flush against the trailing

edge. Use a toothpick to place a small amount of

15 minute epoxy in the aileron torque rod hole.

Then reinstall the aileron onto the CA hinges and

aileron torque rod. Press the aileron against the

trailing edge of the wing and the T-pins as shown

below. Remove any excess epoxy with alcohol

wipes.

3. Remove the T-pins. Allow enough hinge gap to

ensure maximum control throws. Next, place 3-4

drops of thin CA on each side of all hinges. Do

not over soak the CA hinges. Glue may run out

and cause binding. Repeat for other wing panel.

4. Prepare to epoxy the wing halves together.

Assemble all needed items prior to mixing epoxy.

Dihedral brace, wing dowel, masking tape,

wipes, alcohol, mixing stick, application brush,

wax paper, and epoxy. Use 15-30 min epoxy to

allow adequate working and clean up time.

5. Mix epoxy in a mixing cup. Use mixing stick to

apply epoxy into the dihedral brace slots in each

wing panel and on the plywood dihedral brace.

Brush epoxy on each root rib on each wing panel.

Scrape away excess epoxy with the mixing stick.

Insert the dihedral brace into one wing and slide

the other wing on the dihedral brace. Press the

root ribs together. Wipe off excess epoxy. Use

masking tape to hold the wing panels tightly

together until epoxy cures. Use alcohol wipes to

wipe any excess epoxy, smears, or finger prints

from the covering material before it cures.

6. After epoxy is fully cured remove masking tape.

Center the aileron servo mount over the pre-cut

servo hole. Trace around the edge with a felt tip

pen or pencil.

7. Remove the aileron servo mount and lightly cut

thru the covering material inside the lines. Do

not cut into the underlying balsa wood.

8. Carefully remove the covering material exposing

the balsa skin for proper gluing.

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9. Wipe away the ink tracing and then epoxy the

aileron servo mount in place centered over the

aileron servo cut out. The aileron servo mount

should be flat across the wing center joint to

provide a flat surface for mounting the aileron

servo. The epoxy should fill the small gap

between the servo mount and center joint of the

wing halves.

10. Attach two easy links to the aileron servo arm as

shown. Use a 2mm or 5/64 bit to drill out the

servo arm holes if necessary. Do not over tighten

the nut. The easy link must rotate freely in the

servo arm. Secure the nut with Lock Tite or a

small drop of CA glue.

11. Install the servo in the center of the aileron servo

mount with the servo output arm facing the

trailing edge. Mark the location of the servo

mounting holes.

12. Use a 1/16 bit to drill the servo mounting holes.

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13. Before installing the servo, install both aileron

pushrods into the nylon aileron control horns as

shown.

14. Next, insert both aileron pushrods into the easy

links and then slide the aileron servo into the

aileron servo mount.

15. Mount the aileron servo using servo mounting

screws

16. Tape the trailing edge of each aileron to the

trailing edge of the wing. Rotate the aileron

servo output arm parallel to the trailing edge of

the wing. Then carefully tighten the easy link set

screw against the wire pushrod on each side to

ensure the ailerons are centered when the servo

arm is at the centered position. Remove the tape

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17. Use wire cutters to cut off the excess aileron

pushrod wire. Leave approximately 1/4" to 3/8”

extended out of the easy link for any future

adjustments.

18. Aileron servo installation is now complete.

19. Gather the main landing gear parts as shown

below. Note that each axle bolt has a regular nut

and a nylon lock nut.

20. Insert the axle bolt through the wheel and screw

the regular nut on the bolt all the way against the

wheel. Do not over tighten against the wheel.

The wheel must turn freely but without excess

play or wobble.

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21. Insert the axle bolt through the main landing gear

strut and screw the nylon lock nut tightly against

the main landing gear strut. Keep the axle bolt

from turning with a Phillips head screwdriver.

Check that the wheel freely rotates without

excess play or wobble. Adjust bolt and nuts as

necessary.

22. Main landing gear assembly is now complete.

Locate the self-tapping screws for mounting to

the wing.

23. Place a drop of thin CA into the predrilled

landing gear mounting holes to harden the wood

mount.

24. Mount the landing gear to the bottom of the wing

using two self-tapping screws. Do not over

tighten and strip the threads in the plywood wing

mounts.

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25. Center the plastic belly pan in position over the

wing dowel and trace a dowel relief cut out on

the front of the belly pan.

26. Use scissors or modeling knife to cut the dowel

relief out of the plastic belly pan.

27. Trial fit the belly pan on the bottom of the wing

and make sure there is no interference from the

wing dowel to the belly pan.

28. Install the wing to the fuse with both wing bolts.

Align the belly pan to the fuse. Use a pencil to

lightly trace the outline of the belly pan on the

bottom of the wing.

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29. Remove the belly pan and scuff the edges where

it contacts the bottom of the wing with a small

piece of medium sandpaper. Clean the edges

with alcohol to allow good CA glue adhesion.

30. Use a small piece of medium sand paper to scuff

the surface of the covering material just inside

the line where the edges of the belly pan will

contact the bottom of the wing. Clean the area

with alcohol to give a good CA glue bond.

31. Align the belly pan on the wing along the pencil

lines and tack glue in place at each corner with

thin CA.

32. Press the edges of the belly pan to contact the

bottom of the wing and glue in place with thin

CA glue. Do not use excess glue to avoid runs

and drips of glue on the wing and belly pan.

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The wing assembly is now complete.

STAB AND ELEVATOR

ASSEMBLY

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1. Remove the elevator from the stab. Remove

each CA hinge and push a T-pin through the

center of each CA hinge. Reinstall each hinge in

the trailing edge of the stab and push the hinge

half way in so the T-pin is flush against the

trailing edge. Then reinstall the elevator onto the

CA hinges. Press the elevator against the trailing

edge of the stab and the T-pins as shown below.

2. Remove the T-pins. Allow enough hinge gap to

ensure maximum control throws. Next, place 3-4

drops of thin CA on each side of all hinges. Do

not over soak the CA hinges. Glue may run out

and cause binding.

3. Insert the nylon elevator control horn into bottom

of the elevator through the predrilled holes in the

elevator. Make sure holes in the control horn are

facing forward toward the trailing edge of the

stab. Lightly trace around the base of the

elevator control horn with a pencil.

4. Remove the elevator control horn. Use a T-pin to

punch small holes through the covering material

under the base of the control horn on the bottom

of the elevator. Clean the area with alcohol.

This will allow the CA glue to penetrate and

bond the control horn to the wood.

5. Use a small piece of medium sand paper to scuff

the bottom of the elevator control horn as shown.

Clean the bottom surface with alcohol for a good

CA glue bond.

6. Reinstall the elevator control horn to the bottom

of the elevator. Glue in place with thin CA

around the base. Allow the CA to wick under the

control horn but do not allow excess CA to run

out and bond to the covering material.

7. After the CA has cured, use wire cutters to clip

the prongs flush with the top of the elevator

surface. Apply a drop of thin CA to each prong

to bond the control horn to the top of the elevator

surface.

8. Reinstall the stab in the fuse slot and push fully

forward with the elevator horn on the bottom

right side. Install the wing with the wing bolts in

place. Measure from the trailing edge wing tip to

the trailing edge stab tip on both left and right

sides. Make sure both sides are equal

measurements.

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9. Lightly trace the outline of the fuse on the top

and bottom of the stab with a pencil or felt tip

pen. Use care not to move the stab while tracing

the outline.

10. Remove the stab and use a T-pin to punch several

holes through the covering material inside the

fuse outline lines where the fuse sides will

contact the stab surface. Punch holes on the top

and bottom of the stab to allow the CA glue to

penetrate to the wood beneath the covering.

11. Use a small piece of medium sand paper to scuff

the surface of the covering material just inside

the line where the edges of the fuse will contact

the surface of the stab. Clean the area with

alcohol to remove the ink lines and give good CA

glue adhesion.

12. Reinstall the stab pushed fully forward, aligned

with the lines, and with the elevator control horn

on the bottom right side. Re-measure from the

trailing edge wing tip to the trailing edge stab tip

on both left and right sides. Make sure both sides

are equal measurements. Glue stab in place

using thin CA glue. Use care not to move the

stab during gluing. Allow glue to wick in under

the fuse joint. Use care to not allow excess CA

to run out and cure on the covering material.

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13. Install the wire elevator pushrod into the control

horn and attach the nylon pushrod keeper as

shown.

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The stab and elevator installation is now complete.

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AeroWorks BD-5B ELECTRIC ARF Assembly Manual

AeroWorks BD-5B ELECTRIC ARF Assembly Manual

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