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Last Updated: January 10, 2008 - 09:28:40 PM |
The Wemotec F-16C Fighting Falcon kit as shown with major assenblies fitted
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The model comes well packed from the manufaturer
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Parts are shown that come with the kit
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The two halves of the intake tube are made from carbon fiber
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The fuselage and wings are molded as one piece, keeping the assembly lightweight
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Side view of the scale shape of the fuselage
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Front view shown
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Rear view of pre-installed formers
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Bag of hardware is shown that is included with the kit
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The HW 620 86mm custom Midifan from Wemotec is included in the kit
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Contents of the fan assembly are shown
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The fan housing is molded from carbon fiber to keep it light weight and strong
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Shown are the basic parts from the fan kit that are required to assemble it for this model
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Construction begins with the power plant assembly. Install the shaft adapter for the fan over your motor shaft
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Apply Loktite to the shaft adapter set screw and install it in the adapter
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Make sure there is enough clearance on the adapter so the fan does not rub on the housing. A good starting point is shown.
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Install plugs if you wish on the motor wires
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Install sockets on your ESC to match the motor
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Plugs are also installe don the power wires for the ESC. This allows you to interchange motors and ESC's if necessary
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Loktite is applied to the motor threads only!!! Do Not apply blue Loktite to the screws as it will touch the housing and can disolve the housing plastic. Clean up any excess Loktite
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Install the motor in the housing
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Install the retaining screws in the motor to mount it to the housing
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Insure the motor is centered in the assembly
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Use a tool to balance your fan assmebly. Small pieces of electrical tape can be placed inside the fan outer hub and CA'ed in place to adjust balance
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Install the fan rotor on the shaft adapter
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Install the supplied washer, then the aluminum nut
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A slot can be cut into the shaft to allow for tightening. Be sure to cover the motor anf fan with a cloth so metal dust from cutting doesn't contaminate the assembly
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Use a screwdriver to hold the shaft in the slot you cut, then tighten the nut with a wrench
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Install the hub if desired and tighten with the supplied screw
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Sand the outer lips of both halves of the carbon fiber intake duct
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Halves are shown preped and ready to be glued
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Apply a piece of masking tape that was made 3 layers thick along the lenth of the seam
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Install the second half, using th masking to hold it in place
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Apply epoxy with a small brush along the seam lip
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Clamp the assembly until the eopxy sets
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Remove the clamps once the epoxy sets
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Remove the tape from the inside of the duct
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Repeat the procedure for the other side, applying a 3-layered tape strip tot he inside, then epoxy along the seam
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Clamp the second half and allow the epoxy to set
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Remove the clamps and tape
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The tape prevents overspill of epoxy in the inside of the intake
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Use a dremel and cutting wheel to remove most of the lip
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Remove the lip from the other side
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Cut off as much of the lip as you can
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Sand the remaining area until it si nearly flush
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Prepare a 2" strip of 5oz fiberglass cloth by soaking it in resin
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Apply the cloth along the seam, then remove all excess and allow it to set
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Apply a second strip to the other seam along the bottom
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Trim the rear of the Intake Cover as shown
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Trim the top of the cover along the molding lines
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Remove the trimmed fiberglass and sand
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Install the fiberglass intake on the fuselage and check for fit, then trim as necessary
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Use tape to hold the intake in position
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Use a pencil to transfer the inside pattern of the fuselage to the top of the intake
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Pattern is now drawn on the intake
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Outline the pattern in marker so it is easier to see
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Use a Drenel and cutting wheel to rought cut the marked area
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Remove the center piece
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Sand the edges to a smooth finish, then remove marks with alcohol and a paper towel
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Install the carbon fiber intake duct in the fuselage
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Check for fit at the rear former
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Install the intake cover and make sure it does not bind on the duct
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Check the fit of the cover
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Make sure the edge of the inner carbon fiber duct is flush against the bottom inside ridge of the fiberglass intake cover
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Make a mark on the bottom of the cover 100mm from the front
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Make a 1/16" ply plate 40mm x 40mm and an inside 1/16" plate 30mm x 40mm. Note the grain orientation...this is important
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Epoxy the two halves together, making sure the inner place is centered
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Use a punch to make a mark for drilling at the 100mm line you drew earlier
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Drill the hole with a 5/64" bit
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Rough up the inside area for the towkhook plate with some 60 grit sandpaper
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Make a towhook as shown using 2-56 steel rod
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Mark a drill hole with a punch centered on the two ply pieces and 10mm from the front edge
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Drill the hole for the towhook
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Use a dremel to slightly slot the area for the towhook. Cut about 1/32" deep, just enough to prevent the hook from twisting
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Clean up the slot with a knife
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Use coarse sandpaper to rough up the hook on the short side
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Insert the hook in the ply
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Use epoxy to glue the hook in place
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Slightly taper the outside edges to the contour of the intake, then apply epoxy as shown
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Install the towhook through the hole in the intake and allow the epoxy to set. Note the orientation of the plate with the 10mm of spacing at the front
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Use a pair of pliers to bend the hook into shape
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Mark the hook to a length of 3/4" and remove the excess. Round the end with sandpaper
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Check the clearance of your towhook ring, then set the assembly aside
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Use a dremel to cut out the notches in the tail area of the fuselage
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A file and sandpaper can be used to smooth the area
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A saw can also be used to cut and remove the excess fiberglass
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Use a small saw to cuth the Tail Brake pieces in half
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Sand and round the edges
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Use a drill to open up the holes for the tailerons on both sides
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Custom cut the tail of the brake so it fits arouns the taileron shaft, then apply epoxy to the area
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Apply epoxy to the shaft lip and install flush to the fuselage
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Make sure it is recessed completely and even with the outside.
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Custom fit the second brake assembly
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Apply epoxy to the hole and brake, then glue it in place
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Tape the piece to hold it straight until the glue cures
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Install a Taileron, then mark a cut line with a saw
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Remove just enough of the shaft so there is enoguh for the wheel collar to hold
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Sand the end and remove all ridges
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Install the taileron and wheel collar, then mark the outer locations of the wheel collar on the fuselage with masking tape
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Use a file to notch the area, so the collar is far enough away from the exhaust area so it doesn't rub
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Fine sand the area
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Install the supplied washer
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Install the Wheel collar, holding the taileron to the fuselage side. Remove and sand the shaft until it is flush with the inner part of the collar
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Final fitting completed, you will have space between the collar and Exhaust nozzle
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Notch the other taileron shaft
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Shorten the shaft the same as the first
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Make sure to remove any ridges on the inside of the taileron
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Sand the shaft and round the end at the edges
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Install the taileron and wheel collar, then use masking to mark the outer sides of the collar
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Once again, use a file to notch the wheel collar area. It should be wide enough to allow the wheel collar to turn without binding.
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Install the second washer
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Install the wheel collar over the shaft and tighten
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Taileron mounting completed
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Drill three holes for the motor to ESC wires as shown
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Solder ends to the 12ga wires that will plug into the motor
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A piece of 1/64" ply is cut 3/4" wide to make an airfoil for the wires
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The ply is inserted into the heat shrink and just fits
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Solder plugs for the ESC side to the wires
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Slide the airfoil over the wires as shown
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Run the wires through the Carbon fiber motor cover that was supplied with the motor assembly
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Slide pieces of heat shrink over the motor wires
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Install the wires on the motor connectors
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Slide the heatshrink in position, then use a heat gun to shrink the tubing in place
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Apply some thick CA to the lip of the motor cover
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Install the cover in the motor housing
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1/2" tape is applied to the rear of the motor housing to build up the area around the former
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Remove the outer spacer tape
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An Exhaust Duct is made from clear mylar
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Temporarily tape up the motor wires and run them down through the fan so they are out of the wya, then shape the duct
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Tape the Nozzle flush to the rear of the fuselage. Make sure the mylar duct fits well to the rear of the Exhaust Nozzle
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Trim away any excess material with a razor
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Duct should be flush to the rear and note that the wheel collars should clear the nozzle
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Use 1" strips of packing tape to seal up the inside of the duct
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Tape the outside of the duct as well with a 1" wide strip
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Measure the distance from the end of the fuselage to the rear of the motor cover
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Make amark on the duct at this distance. Note you will cut rearward from this mark for the airfoil to exit
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Make a small plate from 1/64" ply for the airfoil as shown
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Mark the area with tape, then cut the airfoil at the thick side of the duct, where it overlapped. Glue the plate in place with CA or epoxy, then another piece of 2" wide packing tape can be used to seal the plate to the duct
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The airfoil was removed and the bottom was tapered rearward to the andgle of the tapered mylar exhaust duct
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Install the airfoil, then run the wires through the duct
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Test fit the assembly and adjust as necessary. Shown is a fitted and assembled tail section
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Solder to 4mm sockets to the battery wires for the ESC
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Plug the wires into the ESC
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Use heat shrink to hold the wires in place and prevent them from coming loose
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Solder a Deans Ultra plug to the other end for your battery, or use any other plug that you use for your power needs
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Make an airfoil from hardwood about 3/16" thick and 3/4" wide. An old piece of wooden Helicopter tail rotor blade was used and cut to shape as shown. It already had a good airfoil shape to start and was long enough to act as a spacer for the intake duct. CAREFULLY drill a hole straight through the center length of the airfoil with a 5/64" bit
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Drill a hole about 3/8" - 1/2" from the front lip of the intake duct
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Position the duct, then drill a mark on the other side, using the airfoil as a guide , which will hlp you keep it visually centered. Sand the length of the airfoil spacer so it matches the contour of the intake duct and fits flush ont he top and bottom. it shoudl also fit without deforming the shape/opening of the intake
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