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Instruction Manual

BD-5 specs: Wingspan= 30 short wing version = 36 long wing version Length= 26.5 Weight=20-22 oz. Wing area=146 sq/in short wing =175 sq/in long wing Wing loading= 20-22 oz/ft2 short wing = 16-18 oz/ft2 long wing

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Wings

Glue one of the cut pieces onto a full sheet. Make four of these.

Mark each wing in while in the block so you can use the marks as guides later on. You will use these marks when you glue on the wing skins. Take the wing cores out of the blocks. Cut inch off the leading edge of each wing.

Make sure you have something to use for weight. Apply 15 minute epoxy generously on 2 wing skins, one for the top and one for the bottom. Make sure you make a top and a bottom skin. Place the bottom skin in the bottom of the block form the wing came in with the epoxy up, and with the leading edge skin flush with the forms edge. Put the foam core on the skin using the marks you made earlier as guides to line up the wing and form. Put the top skin, epoxy down, on the wing core. Put the top of the block form on using the marks you made earlier to line it up (see picture below). Put weight on top of the block form until the epoxy cures. The form will protect the wing and should support up to 30 lbs of weight. Be sure the weight is distributed evenly across the top of the form for the best results.

Cut one wing skin into four pieces. First, cut it in half and then cut each half diagonally.

Prepare to cut the trailing edge of the wing. Mark the trailing edge where the wing is 9/32 thick on both ends of the wing. Draw a line from end to end connecting the marks you just made. Cut this portion of the wing off and sand smooth. When making the opposite wing, use this first wing as your guide for the measurements because they must match up. Epoxy a 1/16 balsa strip to the trailing wing edge. (See below).

After the epoxy has cured, remove the wing from the block form and trim off excess skin from both ends of the wing. Trim off excess wing skin from the leading edge and sand to a smooth finish. Take care not to cut into the foam core!

Install x 3/8 balsa strip on the leading edge with epoxy making sure its centered. Secure with tape. Epoxy 1/2x1/4x3.5 balsa tip to the tip of the wing.

Inboard trailing edge: Cut a 2 inch piece of aileron off the stock provided. Make a mark on the wing 1 inch out from the inboard edge. Epoxy the 2 inch piece of aileron to the wing butting it up to the mark you just made to make a smooth airfoil. Trim off any excess. Sand down the entire wing half rounding the airfoil leading edge and the wing tip. Finally, sand with 220+ sand paper for a very smooth finish. Repeat steps to make the opposite wing. Be sure you make the opposite wing to match the first. This means you need to use the first wing as a guide as a measurement as using 9/32 on the second wing might not match up exactly. Wing dihedral

Trim the ailerons to fit the wing. Measure in 1/8 inch on the bottom leading edge of the aileron and trim off the shaded area as shown in picture above. Cover wings and aileron with monokote or favorite covering. Fuselage assembly

Identify the left and right hand fuselage sides. Each half has 2 dots that match up to the wing cutout template. Cut out the wing cutout template provided. Line up template dots with fuselage dots and trace around. Make sure the marks you traced are on the outside of both fuselage halves. See below.

Sand the inboard edge of one wing at an angle so you will have 1 inches lift at the tip of the wing for the 30 inch wings and 1 inches for the 36 inch wings (see drawing above). Epoxy the 2 halves together setting the correct dihedral for your wing length. Apply one inch fiberglass tape over the wings center section to help stiffen the wing.

On either fuselage side, epoxy the bottom motor mount into place inch forward from the aft end of the fuselage and flush with the cutout.

Draw a line down from the aft canopy cut out.

Find F-1, F-2, F-3, motor mount bottom and top, and horizontal mount. Using F-3 as a guide, slightly bevel the forward side of the horizontal lower mount (HLM) until it butts up to F-3. Make a mark where the HLM ends on the aft fuselage. Draw a line along the bottom of the HLM. Using the marks you just made, epoxy the HLM into place with the HLM tilted slightly up

toward the top of the fuselage (see below). When you put both fuselage halves together, the HLM will level out. Do not install F-3 at this time.

Measure 4 inches aft from the forward fuselage and draw a line on the inside of both fuselage halves.

Epoxy F-1 and F-2 into place. Epoxy HLM to the opposite fuselage half, keeping it level. Epoxy the motor mount bottom to opposite fuselage half. Epoxy motor mount top into place. This will be a tight fit. Install it flush with the top of the cut out, skinny side aft. Epoxy F-3 into place. Dont glue the bottom inch sides or bottom as this will be cut out when the wing is installed.

Epoxy both fuselage sides to the fuselage bottom. Dont glue the fuselage sides together yet. Glue the fuselage sides to the aft bottom as shown below.

Epoxy the top aft fuselage into place, keeping it flush with F-3 at the front and flush with the aft portion of the fuselage top at the back. Sand the aft

top fuselage flush. From the scrap depron provided, add two layers to the aft top fuselage. See below.

From scrap depron, epoxy inch strip to the bottom inside forward fuselage between F-1 and F-2. Epoxy a 3/8 inch strip to the same location.

Using depron scrap, cut six pieces (three for each corner) to add to the forward cockpit. Cut 2 pieces of scrap for the center. Epoxy everything in place. Sand the fuselage into shape using these next six pictures as a guide.

Sand F-1 flush. Glue three pink nose cone pieces together and epoxy to the nose.

Your fuselage should now be sanded to the right shape.

Epoxy motor mount into the aft fuselage leaving at least 1 3/4 inches hanging out past the lower aft fuselage.

Get your canopy pieces together.

Do the same for the forward canopy mount. Draw an outline on both pieces to trim and fit to match the contours of the fuselage.

Place the aft canopy piece on the fuselage. Note the angle to bevel the lower edge of the piece. Bevel the lower edge of the aft canopy mount matching the fuselage cut out.

Place the canopy floor in fuselage cut out and outline the area to trim away. Epoxy three fuselage pieces together while these pieces are sitting in the fuselage cut out, and final sand to match the fuselage. Make sure you dont glue them to the fuselage. Trim the canopy to match the canopy floor. It may be necessary to add additional aft canopy pieces, from scrap, for a good windshield fit. Paint and mount the plastic canopy to the canopy frame. Note the canopy fit in the picture below (even though your plane isnt this far along yet.)

Cut out two holes in F-3 so you can epoxy the wing into place and run wires through later. Make sure the wing is centered in the fuselage and not crooked.

Cut out airfoil lines on the fuselage sides. Cut off the lower portion of F-3 so the wing will slide through. Using Dubro hinge tape (not included), tape each aileron to the wing. Install control horn on the top inner surface of each aileron.

Cut out an area big enough to fit your motor and the tail. A dremel helps out in this area. Trial fit motor to the motor mount. You will install the motor and wires after painting.

Trial fit the horizontal stab and check for good alignment. Mark where the horizontal stab meets up to the fuselage. Round the leading edges of the horizontal stab up to the marks. Epoxy the horizontal stab into place being sure to watch your alignment. Cut elevator stock provided to the correct length. Bevel the elevator the same way you did the ailerons. When finished, cover the elevator with monokote. Install the elevator with Dubro hinge tape in the same manner you did the ailerons.

Draw a center line down the horizontal stab as shown.

Center rudder on the turtle deck top and draw a line on either side. Cut out area to install rudder with a razor. A flat tipped screw driver works well to remove the cut out area. Epoxy the rudder into the fuselage being sure to watch your alignment. Paint your BD-5. We recommend using Krylon H2O from Wal-Mart. It is a water based latex paint that will not eat the foam. Be sure to test any other paint you use on a scrap piece of foam first.

With speed controller mounted in forward fuselage, run three motor wires to the aft fuselage to connect to the motor. Mount motor into position.

Cut a slot in the fuselage about midway along the top of the wing for a GWS naro standard servo or equivalent. Attach servo to control horn with the rod provided. Do the same to the other side. Cut a hole in the lower fuselage and lower aft fuselage for cooling air. Connect servo and speed control wires to receiver. Run antennae out to where it wont get caught in the propeller. Control throws and center of gravity Elevator control throws Low rate 3/8 inch up High rage 5/8 inch up Down travel as much as you can get. Cut out slot in aft fuselage below the horizontal stab for the servo elevator as shown. Attach a 12-18 inch servo extension to your GWS naro standard servo (or equivalent), and install into fuselage. Mount the elevator control horn straight back from elevator servo control horn. Attach control rod. Aileron control throws Low rate 3/8 inch up High rate inch up Low rate 5/16 inch down High rate 5/16 inch down Center of gravity Measure from the leading edge at the root 1 inch back. Hang your aircraft upside down when measuring center of gravity.

Power gear recommendations We recommend a battery of 1800-2100 mah three cell 11.1 volt lipo. This provides long flight times and plenty of power for this airplane. We recommend Himax brushless motors HA-2015 or HA-2025 in a gear box with a KV of 4200-5300 with an 8x6 prop. We recommend a 20-25 amp speed controller. We recommend GWS naro standard servos or Hitech HS-55 or HS-81 micro servos. Flight characteristics Fast. This is not a beginner aircraft. We recommend that you be an intermediate to expert flyer. Take off from the ground. Do not throw. We have never hand launched. Check for tip stalls on the first flight up high. This plane has little wing area and does not fly like a trainer. We have added washout to the wing tips to help prevent tip stalls. The short wing version will fly and land faster than the long wing version. Land with plenty of forward speed on your first landings and fly it to the ground until you get used to the flight characteristics. Enjoy, and fly safe!