AeroWorks 50cc Ultimate 20-300 ARF-QB Assembly Manual

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[Page 1] AeroWorks 50cc Ultimate 20-300 ARF-QB

1 50cc Ultimate 20-300 ARF-QB (Quick Build) ASSEMBLY MANUAL AEROWORKS™ 4903 Nome Street, Denver, CO. 80239 - Phone 303-371-4222 - Fax 303-371-4320 E-mail - [email protected] 2008 - Copy write Protected – All Rights Res...

[Page 2] AeroWorks 50cc Ultimate 20-300 ARF-QB

2 TABLE OF CONTENTS Page Aeroworks Contact Information ………………………………………………………………. 3 Introduction …………………………………………………………………�...

[Page 3] AeroWorks 50cc Ultimate 20-300 ARF-QB

3 4903 Nome Street Denver, CO 80239 Phone: (303) 371-4222 Fax: (303) 371-4320 Website: www.aero-works.net E-mail: [email protected] Thank you for choosing the Aeroworks 50cc Ultimate 20-300 ARF-QB. We put great effort in...

[Page 4] AeroWorks 50cc Ultimate 20-300 ARF-QB

4 INTRODUCTION Your new 50cc Ultimate 20-300 ARF-QB is a highly aerobatic airplane. It is capable of both precision and 3-D maneuvers. The aircraft builds easily, quickly, and precisely due to its state of the art CAD design, LASER cut ...

[Page 5] AeroWorks 50cc Ultimate 20-300 ARF-QB

5 KIT CONTENTS 50cc Ultimate 20-300 ARF-QB Materials List BASIC AIRCRAFT PARTS: Fuselage – covered, firewall fuel-proofed preinstalled fin: (4) 8-32 blind nuts installed for the main landing gear mounting (2) 1/4” blind nuts insta...

[Page 6] AeroWorks 50cc Ultimate 20-300 ARF-QB

6 (14) pin point hinges glued (2) Aileron servo string installed (2) Pilot holes pre drilled for control horns mounting Horizontal Stabilizer –1 Left 1 right with elevator as- sembly with (10) pin point hinges (glued)--- covered (2) Pilot...

[Page 7] AeroWorks 50cc Ultimate 20-300 ARF-QB

7 #10: (24) 6.35mm aluminum engine stand offs. #11: (2) Aluminum stabilizer tubes – 383mm; 176mm anodized black (4) 4-40x16mm hex style head bolts for stab mount- ing (4) #6 bonded washers for stab mounting (4) Φ3mm spl...

[Page 8] AeroWorks 50cc Ultimate 20-300 ARF-QB

8 Hardware: ITEMS NEEDED TO COMPLETE • 50 CC Gas engine and ignition • Pitts style muffler • Engine mounting bolts, and washers. • 3 1/2” Spinner and propeller of choice • 4 x aileron servos (min 180 in./oz. Torque, Digi...

[Page 9] AeroWorks 50cc Ultimate 20-300 ARF-QB

9 2. Open your kit slowly and take care not to dam- age 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 ...

[Page 10] AeroWorks 50cc Ultimate 20-300 ARF-QB

10 6. Your model is covered with Ultracote™ cover- ing. In case of repairs, the colors are: Yellow/Silver/Blue Scheme Pearl Blue #845 Silver #881 Cub Yellow #884 White #870 Red/Ye...

[Page 11] AeroWorks 50cc Ultimate 20-300 ARF-QB

11 1. Go over all seams and color overlaps with your sealing iron. Note: Even if your models covering has no wrinkles out of the box it is still very important to go over all seams and overlaps to make cer- tain they are sealed securely. ...

[Page 12] AeroWorks 50cc Ultimate 20-300 ARF-QB

12 Aileron Servo Installation 1. Gather the aileron servos, servo mounting screws, (4) 6” Servo extension, (4) 1 1/4” Servo arms and (4) Aeroworks Safety Clips as shown below. Note: The ailerons have been pre-hinged and glued ...

[Page 13] AeroWorks 50cc Ultimate 20-300 ARF-QB

13 5. Pull servo extension through wing and pro- vided exit holes in wing panel. 6. Install servo in servo well with the output arm toward the leading edge of the wing. Drill holes for servo mounting screws. 7. Install servo with servo m...

[Page 14] AeroWorks 50cc Ultimate 20-300 ARF-QB

14 Aileron Control Linkage Installation 1. Gather the aileron control linkage parts as shown below. 4 pushrod assemblies with ball links 8 4-40 Bolts and lock nuts ...

[Page 15] AeroWorks 50cc Ultimate 20-300 ARF-QB

15 6. Securely fasten the control horn to the aileron with six wood screws as shown. 7. Tape the trailing edge of the aileron to the trail- ing edge of the wing in the neutral position. Plug the servo into the receiver and turn radio on...

[Page 16] AeroWorks 50cc Ultimate 20-300 ARF-QB

16 2. Use loctite to prevent the strut mounting bolts from loosening. 3. Wing assembly is now complete. Note: Check mounting bolts are tight before each flying session. Note: Do not over tighten bolts this could damage or strip th...

[Page 17] AeroWorks 50cc Ultimate 20-300 ARF-QB

17 1. Remove the rear inner cabane mounting bolts as shown. 2. Remove the 4-40 mounting bolt on the rear ca- bane as shown below. 3. Remove the rear cabane as shown below. 4. Slide the male end of a 6” extension through the plasti...

[Page 18] AeroWorks 50cc Ultimate 20-300 ARF-QB

18 5. Route the extension into the fuse as shown be- low. Reinstall the rear cabane at this time. 6. Use blue loctite on the cabane mounting bolt as shown below. Reinstall the mounting bolts at this time. Note: We recommend removing a...

[Page 19] AeroWorks 50cc Ultimate 20-300 ARF-QB

19 STAB AND ELEVATOR ASSEMBLY Elevator Servo Installation 1. The elevators have been pre-hinged and glued to the stabs and are ready for flight. No other steps are necessary for hinging. Clear covering has been provided for sealing of...

[Page 20] AeroWorks 50cc Ultimate 20-300 ARF-QB

20 4. Install the control horns using the same method described for the wings. 3. Correct installation of ball link, flat washer and brass spacer to servo arm shown below. 5. Use tape to hold elevator in the neutral position. Pl...

[Page 21] AeroWorks 50cc Ultimate 20-300 ARF-QB

21 Rudder Installation 1. Gather the rudder, hinges, epoxy, Vaseline, stir sticks, mixing cup and alcohol as shown. Use 15-30 minute epoxy to ensure adequate working and cleanup time. RUDDER AND RUDDER SERVO INSTALLATION 2. Prep all ...

[Page 22] AeroWorks 50cc Ultimate 20-300 ARF-QB

22 5. Mix epoxy in mixing cup and use a tapered stick to apply the epoxy inside the pre-drilled holes in the leading edge of the rudder. Apply epoxy onto each hinge. 6. Carefully slide the rudder onto each hinge and against the traili...

[Page 23] AeroWorks 50cc Ultimate 20-300 ARF-QB

23 2. Assemble the ball links between the control horns as shown. Secure with nylon lock nut. Note: Mount ball link to bottom control horn hole to obtain full rudder deflection 4. Use thick CA on each screw prior to installing to...

[Page 24] AeroWorks 50cc Ultimate 20-300 ARF-QB

24 9. Gather the rudder servo, servo mounting screws, and a 3” double output servo arm as shown be- low. 6. Feed the rudder cable through the pre installed cable exit tube in the tail of the fuse toward the front. Repeat for other side....

[Page 25] AeroWorks 50cc Ultimate 20-300 ARF-QB

25 10. Install the rudder servo with the output shaft fac- ing forward as shown below. 11. Install the ball link onto the threaded coupler as shown below. 12. Thread the brass swag tube onto the pull pull cable followed by the threaded...

[Page 26] AeroWorks 50cc Ultimate 20-300 ARF-QB

26 14. Loop the cable back through the brass swage tube and pull tight as shown. 15. Crimp the brass tube with a crimping tool or pli- ers. 16. A drop of thin CA may be applied to the swage tube to help secure the cable. 17. In...

[Page 27] AeroWorks 50cc Ultimate 20-300 ARF-QB

27 18. Install the servo arm onto the rudder servo as shown below. 19. Plug the rudder servo into the rudder channel of the receiver and power up. Turn on transmitter to center rudder servo. 20. Tape the rudder balance tab to the to...

[Page 28] AeroWorks 50cc Ultimate 20-300 ARF-QB

28 22. Finished pull pull installation shown below. ...

[Page 29] AeroWorks 50cc Ultimate 20-300 ARF-QB

29 Tail Wheel Installation 1. Tape the rudder balance tab to the top leading edge of the vertical fin in the neutral position as shown. This ensures the rudder is straight when the tail wheel steering springs are installed. 2. Gather ...

[Page 30] AeroWorks 50cc Ultimate 20-300 ARF-QB

30 5. Mount the tail wheel steering tiller using two wood screws. 6. Place tail wheel strut over the pre-drilled holes in the bottom rear of the fuse. 7. Place a drop of thick CA on tail wheel strut mounting screws before inserting in...

[Page 31] AeroWorks 50cc Ultimate 20-300 ARF-QB

31 10. Use pliers to twist spring ends closed around the rudder and tail wheel tillers. 12. Repeat for opposite side tail wheel spring. Ad- just length and spring tension so that tail wheel is centered when rudder is centered. 13. ...

[Page 32] AeroWorks 50cc Ultimate 20-300 ARF-QB

32 Main Landing Gear Installation 1. Gather the landing gear parts as shown below. (1) landing gear strut, (2) wheels, (2) axle as- semblies, (4) wheel collars, (2) wheel pants and landing gear mounting hardware. MAIN LANDING GEAR , A...

[Page 33] AeroWorks 50cc Ultimate 20-300 ARF-QB

33 5. Install the axle into the gear strut with nylon lock nut. Only snug tighten at this time. 6. Align the wheel pant mounting holes with the pre-drilled holes in the landing gear. Adjust the angle of the axel if necessary. 7. Inst...

[Page 34] AeroWorks 50cc Ultimate 20-300 ARF-QB

34 9. Secure the wheel pant using the supplied 4-40 mounting bolts, lock washers, and flat washers. Use blue Loctite on the mounting bolts. 10. Final gear assembly with wheel pants installed shown below. ...

[Page 35] AeroWorks 50cc Ultimate 20-300 ARF-QB

35 Engine Installation 1. The 50cc Ultimate 20-300 will accept a wide range of engine types. Illustrations for a DA-50 installation are provided below. Gather the en- gine, and mounting hardware as shown below. Note: 2 1/2�...

[Page 36] AeroWorks 50cc Ultimate 20-300 ARF-QB

36 5. Remove the 4 Phillips head screws holding the top hatch to the motor box. 6. Using mounting bolts and flat fender washers mount engine to firewall. Tighten the bolts evenly to prevent crushing of the firewall. 7. Engine instal...

[Page 37] AeroWorks 50cc Ultimate 20-300 ARF-QB

37 2. Mark the location of the throttle pushrod on the firewall. 3. Remove the engine and the upper right standoff. Drill the throttle pushrod hole through the fire- wall as shown below. 5. Re-install engine and slide the pushrod throu...

[Page 38] AeroWorks 50cc Ultimate 20-300 ARF-QB

38 6. Attach ball link to throttle arm of carburetor 7. Place the throttle servo into the plywood servo mounting tray as shown below. 8. Place the servo and tray inline with the throttle pushrod. 9. Position the throttle servo as...

[Page 39] AeroWorks 50cc Ultimate 20-300 ARF-QB

39 10. Mark the location of the plywood mounting tray inside the fuse. 11. Mark and pre-drill servo tray for the servo mounting screws. 12. Remove servo from tray. 13. Apply epoxy to the bottom of the servo mount- ing tray as sho...

[Page 40] AeroWorks 50cc Ultimate 20-300 ARF-QB

40 15. Assemble ball link and threaded coupler to servo arm as shown below. 16. With the servo arm centered and the throttle arm of the carburetor at half throttle, measure and mark the end of the throttle pushrod wire that will be inse...

[Page 41] AeroWorks 50cc Ultimate 20-300 ARF-QB

41 19. Attach the throttle pushrod with the 4/40 ball links and secure. Power up the receiver and throttle servo and adjust pushrod for proper op- eration. Ensure the servo or rod does not bind or jam at closed or full open positions. 20...

[Page 42] AeroWorks 50cc Ultimate 20-300 ARF-QB

42 1. Gather the ignition module, ignition battery, regulator, switch, and mounting hardware as shown. 2. Position the ignition module outside the engine box ensure spark plug lead connects to the en- gine without excess tension or chaf...

[Page 43] AeroWorks 50cc Ultimate 20-300 ARF-QB

43 5. Roll the supplied foam rubber to make a 4 layer pad as shown. Make the pad slightly larger than the ignition module. 6. Install the ignition module and the foam pad with a nylon tie as shown. 7. Drill hole in fire wall for...

[Page 44] AeroWorks 50cc Ultimate 20-300 ARF-QB

44 9. Install the ignition switch as shown below. Fol- low the switch manufacturers directions for spe- cific switch mounting instructions. 10. Install the ignition regulator as shown below. Follow the regulator manufacturers direction...

[Page 45] AeroWorks 50cc Ultimate 20-300 ARF-QB

45 Fuel Tank Assembly 1. Gather the fuel tank parts as shown below. A 750cc (26oz) fuel tank has been provided. FUEL TANK ASSEMBLY AND INSTALLATION 2. Locate the (4) supplied brass fuel barbs. Two for the fuel tank and Two for the smo...

[Page 46] AeroWorks 50cc Ultimate 20-300 ARF-QB

46 5. Final assembly of rubber fuel stopper with fuel pick up tube shown below. 6. Install air vent tube into rubber stopper and bend upward. Air vent tube should rest as close to the top of fuel tank as possible. Without touching the t...

[Page 47] AeroWorks 50cc Ultimate 20-300 ARF-QB

47 9. Secure the rubber stopper with set screw. Take care not to strip threads by over tightening set screw Fuel Tank Installation 1. Gather the fuel tank parts as shown below. Fuel tank, fuel tubing, foam rubber, fuel “T”, fuel f...

[Page 48] AeroWorks 50cc Ultimate 20-300 ARF-QB

48 4. Use nylon ties to secure fuel line. Note: Gasoline will cause the fuel line to swell over time. Always secure fuel lines with nylon ties to prevent them from pulling off during flight. 5. If using a smoke tank install...

[Page 49] AeroWorks 50cc Ultimate 20-300 ARF-QB

49 9. Cinch the nylon ties securely to hold the tank against the foam on the fuel tank floor. Cut off excess nylon tie material after tank is firmly in- stalled. 8. Install the fuel tank with the vent line towards the top of the fuse as s...

[Page 50] AeroWorks 50cc Ultimate 20-300 ARF-QB

50 12. Attach the fuel line to the carburetor as shown. Use a small nylon tie to secure the hose to the carburetor. 13. Gather the fuel filler dot and drill bits as shown below. Note: We recommend you start with a smaller...

[Page 51] AeroWorks 50cc Ultimate 20-300 ARF-QB

51 1. Gather the receiver, battery, switch, regulator and mounting hardware as shown below. 3. Install the receiver using the supplied Velcro ties and foam pad as shown below. Refer to receiver manufactures instructions for specific recei...

[Page 52] AeroWorks 50cc Ultimate 20-300 ARF-QB

52 5. Final radio installation shown below. 6. Push receiver antenna all the way into the pre installed receiver antenna guide tube. Note: Apply baby powder or corn starch to antenna wire to assist getting antenna into their guide t...

[Page 53] AeroWorks 50cc Ultimate 20-300 ARF-QB

53 2. Measure and mark a reference line 3/16” back from front of fuse as shown. 3. Measure and mark a center line on bottom of fuse as shown below. 4. Measure and mark the center of the template as shown below. Extend the center li...

[Page 54] AeroWorks 50cc Ultimate 20-300 ARF-QB

54 5. Align centerline marks of template and fuse, align template with 3/16” reference mark on fuse. Use masking tape to securely hold the tem- plate to the fuse. 6. Trace around the cylinder head of the motor be- ing careful to keep th...

[Page 55] AeroWorks 50cc Ultimate 20-300 ARF-QB

55 9. Trace around the muffler being careful to keep the template in the same location. 10. Using a hobby knife cut out the template for the hot air exit and muffler relief hole. 11. Dry fit template and check to see if the template li...

[Page 56] AeroWorks 50cc Ultimate 20-300 ARF-QB

56 13. Once satisfied with fit. Align template with the center mark on cowl and fit flush with rear of cowl. Tape template to bottom of cowling and mark cut lines with removable marker. Note: Take care and test painted areas prior to ...

[Page 57] AeroWorks 50cc Ultimate 20-300 ARF-QB

57 Manual Choke Installation 2. Assemble the choke pushrod as shown below. Use the nylon ties to form the mount between the upper and lower standoffs 3. Finished choke installation shown below. Manual Choke Installation 1. Gather...

[Page 58] AeroWorks 50cc Ultimate 20-300 ARF-QB

58 DECAL INSTALLATION Decals Available through Aeroworks 1. Placement of optional decal package shown, in- cluded decals will differ. 2. Placement of optional decal package shown, in- cluded decals will differ. ...

[Page 59] AeroWorks 50cc Ultimate 20-300 ARF-QB

59 1. Decals supplied with the kit will vary from the photos below. Installation step are the same Gather supplied decals, transfer tape, ruler, scis- sors, hobby knife, plastic squeegee or credit card, Windex or Application fluid like Ra...

[Page 60] AeroWorks 50cc Ultimate 20-300 ARF-QB

60 5. Press transfer tape to top of decal. 6. Peel backing from decal. 7. Spray model surface with application fluid, Windex or soapy water solution. 8. Spray back side of decal with application fluid, Windex or soapy water so...

[Page 61] AeroWorks 50cc Ultimate 20-300 ARF-QB

61 9. Position decal in proper location. Application fluid will allow decal to be moved slightly. 10. Using a plastic squeegee or credit card. Spread decal smooth and remove all excess application fluid. Let decal set until dry enough to b...

[Page 62] AeroWorks 50cc Ultimate 20-300 ARF-QB

62 13. Repeat installation process of bottom decal for top decal installation. Use application fluid for easier installation 14. Place top decal over bottom decal. Position evenly and centered on bottom decal. Press top decal onto bottom d...

[Page 63] AeroWorks 50cc Ultimate 20-300 ARF-QB

63 2. Glue or screw in dash panel and pilot figure ac- cording to manufactures recommend installation procedure DASH AND PILOT INSTALLATION Available Through Aeroworks 3. Reattach canopy using mounting screws. 1. If installing pilot or da...

[Page 64] AeroWorks 50cc Ultimate 20-300 ARF-QB

64 1. Mount the cowl using the cowl mounting bolts and rubber backed washers. The rubber backed washers are to prevent the fiberglass cowl from cracking and to prevent mounting bolts from loosing from normal engine vibration. PRE-FLIGHT PR...

[Page 65] AeroWorks 50cc Ultimate 20-300 ARF-QB

65 6. Secure outer cabanes with 6-32 x 15mm bolts, flat washer and lock nut. Note: Outer struts have been pre-marked LB (left bot- tom) and RB (right bottom) for easy reference. 7. Ensure lock nuts are tight and will not co...

[Page 66] AeroWorks 50cc Ultimate 20-300 ARF-QB

66 10. This will give you a simple and virtually invisi- ble method for connecting the top wing aileron servo to the servo extension wire to the re- ceiver. ...

[Page 67] AeroWorks 50cc Ultimate 20-300 ARF-QB

67 Center of Gravity 1 1/2” Back Measured off the Top Wing From the Wings Leading Edge at the Wing Tip CENTER OF GRAVITY 3. Start at recommended CG until you are comfort- able with the flight characteristics of the aircraft. ...

[Page 68] AeroWorks 50cc Ultimate 20-300 ARF-QB

68 1. The amount of control throw should be adjusted using mechanical means as much as possible and then electronically with the radio. The control throws are shown in degrees and inches of de- flection measured at the widest point of the co...

[Page 69] AeroWorks 50cc Ultimate 20-300 ARF-QB

69 7. Location for throw meter to measure Elevator throw in degrees. ...

[Page 70] AeroWorks 50cc Ultimate 20-300 ARF-QB

70 Control Throw Deflection Table Low Rate High Rate Aileron 1” or 15˚ up 2” or 30˚ up 1” or 15˚ down 2” or 30˚ down Rudder 4” left 6” left 4” right 6” right Elevator 3/4” or 14˚ up 2” or 22˚ u...

[Page 71] AeroWorks 50cc Ultimate 20-300 ARF-QB

71 Aerobatics The 50cc Ultimate 20-300 ARF-QB is capable of any aerobatic maneuver. After you gain some con- fidence and little experience flying the airplane you can cut loose and perform any maneuver you can think of. Here is a list of...

[Page 72] AeroWorks 50cc Ultimate 20-300 ARF-QB

72 50 cc Ultimate 20-300 ARF-QB NOTES ___________________________________________________________________________ ___________________________________________________________________________ _______________________________________...