Hi,

Well after finding lots of stuff laying about for way too long. It is finally time to start putting some of it into flying condition.

I say build thread, but this is perhaps more of an assembly thread, as the airframe is mostly complete out of the box.

First job is to make the wiring harness for the wings. Each wing has a flap and and aileron so I used some multiplex plugs and sockets to make them easy to connect.

I intend to mount the receiver on a small shelf just behind the wing root inside the fuselage.

I used a cornflake packet to cutout the templates by tracing the fuselage outline, then trimming with scissors until it fits inside.

When perfect drawn into some 2mm ply for the actual templates.









I've not fixed them into place until the rest of the model is assembled and I am ready to finalise the CofG position.

A quick layup of the servos to work out the wiring lengths.







Time to wire the servo side of the wings.

Fit the wings and mark the wing with the fuselage position. This will then aid with the holes for the servo wires.







CofG range marked. Shame I smudged it!



Pin drill used to carefully drill the wire exit holes.

Holes gradually made larger by going through all the drill sizes. All this is done by hand, not using a drill as the skins are very thin.







Larger heat shrink used to protect the wires from the carbon skin.

Completed wing loom.



Volz VMS connectors joined onto the end of the wires so I can just plug the servos in as required.





All four looms.



Ready for initial radio setup.



Graupner HoTT 12 chan RX (To be changed to 8 Chan when it arrives)



A few setup notes for my six flight modes, switch positions and servo channel numbers.

Trial fit of servos into the wing. I intend to use some servo frames to hold everything into place.







Radio Setup



Checking servo movements

I've managed to build quite a bit more on this over Saturday.

Due to the new parts turning up last week from Germany.



Kontronik Kira 480-31 with 5.2:1 Gearbox


Kontronik Koby 55LV Speed Controller with S-Bec, This now saves me from having to fit a separateBEC module from the originally planned Beat 55 ESC.


Graupner HoTT GPS Unit and Vario, I don't this will work in the Carbon / Kevlar fuselage, but if not I have another glider it will go into.


Vented Aeronaut Spinner




A selection of folding prop blades, depending on if I go with a 3s or 4s Lipo Flight battery. I am probably going to keep it as light as possible.

Motor Assembly.





The motor is supplied with its own silver connectors.






Speed Controller





Final Heat Shrink Tubing


Deans connector for main power.


A complete test of all the electrical bits.

Motor Installation.



I bought a GRP ring for the motor to act as a template and to go behind the fuselage firewall as a further reinforcement.



Marked out for cooling holes







Pin drill to start with







Transferred to firewall



Start of drilling



Finished



Motor installed



Cooling

Sweet .... I'm putting together a MG at the moment myself too, so this thread is well timed.

Looking forward to your progress as it unfolds

Lots of room for cooling air around the motor. I may yet fit the Kontronik motor heatsink, but the motor has a fan on it anyway.







Aeronaut Spinner





Out a fraction, but I can adjust it if it becomes an issue.



ESC supported by the motor cables and suspended in the centre of the airflow.

Moving onto the wing servo installation.

I made a mistake of installing the Aileron servos the wrong way round, with the servo shaft too far away from the control surface, this prevented the covers from fitting. :cry:

But the good news is because I used the servo frames for the installation it was very easy to turn them round into the correct positions. Just be aware of that when looking at the following photos, I would hate for anyone to glue them in the wrong way.







I used the radio to subtrim the Left and Right Aileron and Flap servos so they were matched perfectly before installing them.



I taped the wings to stop any stray epoxy being a problem.

The flap servo horns need trimming for a flush fit.







Time to raid the kitchen for supplies.





The cling film will allow the servos to be removed after the epoxy has set.



10 minute epoxy





Initial Positioning

Before I installed the servos with glue, I set up the radio and made all of the pushrods the correct lengths. The wing control surfaces were then taped and the servo installed with the pushrods connected. This then should ensure that the servos it firstly glued in the correct location, and that little extra trim adjustment will be required on the radio afterwards.



Some gentle pressure to keep it in place until the epoxy starts to harden.







Notice all of the taped surfaces

A tidy up after the epoxy has set.



Complete wing assembled





The oh dear I put the aileron servo in the wrong way moment!!



Not to worry all fixed now.



Time for a quick radio check.





The flap movement is a bit low compared with a lot of gliders. But i will make judgement after a flew flights to see if is worth all the bother of adjusting it to get more.