The New Pocket Combat Wing-250 Build/Q&A and Stock PCW Build

birdofprey · May 31, 2004, 08:53 PM

Due to popular demand, EdgeRC has developed a Johnson-250 powered version of the popular Pocket Combat Wing (PCW).

This thread will cover the recommended build procedures for the Pocket 250 and a stock PCW. The builds are almost identical except at a few points along the way. The majority of the photos will be of the Pocket-250 and when applicable a stock PCW will be used to identify those points that differ between the two builds.

This thread may also serve as a photo step-by-step CD instruction manual that may be included with the kits in the future.

Along the way please feel free to ask questions. I will attempt to outline different methods of completing certain steps along the way as well. This way, if some of the tools used in construction are not available to the builder, other tools may be able to be used as a different yet effective solution.

This thread should also help to answer very common questions such as component location and covering methods as well as ease of assembly. The build is the same as the methods used to build the PCW in the PCW Crash Video located here:
http://www.edgerc.com/video.htm

I am building the PCW-250 in real time as well as typing a description of the steps for this thread. By following these steps most people can assemble a PCW in a matter of a few hours. It will take me a few more hours to shoot the pictures and type the information needed along the way.

As a starting point, here is a list of items that will be needed to build the PCW in either form (stock or 250):

1-PCW kit (stock or 250)
1-low-temp hot glue gun and a stick of glue.
1-sharp hobby or utility knife.
1-can of 3M-77 spray adhesive (old or new formula).
1-hobby covering iron
1-pair needle-nose pliers.
1-bottle of CA glue
1-Roll minimum, LOW-TEMP covering film (Econokote, Ultracote/Oracover, etc.).
Soldering supplies (25 watt pen and rosin-core solder rec.)
Small screw drivers
¾ to 1-inch fiberglass strapping tape
Clear packaging tape
Spray paint (optional) for painting the molded motor mount and landing skid. (Rust-oleum, Krylon, Testors, etc.)

Electronics needed:
Etec-1200mA 2 cell (7.4V LiPo battery or equiv.)
2-Pico+Std. servos or equiv.
1-7 Amp+ ESC for the 250 or a 2 Amp minimum ESC for the stock PCW
1-Micro receiver (GWS R4P horizontal pin or a Berg4 or equiv.)

It is assumed that the builder has a TX with dual-rates and a battery charger that is capable of charging LiPo batteries safely.

*************************
*************************
UPDATE, I have got the maiden flight video of the Pocket-250 in this build thread up on my site. www.edgerc.com on the Pocket-250 page and also on the videos page. Thank you to Skypyro for his time putting the video together, and the time he took to shoot the video for us to enjoy.

Here is a direct link to the video as well:
http://www.edgerc.com/J250movie.wmv
It is 14+Mb!!!

Dial up users may want to use the lower res version:
http://www.edgerc.com/J250moviesmall.wmv
8+Mb may be a little easier to handle.

More info on the maiden flight is in post 134 of this thread!!!
************************
************************

OK, on to the build.

birdofprey · May 31, 2004, 08:58 PM

Step 1-(not pictured) Remove the cores from there beds and notice the precut trailing edge and carbon spar slot. The spar slot is on the top of the wing, not the bottom like many other wings.

Step 2-(not pictured) Remove any melted EPP foam debris from the cores that may be left from the cutting process.

Step 3-(pictured) With the Low-temp hot glue gun heated up, apply a bead around the perimeter of one wing core root and then down the center of the root. The second half of the wing will then be pressed firmly to the half with the hot glue and aligned. The panels must be placed together quickly before the glue cools.

birdofprey · May 31, 2004, 09:11 PM

Step 4-Incert the 9-inch carbon tube spar into the spar slot, and apply low-temp hot glue to the spar and foam by pressing the tip of the glue gun between the spar and the foam and injecting the hot glue about every inch along the length of the spar on both sides. The spar does NOT have to be completely covered in glue to have a strong bond, and filling the spar slot with hot glue will only add weight and waste the glue.

Basic airframe assembly is complete.

CenTexFlyer · May 31, 2004, 09:16 PM

Ummm... shouldn't this be in the flying wings forum?

papasmurf · May 31, 2004, 09:25 PM

Justin, did you get my PM from the other day? Glad to see a 250 version is finally coming out. I love that little motor.

birdofprey · May 31, 2004, 09:29 PM

Quote:

Originally Posted by CenTexFlyer

Ummm... shouldn't this be in the flying wings forum?

Ummm... This is a Foamie... It is also a ParkFlier... And it is a wing... The wing forum is also a trial forum. So the answer is NO.

birdofprey · May 31, 2004, 09:36 PM

Quote:

Originally Posted by papasmurf

Justin, did you get my PM from the other day? Glad to see a 250 version is finally coming out. I love that little motor.

I did. Thanks, and your kit should arrive tomorrow.

RonB · May 31, 2004, 09:56 PM

I just purchased a pctwin and was wondering about putting a single 250 on it. Has that been done or would it be too sluggish. Keep up the good work guys. Love your wings
Ron

asjeep · Jun 01, 2004, 01:16 AM

rather than hot glue would it be better to use super 77 to glue the cores together? i did this on a unicorn and a zagi and came out well.....

ScYcS · Jun 01, 2004, 06:53 AM

Justin,

i remember you saying that the PCW is NOT recommended to be equipped with the Johnson 250. What the deal?!

RocketRob · Jun 01, 2004, 08:17 AM

Every one thinks they need more power? Ugh Ugh Ugh!

birdofprey · Jun 01, 2004, 08:43 AM

RonB,

Contact me directly, and I will give you a motormount that you can use on the twin to run a single 250. It will work very well.

asjeep,

After all of the planes I have built (many using the 3M-77 method for joining the wings) I have found that I like the hot glue method best, so that is what I recommend. It may not be the way you have assembled your planes, but there is more than one way to 'skin a cat' so to speak.

ScYcS,

The deal is that on the original version, it was (in most cases) to heavy of a motor to use with the wood rib design. Since the release of the PCW-V2 using the new mount design, we found that we could install the 250 motor onto the PCW and not come out too heavy like we did on the old version, and the PCW-250 retained much of the durrability of the stock PCW-V2. The motor on the PCW-250 sits further forward than it would have on the old version of the PCW with the wood rib. This means that an additional amount of weight does not need to be added to the nose to make it balance on this version.

Everyone,

This was to be a real time build, but just as I got started, my wife informed me that we had to do some shopping and the build instantly stoped. I will pick up the build shortly today.

Thanks,

Justin

jimklein · Jun 01, 2004, 09:00 AM

Family comes first, good call!

asjeep · Jun 01, 2004, 10:27 AM

planes come first

i hate shopping

what kinda of hot glue are you using? low temp? high temp? just never had the stuff hold up for me, but i might just have to try it

ScYcS · Jun 01, 2004, 10:35 AM

The problem i have with hot glue is that it dries too quickly....can be a pain in the rear.

May 31, 2004, 08:53 PM	#1
birdofprey Is amused by something Join Date: Nov 2002 Location: Lucas, Kansas Posts: 1,662	The New Pocket Combat Wing-250 Build/Q&A and Stock PCW Build Due to popular demand, EdgeRC has developed a Johnson-250 powered version of the popular Pocket Combat Wing (PCW). This thread will cover the recommended build procedures for the Pocket 250 and a stock PCW. The builds are almost identical except at a few points along the way. The majority of the photos will be of the Pocket-250 and when applicable a stock PCW will be used to identify those points that differ between the two builds. This thread may also serve as a photo step-by-step CD instruction manual that may be included with the kits in the future. Along the way please feel free to ask questions. I will attempt to outline different methods of completing certain steps along the way as well. This way, if some of the tools used in construction are not available to the builder, other tools may be able to be used as a different yet effective solution. This thread should also help to answer very common questions such as component location and covering methods as well as ease of assembly. The build is the same as the methods used to build the PCW in the PCW Crash Video located here: http://www.edgerc.com/video.htm I am building the PCW-250 in real time as well as typing a description of the steps for this thread. By following these steps most people can assemble a PCW in a matter of a few hours. It will take me a few more hours to shoot the pictures and type the information needed along the way. As a starting point, here is a list of items that will be needed to build the PCW in either form (stock or 250): 1-PCW kit (stock or 250) 1-low-temp hot glue gun and a stick of glue. 1-sharp hobby or utility knife. 1-can of 3M-77 spray adhesive (old or new formula). 1-hobby covering iron 1-pair needle-nose pliers. 1-bottle of CA glue 1-Roll minimum, LOW-TEMP covering film (Econokote, Ultracote/Oracover, etc.). Soldering supplies (25 watt pen and rosin-core solder rec.) Small screw drivers ¾ to 1-inch fiberglass strapping tape Clear packaging tape Spray paint (optional) for painting the molded motor mount and landing skid. (Rust-oleum, Krylon, Testors, etc.) Electronics needed: Etec-1200mA 2 cell (7.4V LiPo battery or equiv.) 2-Pico+Std. servos or equiv. 1-7 Amp+ ESC for the 250 or a 2 Amp minimum ESC for the stock PCW 1-Micro receiver (GWS R4P horizontal pin or a Berg4 or equiv.) It is assumed that the builder has a TX with dual-rates and a battery charger that is capable of charging LiPo batteries safely. *********************** ********************* UPDATE, I have got the maiden flight video of the Pocket-250 in this build thread up on my site. www.edgerc.com on the Pocket-250 page and also on the videos page. Thank you to Skypyro for his time putting the video together, and the time he took to shoot the video for us to enjoy. Here is a direct link to the video as well: http://www.edgerc.com/J250movie.wmv It is 14+Mb!!! Dial up users may want to use the lower res version: http://www.edgerc.com/J250moviesmall.wmv 8+Mb may be a little easier to handle. More info on the maiden flight is in post 134 of this thread!!! ******************** ********************** OK, on to the build. Last edited by birdofprey; Jul 02, 2004 at 11:39 AM. Reason: Added update info with video links

May 31, 2004, 08:58 PM	#2
birdofprey Is amused by something Join Date: Nov 2002 Location: Lucas, Kansas Posts: 1,662	Step 1-(not pictured) Remove the cores from there beds and notice the precut trailing edge and carbon spar slot. The spar slot is on the top of the wing, not the bottom like many other wings. Step 2-(not pictured) Remove any melted EPP foam debris from the cores that may be left from the cutting process. Step 3-(pictured) With the Low-temp hot glue gun heated up, apply a bead around the perimeter of one wing core root and then down the center of the root. The second half of the wing will then be pressed firmly to the half with the hot glue and aligned. The panels must be placed together quickly before the glue cools. Attached Thumbnails 60.6 KB · Views: 6405 66.8 KB · Views: 6434 Last edited by birdofprey; May 31, 2004 at 09:15 PM.

May 31, 2004, 09:11 PM	#3
birdofprey Is amused by something Join Date: Nov 2002 Location: Lucas, Kansas Posts: 1,662	Step 4-Incert the 9-inch carbon tube spar into the spar slot, and apply low-temp hot glue to the spar and foam by pressing the tip of the glue gun between the spar and the foam and injecting the hot glue about every inch along the length of the spar on both sides. The spar does NOT have to be completely covered in glue to have a strong bond, and filling the spar slot with hot glue will only add weight and waste the glue. Basic airframe assembly is complete. Attached Thumbnails 65.4 KB · Views: 6056 99.7 KB · Views: 6024 87.8 KB · Views: 6002

May 31, 2004, 09:56 PM	#8
RonB Registered User Join Date: May 2002 Location: Laguna Hills California Posts: 48	pcw I just purchased a pctwin and was wondering about putting a single 250 on it. Has that been done or would it be too sluggish. Keep up the good work guys. Love your wings Ron

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May 31, 2004, 09:16 PM	#4
CenTexFlyer Registered User Join Date: Dec 2001 Location: Near Austin Posts: 3,818	Ummm... shouldn't this be in the flying wings forum?

May 31, 2004, 09:25 PM	#5
papasmurf "I passed on the kool-aid" Join Date: Jan 2004 Location: Waco, TX Posts: 3,882	Justin, did you get my PM from the other day? Glad to see a 250 version is finally coming out. I love that little motor.

Jun 01, 2004, 01:16 AM	#9
asjeep Registered User Join Date: Jan 2004 Posts: 458	rather than hot glue would it be better to use super 77 to glue the cores together? i did this on a unicorn and a zagi and came out well.....

Jun 01, 2004, 06:53 AM	#10
ScYcS Just fly the darn wing!!! Join Date: Oct 2003 Location: Westfield, NY Posts: 2,209	Justin, i remember you saying that the PCW is NOT recommended to be equipped with the Johnson 250. What the deal?!

Jun 01, 2004, 08:17 AM	#11
RocketRob Size Matters! Join Date: Dec 2002 Location: San Francisco Bay Area Posts: 2,513	Every one thinks they need more power? Ugh Ugh Ugh!

Jun 01, 2004, 08:43 AM	#12
birdofprey Is amused by something Join Date: Nov 2002 Location: Lucas, Kansas Posts: 1,662	RonB, Contact me directly, and I will give you a motormount that you can use on the twin to run a single 250. It will work very well. asjeep, After all of the planes I have built (many using the 3M-77 method for joining the wings) I have found that I like the hot glue method best, so that is what I recommend. It may not be the way you have assembled your planes, but there is more than one way to 'skin a cat' so to speak. ScYcS, The deal is that on the original version, it was (in most cases) to heavy of a motor to use with the wood rib design. Since the release of the PCW-V2 using the new mount design, we found that we could install the 250 motor onto the PCW and not come out too heavy like we did on the old version, and the PCW-250 retained much of the durrability of the stock PCW-V2. The motor on the PCW-250 sits further forward than it would have on the old version of the PCW with the wood rib. This means that an additional amount of weight does not need to be added to the nose to make it balance on this version. Everyone, This was to be a real time build, but just as I got started, my wife informed me that we had to do some shopping and the build instantly stoped. I will pick up the build shortly today. Thanks, Justin

Jun 01, 2004, 09:00 AM	#13
jimklein Registered User Join Date: Jan 2003 Location: Minneapolis Mn Posts: 758	Family comes first, good call!

Jun 01, 2004, 10:27 AM	#14
asjeep Registered User Join Date: Jan 2004 Posts: 458	planes come first i hate shopping what kinda of hot glue are you using? low temp? high temp? just never had the stuff hold up for me, but i might just have to try it

Jun 01, 2004, 10:35 AM	#15
ScYcS Just fly the darn wing!!! Join Date: Oct 2003 Location: Westfield, NY Posts: 2,209	The problem i have with hot glue is that it dries too quickly....can be a pain in the rear.