KAVAN Savage Mini 1000mm - Instruction manual

KAV02.8027

KAVAN Savage Mini - blue

Introduction

The Savage Mini is a kit for a 3D aerobatic model made from carbon-reinforced EPP (expanded polypropylene) foam. Its large control surfaces suit pilots who have mastered a trainer with aileron, elevator, rudder and throttle control. The motor, ESC, radio, flight battery and four servos are selected and installed by the builder.

Before you start

1. If you are not an experienced RC pilot, plan to have a fully competent pilot check your completed model and help you with your first flights. Even though we have tried to provide you with a thorough instruction manual, RC models are rather complicated and an experienced modeller can quickly check over your model to make sure your first flights are successful.
2. Please assemble your model exactly according to these instructions. Do not attempt to modify or change your model in any way, as doing so may adversely change its flying characteristics.
3. Before you begin, please check the entire contents of this kit to make sure that no parts are missing or damaged. This will also help you to become familiar with each component of your plane. If you find that any of the parts are either missing or damaged, please contact your dealer immediately for replacement.
4. Trial fit each part before glueing it in place. Make sure you are using the correct part and that it fits well before assembling. No amount of glue can make up for a poorly-fitting part.
5. The manual shows the initial centre of gravity (CG) and recommended control throws. Use the specified CG for the first flight; otherwise the model may be unstable, difficult to control or unable to fly safely. See the pre-flight section before making any later adjustment.

Note

Your dealer cannot accept kits for return if construction has begun.

Safety precautions

This RC model is not a toy. Use it with care and strictly following the instructions in this manual.

Assemble this model following strictly these instructions. DO NOT modify or alter the model. Failure to do so, the warranty will lapse automatically. Follow the instructions to obtain a safe and solid model at the end of the assembly.

Children under the age of 14 must operate the model under the supervision of an adult.

Assure that the model is in perfect condition before every flight, taking care that all the equipment works correctly and that the model is undamaged in its structure.

Fly only on days with a light breeze and in a safe place away from any obstacles.

General warnings

• An RC aeroplane is not a toy! If misused, it can cause serious bodily harm and damage to property. Fly only in a safe place and follow all instructions and recommendations in this manual. Beware of the propeller! Keep loose items that can get entangled in the propeller away from the spinning propeller, including loose clothing, or other objects such as pencils and screwdrivers. Ensure that your and other people's hands and faces, and animals are kept away from the rotating propeller.
• As the user of this product, you are solely responsible for operating it in a manner that does not endanger yourself and others or result in damage to the product or the property of others. This model is controlled by a radio signal that is subject to interference from many sources outside your control. Interference, equipment failure or pilot error can cause loss of control, so it is advisable to always keep a safe distance in all directions around your model, as this margin will help to avoid collisions or injury.
• Never operate your model with low transmitter batteries.
• Always operate your model in an open area away from power lines, cars, traffic or people. Avoid operating your model in populated areas where injury or damage can occur.
• Carefully follow the directions and warnings for this and any optional support equipment (chargers, rechargeable batteries, etc.) which you use.
• Keep all chemicals, small parts and anything electrical out of the reach of children.
• Moisture causes damage to electronics. Avoid water exposure to all equipment not specifically designed and protected for this purpose.
• The model is mostly made of plastics – it is not fireproof. Keep it away from heat sources, direct sunlight and hot enclosed cars; high temperatures can distort the foam airframe or cause other damage.
• Disconnect the flight battery whenever the model is not in use. Even at zero throttle, the ESC draws current; leaving the battery connected for hours or days can deeply discharge it, damage it and create a fire risk.

Set contents

Printed EPP fuselage, wing, tail and wheel-pant parts; plywood firewall; carbon reinforcements and undercarriage; wheels; plastic horns and fittings; linkage hardware; and an instruction manual. The motor, propeller, ESC, radio, flight battery and servos are not included.

Features

• Printed EPP airframe parts with carbon reinforcement
• Designed and manufactured in the Czech Republic
• Large control surfaces and a low-weight airframe
• Fixed horizontal stabilizer with a separate elevator
• Carbon main undercarriage and wheel pants
• Wingtip side force generators
• Aileron, elevator, rudder and throttle control

Technical specifications

Parameter	Value
Wingspan	1000 mm
Length	1020 mm
All-up weight	Approximately 500 g

You will also need

• A transmitter and compatible receiver with at least 4 channels; a computer radio with dual rates and expo is recommended.
• A brushless power system, suitable 3S LiPo flight battery and charger, and four micro servos: two for the ailerons, one for the elevator and one for the rudder. Select a complete configuration from the table below.
• Regular modeller’s tools: a modeller’s knife (KAV66.770), screwdrivers, pliers, a drill with a Ø3.0 mm bit, and 180–360 grit sandpaper.
• Medium CA (KAV56.9952), thin CA (KAV56.9951), CA accelerator (KAV56.9959) and hot-melt adhesive.

Recommended power systems and servos

• Sunday 3D: For 3D aerobatic beginners and Sunday flyers.
• 3D: For everybody who likes it hot and 3D.

Note

A 20–30A ESC with an adequately rated linear BEC may be used with analogue servos. Use a powerful switching SBEC for high-torque, high-speed digital servos. Check the supply-voltage and current requirements of all four servos.

Component	Sunday 3D	3D
Motor	KAVAN C2830-1300	KAVAN PRO 2830-1100
Propeller	APC 9×4.7"SF	APC 10×4.7"SF
ESC	KAVAN R-30SB Plus	KAVAN PRO-30SB
Battery	KAVAN LiPo 11.1 V 1300 mAh 40/80C	KAVAN LiPo 11.1 V 1300 mAh 40/80C
Servos	KAVAN GO-13MG, Hitec HS-65MG or HS-70MG	KAVAN GO-1013MG, Hitec HS-5065MG or HS-5070MH

Note

The current wiki recommends R-30SB Plus for Sunday 3D; the original printed manual lists R-30B. Use the instructions for the controller you actually install. Both configurations above use a 3S LiPo battery. Keep each motor, propeller and battery combination together.

Parts list

Use the drawing references to identify the supplied parts. Dimensions describe the unassembled parts unless stated otherwise.

Main parts

Part	Quantity	Material	Dimensions	Drawing
Instruction manual	1	paper	A4	—
Fuselage – vertical part	1	EPP	—	(Fig. 28)
Fuselage – horizontal part	1	EPP	—	(Fig. 1)
Wing – left + right	1+1	EPP	—	(Fig. 2)
Canopy	1	EPP	—	(Fig. 28)
Fin and rudder	1	EPP	—	(Fig. 56)
Horizontal stabilizer + elevator	1	EPP	—	(Fig. 9)
Wheel pant	2+2	EPP	—	(Fig. 41)
Side force generator	2	EPP	—	(Fig. 61)
Main undercarriage	1	carbon	—	(Fig. 32)

Carbon parts bundle

Part	Quantity	Material	Dimensions	Drawing
Wing spar	2	carbon	Ø1.5×1000 mm	(Fig. 6)
Fuselage reinforcement	4	carbon	3×0.5×1000 mm	(Fig. 12)
Horizontal tailplane reinforcement	2	carbon	3×0.5×250 mm	(Fig. 9) (Fig. 10)
Horizontal tailplane reinforcement	1	carbon	3×1×250 mm	(Fig. 9)
Elevator + rudder pushrod	1	carbon	Ø1.0×1000 mm	(Fig. 46) (Fig. 50) (Fig. 60)

Small accessories bag

Part	Quantity	Material	Dimensions	Drawing
Firewall	1	plywood	3 mm	(Fig. 53)
Wing joiner	1	plywood	1 mm	(Fig. 7)
Aileron pushrod	2	carbon	Ø1.8×110 mm	(Fig. 23)
Aileron, elevator, rudder horns	1 set	plastic	—	(Fig. 21) (Fig. 45) (Fig. 57)
Tailskid	1	plastic	—	—
Undercarriage plate	1	plastic	—	(Fig. 15)
Wheel	2	plastic	Ø40 mm	(Fig. 36)
Wheel pant holder	2	plastic	—	(Fig. 36)
Wheel axle	2	steel	M3×16 mm	(Fig. 36)
M3 nut	4	steel	M3	(Fig. 36)
M3 washer	4	steel	—	(Fig. 36)
Undercarriage bolt	4	steel	M3×25 mm	(Fig. 35)
Undercarriage bolt holder	2	plastic	—	(Fig. 31)
Undercarriage bracket	2	plastic	—	(Fig. 32)
Clevis	7	plastic	—	(Fig. 23) (Fig. 46) (Fig. 59)
Clevis pin	7	brass	—	(Fig. 23) (Fig. 46) (Fig. 59)
M2 ball link	1	plastic/brass	—	(Fig. 51)
M2/1 threaded coupler	2	brass	—	(Fig. 48) (Fig. 51)
M2/2 threaded coupler	2	brass	—	(Fig. 23)
Clevis spacer	2	plastic	Ø2 mm	(Fig. 46)
Pushrod guide	10	plastic	—	(Fig. 43)
Aileron servo arm	2	plastic	—	(Fig. 16)
Motor mount screw	4	steel	Ø2.9×6 mm	(Fig. 62)

Main section

Model assembly

Danger

Keep the propeller removed during assembly, radio setup and the initial motor test. Keep the flight battery disconnected except when a powered check is required. Switch on the transmitter with the throttle at minimum before connecting the flight battery; disconnect the battery before switching off the transmitter.

Drawing symbols

Follow the drawings in numerical order. The labels in the original drawings mean:

Drawing label	Meaning
Medium CA	Medium-viscosity cyanoacrylate adhesive
Thin CA	Thin cyanoacrylate adhesive
No glue / Do not glue	Leave the indicated joint unglued at this stage
Carbon	Fit the carbon reinforcement
Red drops	Apply a few drops of the indicated adhesive
Accelerator	Apply CA accelerator
Hot glue	Use hot-melt adhesive
TS / Top side	Upper surface
BS / Bottom side	Lower surface
L + R	Make matching left and right assemblies
Drill symbol and Ø	Drill to the specified diameter
Cut / Cut line	Cut along the marked line
Roughen / Sand to shape	Roughen the bonding surface or sand the end to the illustrated shape
Servo neutral	Centre the servo electrically before setting its arm

Use the dimensions printed on the drawings. The images on screen are not full-size templates. Check the assembled linkage lengths before gluing the fittings permanently.

Wing, tailplane and fuselage reinforcement

1. Cut the horizontal fuselage at the marked line. Glue the wing panels to it with medium CA, keeping the profiles aligned. Leave the marked transverse joint unglued for the plywood wing joiner. (Fig. 1) (Fig. 2) (Fig. 3)
2. Cut the 960mm spar slots 3 mm deep on the top and bottom of the wing. Cut through the centre section for the plywood joiner. Shorten both Ø1.5×1000 mm carbon rods to 960 mm and glue one to each face with thin CA. Fit the plywood joiner in the centre slot with thin CA. (Fig. 4) (Fig. 5) (Fig. 6) (Fig. 7) (Fig. 8)
3. Reinforce the tailplane with thin CA: on the underside, fit the 3×1×250 mm strip and two 3×0.5×125 mm diagonal strips cut from one 250mm strip; fit the remaining 3×0.5×250 mm strip across the upper face. Glue the tailplane to the horizontal fuselage with medium CA, keeping it straight and the elevator free. (Fig. 9) (Fig. 10) (Fig. 11)
4. Cut the four 3×0.5×1000 mm fuselage strips according to the layout. Each provides a 600mm longitudinal strip P; use the remaining lengths for diagonals D1–D5. Fit matching reinforcements on the top and bottom with thin CA. Glue the undercarriage plate into the underside with medium CA. (Fig. 12) (Fig. 13) (Fig. 14) (Fig. 15)

Servos and aileron linkages

1. Centre all servos electrically before fitting their arms. Separate the aileron arm extensions, screw them to the original arms and trim the projecting screw ends flush. Make mirrored left and right assemblies and secure the arms to the servos. (Fig. 16) (Fig. 17) (Fig. 18)
2. Open the servo recesses as shown and cut the indicated clearance slots 9 mm deep. Secure the aileron servos with hot-melt adhesive. Separate horns a, b and c; retain b and c for the tail. Glue horns a into the ailerons with medium CA, seating each flange flush against the foam. (Fig. 19) (Fig. 20) (Fig. 21) (Fig. 22)
3. Shape the ends of the two Ø1.8×110 mm carbon aileron pushrods. Glue the fixed clevis and threaded coupler with thin CA; leave the screw-on clevis adjustable. Set each linkage to 134 mm between pin centres and 100 mm between the indicated fitting faces. These are assembled dimensions, not rod cutting lengths. Connect and secure the pins with the servos and ailerons at neutral. (Fig. 23) (Fig. 24) (Fig. 25)
4. Prepare the elevator and rudder servo arms. Fit the elevator servo in its horizontal-fuselage recess with hot-melt adhesive, with the arm pointing to the underside as illustrated. Retain the rudder servo for the later installation. (Fig. 26) (Fig. 27)

Lower fuselage and undercarriage

1. Glue the canopy profile to the vertical fuselage with medium CA. Split the fuselage into lower part d and upper part e along the marked line. Glue part d into the horizontal fuselage, checking that it is square. Fit the two undercarriage bolt holders from the upper side. (Fig. 28) (Fig. 29) (Fig. 30) (Fig. 31)
2. Drill the wheel-axle holes in the carbon undercarriage to Ø3.0 mm. Position the undercarriage on its plate and secure it with the two brackets and four M3×25 mm screws. (Fig. 32) (Fig. 33) (Fig. 34) (Fig. 35)
3. Separate the wheel-pant parts and holders. Drill the wheel hubs and holder holes to Ø3.0 mm. Fit each Ø40mm wheel on an M3×16 mm axle screw with two M3 nuts and two washers in the illustrated order. Roughen the holder tabs, orient the small locating hole as shown, and secure the axle to the undercarriage. Leave the wheels free to rotate. (Fig. 36) (Fig. 37) (Fig. 38) (Fig. 39) (Fig. 40)
4. Glue each pair of EPP wheel-pant halves together with medium CA. Glue the completed pant to the roughened holder tabs, keeping adhesive clear of the wheel and axle. (Fig. 41) (Fig. 42)

Elevator linkage and upper fuselage

1. Separate the ten pushrod guides. Glue five into the horizontal fuselage with medium CA and align their holes. Fit elevator horn c with thin CA and accelerator. (Fig. 43) (Fig. 44) (Fig. 45)
2. Cut the Ø1.0×1000 mm carbon pushrod stock into two 500mm blanks. Glue a spacer and fixed clevis to one end of each with thin CA and accelerator. Pass the elevator rod through its guides, connect the clevis to the elevator horn and fit the adjustable clevis with its M2/1 threaded coupler to the servo arm. (Fig. 46) (Fig. 47) (Fig. 48) (Fig. 49)
3. With the elevator and servo at neutral, adjust the rod to give 472 mm between clevis pin centres and 442 mm between the indicated fitting faces. Allow for the rod insertion depth before trimming the blank; these are assembled dimensions. Glue the rod into the coupler with thin CA and accelerator, leaving the threads adjustable and the guides free. (Fig. 50)
4. Fit the ball link and its threaded coupler to the centred rudder servo arm. Secure the servo in the fuselage with hot-melt adhesive. Glue the plywood firewall into the nose with medium CA. (Fig. 51) (Fig. 52) (Fig. 53)
5. Glue the remaining five pushrod guides into upper fuselage part e with medium CA. Glue part e into the horizontal fuselage, then glue on the fin and rudder assembly. Check alignment and free movement of both tail controls. (Fig. 54) (Fig. 55) (Fig. 56)

Rudder linkage and final assembly

1. Glue rudder horn b into its slot with medium CA and accelerator. Pass the remaining prepared carbon rod through the guides and secure the clevis to the rudder horn. With the rudder and servo at neutral, set 425 mm between the clevis pin and ball-link centres and 400 mm between the indicated fitting faces. Trim the blank allowing for insertion into the coupler, then glue it into the coupler with thin CA and accelerator. Keep the ball link, threads and guides free. (Fig. 57) (Fig. 58) (Fig. 59) (Fig. 60)
2. Glue one side force generator to each wingtip with medium CA. Keep the ailerons free throughout their travel. (Fig. 61)
3. Secure the motor to the firewall with the four Ø2.9×6 mm mounting screws, checking compatibility with the chosen motor mount. Install the ESC and receiver according to their instructions, securing all leads clear of the linkages and providing cooling. Leave the propeller removed until the radio and motor checks are complete. (Fig. 62)

Assembly drawings

Pre-flight preparation

Radio and control checks

1. Connect the servos and ESC to the receiver according to the radio instructions. Check that the BEC voltage is suitable for the receiver and all four servos. Use the dimensions in the linkage drawings to check neutral positions and geometry. (Fig. 24) (Fig. 50) (Fig. 60)
2. With the propeller removed, switch on the transmitter with the throttle at minimum, centre the other controls and trims, and connect the flight battery. Check every control direction and adjust the linkages to neutral.
3. Set the recommended throws. Moving a linkage closer to the servo shaft or farther from the control-surface pivot reduces the throw; the reverse increases it. Check for free movement throughout the selected travel and secure every clevis pin and servo-arm screw.

Control throws

Control surface	Low rate		High rate
	Throw	Expo	Throw	Expo
Ailerons	±30°	45 %	±44° or more	40 %
Elevator	±30°	45 %	±50–60°	45 %
Rudder	±35°	50 %	±47°	50 %

Use low rates for the first flights and classic aerobatics. High rates are intended for experienced pilots flying 3D aerobatics. Set the expo direction according to the transmitter instructions so response is softer around neutral.

Motor rotation

With the propeller removed, check motor rotation. If necessary, disconnect the flight battery before swapping any two of the three motor wires, or change rotation using the ESC programming procedure. Once the radio and motor settings are correct, disconnect the battery and fit the propeller according to the motor and propeller instructions.

Centre of gravity

Secure the flight battery to the side of the lower vertical fuselage with hook-and-loop tape. With the model complete and ready to fly, adjust the battery position to obtain a CG 230 mm behind the front edge of the EPP nose, measured along the fuselage as shown. The reference is the foam nose, ahead of the firewall. (Fig. 63)

Attention

Use the specified CG for the first flight. An incorrect CG can make the model unstable or uncontrollable. The original manual permits later adjustment to suit an experienced pilot, but gives no approved adjustment range.

Range check

Fully charge the flight battery and transmitter batteries. Perform the radio manufacturer’s range check with the motor stopped and running at full throttle, securing the model safely and keeping everyone clear of the propeller. The range must remain almost unchanged; a reduction greater than 10 % is unacceptable. Do not fly unless every range and control check passes.

Flying

The model is intended for pilots who have already mastered a trainer with aileron control. Choose calm weather and a clear flying area for the maiden flight. Ask an experienced pilot to inspect the completed model and assist with trimming if needed. Start with low rates and check the model’s behaviour at a safe height before attempting aerobatics.

Appendix

ESC instructions

Follow the instructions for the controller you install (Recommended: KAVAN standard ESCs, KAVAN Plus ESCs or KAVAN PRO ESCs). Verify the ESC and BEC ratings against the chosen battery and servos before connecting power.

Caution

• Do not install the propeller on the motor when you test the ESC and motor for the first time to verify the correct settings on your radio. Only install your propeller after you have confirmed that the settings on your radio are correct.
• Never use ruptured or punctured battery cells.
• Never use battery packs that are known to overheat.
• Never short circuit battery or motor terminals.
• Always use proper insulation material for cable insulation.
• Always use proper cable connectors.
• Do not exceed the number of cells or servos specified for the ESC.
• Wrong battery polarity will damage the ESC and void the warranty.
• Install the ESC in a suitable location with adequate ventilation for cooling.
• Use only batteries that are supported by the ESC and ensure the correct polarity before connecting.
• Switch your transmitter ON first and ensure the throttle stick is in the minimum position before connecting the battery pack.
• Never switch your transmitter OFF while the battery is connected to your ESC.
• Only connect your battery pack just before flying and do not leave your battery pack connected after flying.
• Handle your model with extreme care once the battery pack is connected and keep away from the propeller at all times. Never stand in-line or directly in front of any rotating parts.
• Do not immerse the ESC under water, do not allow it to get wet while powered up.
• Always fly at a designated flying site and follow the rules and guidelines set by your modeller’s club.

Repairs and maintenance

• Please perform the range check in the beginning of each flying session.
• Before every take off please check the correct control surface movement.
• After every landing check the plane for any damage, loose clevises or push rods, bent undercarriage, damaged propeller etc. Do not fly again until the damage is repaired.

Despite the toughness of EPP foam, the Savage Mini can be damaged. Repair minor damage with CA adhesive or clear adhesive tape. Replace seriously damaged parts with suitable original spares obtained through a KAVAN dealer.

After a crash or hard landing, immediately move the throttle to minimum to prevent damage to the ESC.

Failure to lower the throttle stick and trim to the lowest possible positions in the event of a crash could result in damage to the ESC, which may require replacement of the ESC.

Note

Crash damage is not covered under warranty.

Guarantee

KAVAN Europe s.r.o. guarantees that this model kit is free from defects in both materials and workmanship at the time of sale. This warranty does not cover any parts damaged through use or as a result of modification; under no circumstances shall the liability of the manufacturer and importer exceed the original purchase price of the model kit. KAVAN Europe s.r.o. also reserves the right to change or modify this warranty without prior notice. The model kit is subject to ongoing improvement and refinement, and the manufacturer reserves the right to change the design without prior notice.

Since KAVAN Europe s.r.o. has no control over potential damage during shipping, the method of assembly, or the materials used by the modeller to complete the model, no liability can be assumed or accepted for damages associated with the use of the model assembled by the user. The moment the user decides to use the model they have assembled, they assume full responsibility. If the purchaser is not prepared to accept this responsibility, they should immediately return the kit in its complete and unused condition to the place of purchase.

If your RC model requires service, please follow the guidelines below. Failure to comply with these guidelines may result in the warranty being voided.

1. If possible, use the original packaging to pack the model. Do not use the original cardboard box as the final packaging.
2. Include a detailed description of how you have used the model and RC kit, as well as the problem you have encountered. Attach a numbered list of the included accessories and provide any additional information that may assist the service department. Date the note and double-check that it includes your full address and phone number.
3. Provide your name, address, and phone number where you can be reached during business hours. Include a copy of the model’s proof of purchase.

This warranty card entitles you to a free warranty repair of a product supplied by KAVAN Europe s.r.o. within 24 months. The warranty does not cover normal wear and tear resulting from regular use, as this is a product intended for sports and model-making use, in which individual parts operate under much higher loads than those to which ordinary toys are subjected. The model’s moving parts (motor, servos, and their gears, etc.) are subject to natural wear and tear, and replacement may be necessary over time.

The warranty also does not cover any part of the model or RC kit that was improperly installed, handled roughly or incorrectly, or damaged in a crash, nor does it cover any part of the model or RC kit that was repaired or modified by an unauthorised person. As with other delicate electronic products, do not expose your RC system to high temperatures, low temperatures, humidity, or dusty environments. Do not leave it in direct sunlight for extended periods.