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KAVAN Cumul 100 - Instruction manual
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===== Wing outer panels ===== * The wing outer panels are to be assembled in one piece. The winglets will be cut off subsequently. Build the wing panel on a flat building board. The trailing edge has to be supported so the wing tip was be 2 mm above the building board creating the required washout (the railing edge lays flat on the working surface at the '''W50''' root rib, then it is supported in at lest three points sot it was 2 mm above the building board at the '''W74''' end rib). * Assemble the main spar shear webbing. Epoxy the '''W37''' wing joiner bays to the '''W34''' balsa parts. Enclose the bays. Epoxy the '''W36''' plywood plates (front side of the shear webbing) and '''W35''' (rear side). Bind the joiner bays with the provided Kevlar® thread and soak with medium CA or epoxy.<br>{{Note|'''Note:''' Make a left and right pair.|type=info}} '''(Det. A, Fig. 3+9+5)''' * Assemble the wing panels without glue at first. Insert all ribs and riblets into the respective notches in the shear webbing. There are two 5 mm ribs '''W66''' and '''W67''' dividing the outer panel and the winglet (you can glue both two ribs square to the shear webbing and bevel both at 4 degrees angle once the winglet has been cut off, or you can one of them - preferably '''W67''') glue in 8 degrees angle using the supplied 8 deg dihedral jig). * Slide on the '''W83'''/'''W84''' trailing edges onto the ribs. Cyano the '''W50''' root ribs to the shear webbing using the 7 deg dihedral jig (the '''W49''' outer ribs are to be glued later - after the wing panels have been paired with the wing centre section). * Insert, but not glue, the '''W79''' auxiliary spar (5 mm balsa) and the '''W80''' aileron leading edge (7 mm balsa). * Cyano the '''W46''' aileron horn blocks between the '''W56''' and '''W58''' ribs (not to the '''W80''' yet). * Double check the correct position of all ribs and spars; lay the wing on the building plan. Once satisfied, pin down the wing outer panel to your building board with the trailing edge supported as described above. Apply medium cyano to all joints (do not glue the '''W79''' and '''W80''' parts yet). Insert and cyano the '''W78''' wing panel rear spar (6×3 mm pine stick) and the '''W85''' winglet rear spar (4×2 mm pine). * Butt joint the '''W77''' main spar (10×2 mm pine) to the edge of the '''W89''' top D-box sheeting (1.5 mm balsa). Apply white glue to the top of the ribs, riblets and the main spar shear webbing. Insert the '''W89''' main spar into the notches in all ribs and pin it down. Then step by step pin down the '''W89''' balsa sheeting to the ribs. * Butt joint the '''W91''' winglet main spar (8×2 mm balsa) to the edge of the '''W88''' top D-box sheeting (1.5 mm balsa). Apply white glue to the top of the ribs, riblets and the main spar shear webbing. Insert the '''W91''' main spar into the notches in all ribs and pin it down. Then step by step pin down the '''W88''' balsa sheeting to the ribs. * Once the glue has cured, remove the outer wing panel from your building board. Align the top edge of the '''W79''' and '''W80''' flush with the top edge of the ribs and glue them to the ribs, not to each other. Trim the protruding part at the bottom side of the wing. Put the wing panel down onto your building board to check the trailing edge is '''straight and elevated by 2 mm at the wing tip'''. * Glue the '''W43''' wing tip in place. * Glue the '''W90''' support spar in place as well as the '''W77''' and '''W91''' bottom main spar. Use white glue to secure the '''W87''' and '''W86''' bottom D-box sheeting in place. * Sand the front edge of the '''W87'''/'''W89''' and '''W86'''/'''W88''' balsa sheeting flush with the front edge of the ribs and glue the '''W75''' and '''W76''' leading edges in place. * Glue the '''W48''' winglet gussets in place. Glue the '''W44''' bottom cover plates of the aileron servo bays between the '''W56''' and '''W58''' ribs. * Sand the '''W50''' root ribs flush. Trial fit the carbon wing joiners into the respective bays. There should be a tight fit, no play. Trial fit the '''W49''' liteply outer ribs - do not glue yet. * Slide the wing panel onto the carbon wing joiner together with the '''W49''' and '''W7''' liteply ribs. Slide on the wing centre section as well. Check how the ribs and wing parts are matching. Trim them as necessary to achieve a perfect fit. Once satisfied, epoxy the '''W7''' and '''W49''' ribs in place. * Fine sand the entire wing panels, pay attention to the leading edge. * Cut off the winglets. Use a fine razor saw to cut through (from the bottom) between the '''W66''' and '''W67''' ribs. If you have glued the ribs square to the main spar, now bevel both at 4 deg angle in order to achieve the required 8 degrees winglet dihedral. * Cut through the ribs between the '''W79''' auxiliary spar and '''W80''' aileron leading edge with a sharp modeller’s knife or razor saw and remove the flaps. Bevel the leading edge in 28 degrees angle allowing the down deflection of the ailerons (ailerons are hinged on the top side of the wing). * Glue the winglets to the wing panel (the butt joint protects the wing as there is a good chance the winglet breaks of in an accident - whilst the rest of the wing will remain undamaged). * Glue the '''W103''' aluminium alignment pins into holes in '''W49'''/'''W50''' ribs. '''(Fig. 13)''' * Trial fit the aileron servos. Prepare their extension cables. To allow threading the cables after the wing has been covered you should put a thread through the holes in ribs secured by strips of sticky tape. Or you can glue 6 mm plastic tubes (not included in the kit) - see the dotted lines on the building plan. You can use regular servo connectors between the wing centre section and outer panels, but the sturdier MR30 connectors ([https://kavanrc.com/item/mr30-connector-1pair-145913 KAV36.131] - not supplied in the kit) are more suitable for the task. If you are going to use them, install the female part (with sockets) of the connector into the wing panels. It is probably for the best installing all the cables before the wing is covered. Do not forget double check the correct polarity and connection first! The connectors are to be cyanoed to the wing after the covering.
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