KAVAN FunStik 1280mm kit - Instruction manual

Introduction

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

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

Caution: This RC model you will build and fly is not a toy! Although it may seem to be light and slow in flight it is capable of serious bodily harm and property damage. It is your responsibility and yours alone - to build this model correctly, properly install RC equipment and motor and to test the model and fly in accordance with all safety standards (and common sense) as set down in Safety Codes valid in your country. If you are just starting RC modelling, consult your local hobby shop or an experienced modeller in your local RC club to find a good instructor.

You must build the model according to the instructions. Do not alter or modify the model, as doing so may result in an unsafe of unflyable model. Take time to build straight, true and strong. Use proper radio and other equipment that is in first class condition, properly install all the components and test their correct operation before first and any further flight. Fly the model only with competent help from a well experienced modeller if you are not already an experienced RC pilot.

Note: We, as the kit manufacturer, can provide you with a top quality kit and instructions, but ultimately the quality and flyability of your finished model depends on how you build it; therefore we cannot in any way guarantee the performance of your completed model, and no representations are expressed or implied as to the performance or safety of your completed model.

Specification


Wingspan:	1280 mm
Length:	1040 mm
All-up weight:	1450–1500 g
Wing section:	symmetrical
Controls:	Aileron, rudder, elevator, throttle

Recommender power system & RC equipment


	Electric	Glow engine
Motor/Engine	KAVAN C3542–1200	O.S. MAX–25FX II
Propeller	APC 10×6E	9×5–6"
ESC	KAVAN R–50SB	-
Fuel tank	-	100–170 ml*
Battery	KAVAN LiPo 11.1 V 2200 mAh 40/80C	KAVAN NiMH 4.8 V 2000 mAh

Servos

	Electric	Glow engine
Ailerons	2× GO–13MG	2× GO–13MG
Elevator & rudder	2× GO–52MG (2× GO–17MG)	2× GO–52MG
Throttle	-	GO–06MG

*) 100–150 ml fuel tanks are good for regular .20–.25 engines, more powerful and "thirstier" O.S. MAX–25FX II will be happier with 150–170 ml tank.

Recommended glues

Unless stated otherwise, use medium cyanoacrylate (CA) glue (KAV9952 KAVAN CA Medium). D-box sheeting and wing ribs are better to be glued using a water resistant white aliphatic resin, like our KAV9960 KAVAN White Glue (alternatively, you can use this sort of glue for most of wood-to-wood joints). The highly loaded parts (wing roots, wing main spars, firewall etc.) should be glued together using 30 minute (or slower) epoxy (like KAV9967 Epoxy 30min) offering high strength and enough time for the correct positioning/alignment.

Recommended covering material

The iron-on films like ORACOVER® or ORALITE® (if you wanted to keep the weight really down) will work the best for your FunStik.

Tools and accessories

Very sharp modeller's knife (e.g. Excel 16001 with No. 11 blades)
Scissors
Electric drill with drill bits
Wire cutter
Long nose pliers
Screwdrivers
Razor saw
Sandpaper No. 80, 100, 180, 360–400
Needle files
Soldering iron and solder
Clothing pegs
Modeller's pins
Epoxy mixing stick and vessel
Masking tape, clear sticky tape
Rubbing alcohol (for cleaning up excessive epoxy)
Paper tissue or soft cloth (for cleaning up excessive epoxy)
Straightedge with scale
Square edge
Thin clear plastic film (for protecting the building plan)
Permanent marker
Modeller's sealing iron, heat gun (for covering)
Lightweight balsa filler

Model assembly

Wing

Locate all the parts for one half of the wing. Sand to fit all plywood/Lite Ply parts, the inner leading edge, bottom and upper main spars 14 if necessary.
One by one, insert all the wing ribs 1 to 4 into the Lite Ply main spar shear webbing 15.
Insert the inner leading edge, bottom and upper main spars 14 and the trailing edge shear webbing 16 into respective notches in ribs.
Once you are satisfied with the fit and you are sure the wing structure is true and straight, glue all the parts together. We recommend using epoxy for the root ribs 1–3 and the main spars 14.
Epoxy the wing bolt reinforcements 10 and 11 in place.
Use white aliphatic resin to glue the top and bottom D-box balsa sheeting 19 and the top and bottom trailing edge sheeting 20. Be sure the wing still remains true and straight.
Glue the wing centre bottom balsa sheeting 8 and 9 and the top sheeting 9 in place.
Glue the outer leading edge 13, trailing edge 17 and corner gussets 7 (top and bottom) in place.
Glue together the wing tip consisting of parts 5, 6, 22 and 23.
Sand the outer wing end flush with the edges of the outer rib 4.
Glue the wing tip assembly in place and sand flush with the wing.
Glue together the aileron servo box consisting of parts 24–27.
Glue the aileron servo box assembly between the ribs; sand it flush with the edges of ribs. You can glue it to get bottom or top side wing access. The bottom access is preferred, but if you decided to fly your FunStik without the undercarriage (belly landing it on a grassy airfield) it is safer placing the servos and aileron linkage on the top side of the wing.
Glue the aileron servo cable leading stick 28 in place.
Glue together the two aileron parts 18. Sand them in the shape once the glue has cured.
Cut the notches for aileron hinges into the trailing edge and aileron. Insert the hinges into the trailing edge and aileron - do not glue yet. Be sure the aileron moves freely in the required range up and down. The hinges are to be glued after the wing and aileron has been covered.
Assemble the other wing half in the same way.
Caution: Keep in mind you are building LEFT and RIGHT wing halves.
Epoxy the wing joiner 12 into one wing half. Apply epoxy to the contact areas of both two wing halves and the wing joiner. Attach the wing halves together. Double-check the correct alignment! Once the epoxy has cured, glue the top wing centre balsa sheeting 8 in place.
Glue together the centre trailing edge parts 21 and to the wing. Sand them in the shape according to the building plan once the glue has cured.
Carefully sand the entire wing and ailerons clean using No. 180–220 sanding paper/sanding block and then with No. 400. Attach the aileron servo extension cables to the leading sticks 28 using plastic cable ties or strips of clear sticky tape.
The wing is ready to covering now.

Tail feathers

Glue the reinforcement sticks 69 into the horizontal stabilizer 67.
Once the glue has set, sand the entire horizontal stabilizer using a sanding block with No. 180–220 sandpaper. Round the leading and trailing edges. Sand the elevator 68 in the same manner as well.
Cut the notches for elevator hinges into the stabilizer and elevator. Insert the hinges - do not glue yet. Be sure the elevator moves freely within the required range up and down. The hinges are to be glued after the stabilizer and elevator have been covered.
Glue together the fin parts 64 and 65 on a flat working surface. Glue the sticks 71 into the fin. Once the glue has set, sand the entire fin using a sanding block with No. 180–220 sandpaper. Round the leading and trailing edges. Sand the rudder 66 in the same manner as well. Prepare the rudder hinges in the same way you did with the elevator.
Fine sand the entire empennage using a sanding block with No. 400 sandpaper - the tail feathers are ready to covering now.

Fuselage

Prepare all the plywood/Lite Ply parts of the fuselage and the bottom balsa plate 53. Sand to fit if necessary. Check if the rudder and elevator servo tray parts 42 and 43 fit the servos you intend to use. Modify the servo trail parts as needed or make new ones from 3 mm Lite Ply tailored to your servos. If you have opted for a glow engine, make sure your intended fuel tank (wrapped in 3–5 mm foam rubber to reduce fuel foaming due to motor vibrations) fits the openings in formers 34, 35 and 38. Modify the formers as needed.
Pin down the fuselage bottom plate 53 to a flat working surface protected with a sheet of thin plastic film.
One by one, glue the fuselage formers and braces 30 to 49 to the bottom plate 53. We recommend using epoxy for parts 30–44.
Epoxy both two Lite Ply sides 51 and top brace 50 in place.
Now it is the right moment for preparing the engine/motor mount installation. Draw horizontal and vertical centre lines on the front face of the firewall - they will help with the correct alignment of your engine/motor mount. The recommended down thrust (-3 ° down for both electric motor and glow engine) will be achieved with a suitable insert under the top of the motor/engine mount. Usually, no side thrust is necessary.

Glow Engine: Put an engine mount suitable for your glow engine onto the firewall. Align it to the centre lines so the shaft axis (corresponds to the bottom of the engine mounting lugs/top surface of the engine mount lugs) was centred. Mark the position of the engine mount mounting holes to the firewall.

Electric Motor: Put the radial mount cross supplied with your motor (or sold separately) onto the firewall. Align it to the centre lines so the shaft axis was centred and the cross was in the "X" position and mark the mounting holes to the firewall.

Glow Engine & Electric Motor: Drill the holes for mounting bolts (usually M3 screws). Install corresponding blind nuts to the back side of the firewall (M3 blind nuts - e.g. KAV0090/20 - not supplied in the kit) or glue regular hex nuts pressed into small scraps of plywood in there.