WYNNUM NORTH STATE HIGH SCHOOL

1
WYNNUM NORTH STATE HIGH SCHOOL Electric Aero
Skills Project UAV Instruction Manual
Name____________________________________ Teacher
Mr Paterson________________________
2
Materials List with approximate cost (2008
Pricing- prices have changed since)
3
1. Lay out your Depron on a flat surface with no
bumps or things that can mark the Depron. The
Depron is a soft material and can be marked easy
2. Place parts plan over the sheet of Depron and
pin down with sewing pins. The pins must be put
in on an angle or they will not hold the drawing
in the correct position. Put a pin in every
corner plus some down each side
4
3. Going around each part on the drawing use a
pin to push through the plan and swivel a bit to
leave a small hole in the depron. This will
leave a mark to use as a dot to dot drawing later.
4. If your ruler is only 300mm long you need to
make a mark every 300mm as well as each corner of
each part on the sheet. It is very important to
be accurate with this otherwise you will not get
the correct shapes
5
5. Once you have finished marking all the corners
and various other points you can start to lift
the sides of the plan to find the points. Get a
sharp pencil and mark the holes.
6. Use a ruler and lightly draw the lines onto
the Depron. Do Not gouge out the lines as this
will damage the Depron and make it hard to cut
later.
6
7. More and more of the plan should be peeled
back as you complete drawing on to the Depron
8. Once all the drawings are complete the parts
can be cut out.
9. The first piece to cut out is the wing spar.
Using a ruler and sharp knife cut part the way
through the Depron. Not all the way as we want
the 3mm Carbon Fibre spare to fit flush with the
bottom of the wing. When cutting only push
lightly and drag slowly. You may need to go over
the same line 2 to 3 times.
7
10. Use a paddle pop stick and sharpen one end to
a point. Use as a chisel and pick out the depron
between the lines. Do Not Go Through the other
side as the glue will make a mess later.
11. The groove for the carbon rod to fit in the
front of the plane can also be cut out.
12. Use a piece of sand paper and fold it in 2.
Sand out the groove so that the carbon rod fits
down flush with the surface of the Depron. Make
sure there are no bumps in the groove for the
carbon rod to hit and not fit properly.
8
13. Cut all the parts out of the sheet using a
sharp knife and steel ruler. When cutting take
your time. Do not try to cut all the way through
in one cut. It will take 2 to 3 passes with the
knife to cut all the way through.
14. Do Not throw out all the off cuts. They will
be used later.
9
15. This is how all the pieces should look after
they have been cut out.
16. Cut the carbon rod to the length of the
groove and then the nose.
17. Tape each side of the groove, for the rod,
before putting any glue near it. Get everything
ready to go before mixing glue. You only have
about 5 min before the glue will be dry.
10
18. Mix up 5min epoxy and fill the groove in the
wing and nose. Put the carbon rod in and remove
any excess. Remove masking tape as soon as
possible. Otherwise the tape will get stuck
there.
Gluing the Sides on
19. Mark a point out from the trailing edge of
the wing 6mm. Run some masking tape from this
mark to the front of the wing in a straight line.
20. Check to make sure the sides are going to fit
correctly.
21. Get everything ready to glue the sides on.
That includes Pins and Epoxy
11

• 22. Only do one side at a time.
• Mix up 5min epoxy and make sure you are mixing a
  11 ratio.
• Run a bead of epoxy along the top side of the
  side and across the end of the wing section.

23. Place the side onto the bottom of the wing.
Make sure it is in the right position. Use pins
to hold it in position while the glue dries. The
pins need to go in on an angle so they hold.
24. The tail plane can be slid in the back of the
plane to hold the sides in the correct position.
25. Make sure you remove the masking tape as soon
as possible, so it does not get stuck to the
plane.
12
Tailplane
26. Make sure the tailplane fits properly. It
should fit flush with the back and the sides and
not have any gaps on the leading edge of the
tailplane.
27. Make sure that the tailplane looks parallel
with the wing. If it is not it will not fly
straight well.
28. Using epoxy run a bead inside the front of
the tailplane and top and bottom of the groove to
fit the tailplane in.
29. Pin the back of the side to the tailplane so
they are all in alignment. This also stops the
tailplane from moving when the glue is drying.
This pin can be pushed all the way in as it is
not required to come out.
13
Tailplane
30. Cut 2 pieces of 2mm ply 150mm x 30mm wide
31. Epoxy and clamp the ply both sides of the
back of the tailplane.
Front
32. Draw around the front piece on top
polystyrene to get the profile. Use a band saw
or scroll saw to cut the profile.
14
33. Sand both sides flat if they are not already
flat.
34. Draw a line down the center of the front.
35. Cut the polystyrene front profile on bandsaw
or scroll saw.
36. Glue both pieces of polystyrene on each side
of the Depron front profile with epoxy.
37. Cut canopy off the top of the front
38. Cut and Sand front to shape.
Depron center core
15
39. After canopy is cut off. There will be a hole
in the depron.
40. Place the battery to fit into the plane over
the groove. Draw around the battery.
41. Use a knife and cut out the hole to the
bottom of the depron hole. Be careful not to cut
through the side. If this happens it will need
to be glued back together.
42. Check fit of front into the wing part of the
fuselage
43. Once the front is checked it can be glued in.
Glue in the slot and sides of the fuselage.
16
44. Tape around front while glue is drying.
45. The center stiffener needs to be cut down 2 x
30mm at the tailplane end to fit over the ply
stiffener.
46. Mark out the center, glue and fit with epoxy
to the center of the under side of the wing.
47. Make sure the front is glued well to support
the front of the plane
17
Bottom
48. Fit and glue servo tray in place. It glues
down onto the center stiffener and the front of
the plane.
49. Glue back bottom piece in place. Make sure
it is flush with the bottom of the sides.
50. Strap tape across the fuselage to hold the
sides in tight to the servo tray and back bottom
piece while it is drying.
51. Cut 2 pieces of depron 6mm wide and a bit
longer than the access hatch opening
52. Glue and pin the 2 pieces of depron 6mm wide
to both sides, 6mm below the bottom of the side
in the access hatch opening
18
Motor
53. Using a 45mm hole saw cut a disc out of 4mm
ply.
54. Mount the motor on the ply. You will need 4/
1.5 x 10mm long screws.
55. The motor has a shaft that comes out of the
back of it. It needs to be in the center of the
hole in the center of the mount

• Place the motor on top of the ply mount and with
  the motor shaft in the center hole.
• Mark one hole and drill with a 1mm drill.
• Screw the motor to the ply mount. Mark the
  location of the wires as this is the bottom of
  the mount.
• Mark the other holes and remove the motor and
  drill the other holes

19
Motor
57. Find the center along the back of the
tailplane and mark the position.

• 58. Mix a little bit of 5min epoxy. Spread it on
  the back of the tailplane.
• Place the mount on the center marks and use a
  square to keep it square with the top of the
  plane.
• Make sure it looks parallel with the back of the
  plane.
• Make sure the side of the mount with the wires
  sticking out is to the bottom.

• 59. When the glue is dry. Screw the motor on
  with the wires facing down.
• Fit Prop to motor.

20
Elevons
60. The Elevons were cut from the tailplane
61. The bottom of the elevon on each side needs a
chamfer cut off to hinge. This is done with a
knife and a ruler. Place the ruler on the top
leading edge and lean the knife at 45 slowly cut
all the way through. It may take more than one
pass to get through.
62. From the plan cut 2 control horns from 1 or
2mm ply and drill a 1mm hole on the same location
on each horn
63. Mark on the Elevon the location of the horn.

64. Cut the bottom surface with a knife. Do not
cut all the way through. Remove the material
between the lines
21
Elevons
60. Glue each horn in place with a little bit of
5min epoxy.

• 61. Use 40mm wide tape.
• The tape needs to have a good stick and be strong.

• 62. The tape needs to fold up into the hinge
  joint.
• Place the tape on the tailplane first then use a
  ruler to push the tape into the joint so it
  sticks to the tape on the top.
• Use the ruler to rub the tape down firm to the
  entire surface.

63. Get 2 push rods, push them up inside the
plane and connect them to the horns.
22
Servos
64. Cut 2 pieces of 2mm ply 8mm wide. Cut to
150mm long.
65. Glue one to the back of the servo tray.
66. Get a servo to check the length. The other
piece needs to be glued the length of the servo
away from the other piece.

• 67. The servos are to be 20mm each side of
  center.
• Use the servo as a template to draw the 2 holes
  required to fit them.
• Cut out the 2 holes for the servos

• 68. Fit the servos with 2 screws to each servo.
  The control horns should be to the tail end of
  the plane.
• It is not necessary to connect the servos up at
  this stage.

23
Electronics
68. Heat a 6mm brass tube up with a lighter or
gas torch and cut a hole through the styrene into
the front battery hole under the canopy
69. The hole is for the battery wires to come
through to the hatch.
70. The speed controller wires can be plugged
into the motor wires and the red and black wires
can be fed through to the front of the plane.
24
Electronics
71. Wires need to be soldered up in the front
battery hatch
72. The 2 receivers need to be located in the
plane. The main receiver will need a hole cut
through the depron servo tray for all the servo
wires to come through.

• 73. The receivers need to have their aerials 90
  and be taped down with masking tape after all the
  wires are plugged in.
• The Speed controller can also be taped in place.

74. Once all the wires are plugged into the
receiver the radio can be turned on and the
servos can be set up to connect the push rods.
25
Spectrum DX6I 2.4ghz Radio
Elevator and Rudder Stick
Throttle and Aileron Stick
Throttle trim
Elevator Trim
26
DX6i Radio terms

• ACT Active is working
• INH inherent not working
• Model Select Selecting the model you are flying
• D/R Expo Duel rate and Exponential
• Travel ADJ Travel adjustment of the servo. How
  far a servo moves in a 90 degree movement.
• Sub Trim adjusting the servo center position
• Mix 1,2 mixing channels together to do
  different actions
• E.g. Mixing Rudder -gt Ailerons so the Ailerons
  work at the same time the rudder is used.
• Mixing Elevator -gt Elevator can increase the
  movement of the elevator servo more than what the
  travel adjustment can.
• Model Type Acro or Heli
• Model Name change the name of the model

27
Radio set up for UAV F15

• Click wheel
• Adjust list gt Model select gt Model gt roll wheel
  to find wanted model gt click wheel gt Model is now
  selected
• TRAVEL ADJ (adjust) gt Click wheel gt Roll wheel gt
  AILE (Aileron) gt chick wheel gt Roll wheel to 125
  gt Chick Wheel gt check left and right are the same
• Roll to ELEV (elevator) gt click wheel gt Roll
  wheel to 125 gt Click Wheel gt Check up and down
  are the same
• Roll back to List gt click wheel.
• SETUP LIST gt click wheel.
• MODEL NAME gt click wheel gt input your group name
  one letter at a time.
• Wing Tail Mix gt click wheel gt roll down to elevon
  gt click wheel gt roll to ACT gt click wheel gt List.
• Reverse gt AILE gt Click wheel gt Roll wheel to get
  R gt Click wheel gt List
• MIX 1 gtELEV gtELEV ACT ?RATE 125 U ? RATE 125 D

28
Access Hatch
71. Fit the hatch in place and tape it in place
with masking tape.
Canopy
72. Velcro dots are used to hold the canopy on.
73. Use a small amount of epoxy to glue the
Velcro dots on and tape in place while the glue
dries
74. There should be a gap between the canopy and
the fuselage. This is to cool the battery as it
gets hot.
29
(No Transcript)