FlyingBalsa MKII Humpback Manuel utilisateur
MKII 'Humpback'
Instruction Book
Initial release (May 2012)
Motor
Size
Eflite Power 25 or
Power 32
Rotor
Diameter 43”
ength
overall 36”
Weight 54 oz.
Head FlyingBalsa Gen III
Rotor
Airfoil
Aerobalsa high
performance SG6042
4 Channel
Direct rotor control
Pitch / Roll, Throttle
and Rudder
The MKII is a CAD designed, CNC manufactured auto gyro sport flier.
The MKII is designed to be a very stable, forgiving auto gyro with great performance. It was designed and tested
to be capable of flying in winds up to 15 mph and to ROG (rotate off ground) for takeoff's. No hand launches
are needed with the MKII.
By using CNC equipment, design tolerances are very tight and performance is duplicated kit to kit.
We recommend seeking help from the local modelers in your area if you are inexperienced. Orientation could be
your toughest challenge.
We hope you enjoy the MKII as much as we do.
Warranty
FlyingBalsa, C guarantees this kit to be free of defects in both material and
workmanship at the date of purchase. This warranty does not cover any damage of
component parts by modification, use or shipping. In no case shall FlyingBalsa, C
liability exceed the original cost of the kit. Further, FlyingBalsa, C reserves the right
to change this warranty without notice.
In that FlyingBalsa, C has no control over the final assembly or material used for
final assembly, no liability shall be assumed or accepted for any damage resulting from
the use by the user of the final user assembled product.
Table of contents
Table of contents..................................... xx
ist of CNC machined parts................... 1
Kit Contents............................................. , 3
Suggested supplies and tools................... 3
Recommended equipment....................... 3
Building................................................... 4
Horizontal stabilizer.................... 4
Vertical stabilizer........................ 4
Fuselage....................................... 5, 6, 7, 8, 9, 10, 11
Pylon............................................ 1 , 13
Tail installation............................ 14
Tail wheel, rudder, main gear...... 15
Radio installation......................... 16
Motor installation......................... 17
Control surface rigging................. 17
Rotor head installation................. 18
Rotor blade construction.............. 18
Blade balancing............................ 19
Initial setup................................... 19
Preflight........................................ 19
Flying............................................ 0
Contact information..................... 1
Revision history........................... 1
xx
PartsKit Cut
CNCMKII
Pylon Sides
L.G. Block
Firewall
Rotor Blade
Rotor Blade
Rotor Blade
** T ese parts are included in t e gimbal kit
Lower Gimbal **
Retainer **
Control Arm **
Upper Gimbal **
Doubler
Doubler
Fin
Elevator
Elevator
Horizontal stabilizer
Rudder
Fuselage filler plug
Battery Hatc
Pylon Hatc
F-2 F-1
Tongue
Wire Trap
Pylon Core
Pylon Support
Tail W eel Mount
Hatc Supports
Pylon Sides
Pylon Spacers
Blade Reinforcements
Fuselage Side
Fuselage Side
Pylon Forks
Rudder servo mount
* T ese parts are include in t e ead kit
Bearing Retainers*
Head Card*
Head Hinge*
Kit Contents
Documentation:
6 sheets 11” x 17” CAD drawings
1 Instruction book
Blades:
3 each Aerobalsa high performance SG6042 CNC machined for blade bolt bushings and to fit the FlyingBalsa
Generation III rotor head.
CNC parts:
See page 1
Hardware Bag:
1..... rudder horn with 2 screws
2..... main landing gear securing straps with 4 screws
1..... 3/32 x 1 gimbal pivot wire
2..... 3/32 wheel collars for gimbal pivot wire
2..... 4-40 swivel ball links
3..... rudder hinge strips
2..... landing gear hardwood torque blocks
1..... Du-Bro 1/16” nylon wire keeper for rudder pushrod
1..... Du-Bro 1/16” EZ connector for rudder pushrod
2..... Du-Bro 4-40 EZ connectors
6..... 8-32 nylon screws
3..... 4-40 x 3/4 socket head blade bolts
3..... 4-40 self locking nuts
3..... nylon rotor blade bushings
3..... #4 flat washers for blade bolts
2..... #6 flat washers for main landing gear wire
2..... 5/32 wheel collars for main wheels
1..... .050” Allen wrench for 3/32” and 1/8” wheel collars
1..... 1/16” Allen wrench for 5/32” wheel collars
1..... #33 drill bit to ream holes for 4-40 screws
1..... #43 drill bit to ream holes for 2-56 screws
1..... 1/16” drill bit for main landing gear and tail wheel bracket
2..... #2 x 5/8” (or 1/2”) screws to secure the tail wheel bracket
Wood bag:
1..... plywood firewall/landing gear mount
2..... balsa pylon sides
1..... 1/8 x 1/8 x 4 balsa strip
1..... 1/8 x 1 x 4 balsa for forward fuselage filler
1..... 3/32” plywood pylon fork card
1..... 3/32” plywood rudder servo mount
2..... balsa fork spacers
1..... toothpick
1..... 1/16 x 7” rudder pushrod wire
1..... 1/8 x 2-1/4” wood dowel for pylon forks
Other included items:
1..... 1/8 x 4 x 36 balsa for fuselage sheeting
1..... 3/8 x 3/8 x 12 balsa triangle for firewall and pylon reinforcement
1..... Generation III head kit
1..... Generation III gimbal kit
1..... Du-Bro tail wheel bracket
2..... 4-40 x 12 threaded push rods for pitch and roll
1..... pair pre-bent main landing gear
2..... 3” Du-Bro main landing gear wheels
1..... 1” tail wheel
End of kit contents
Suggested Supplies and Tools
In addition to the normal modelers tools we recommend the following:
Square................ for squaring formers and general usage.
3/32 drill bit........ for reaming gimbal pivot hole.
5/32 drill bit........ for drilling the landing gear torque blocks.
#29 drill bit......... for 8-32 tap.
8-32 tap............... for pylon and tank hatch screws.
End of suggested supplies and tools
Recommended Equipment
Motor – Eflite Power 25 or Power 32
Servos - Hitec HS 225MG for pitch and roll, Hitec Hs 85 for rudder control
Receiver – Spektrum AR6210 used in prototypes
Battery – Gen Ace 3S 4000 mah i-Po used in prototypes
ESC- Castle Creations Thunderbird 54 used in prototypes
Prop – APC Thin electric 13 x 8.5
Covering - Ultracote
3
General construction notes:
The CNC cut parts will have small 'tabs' on them when they are removed from their sheets. The tabs must be
removed prior to use. Use care and do not sand or cut into the part while removing the tabs. The term “use thin
CA glue” refers to thin 'cyanoacrylate' glue. For the epoxy glued parts we recommend using 15 epoxy. 5 minute
epoxy will not give you enough time when gluing on the fuselage doublers. For sanding balsa parts, a 'fine' grit
of paper is all you need.
Gimbal and Head assemblies:
The gimbal and head assemblies are self contained separate 'mini kits' and are included with the MKII. These
can be built at the same time the basic model is being built. No further instructions for the head and gimbal will
be noted in this manual. Follow the instructions included with the gimbal and head kits. You will need these
items starting at step 42 in this manual.
Horizontal Stabilizer:
1) ocate the horizontal stabilizer and elevators.
Assemble the horizontal stabilizer assembly on a
flat surface. Simply glue the elevators to the
horizontal stabilizer as shown in this photo. Use
thin CA glue. The “elevators” are fixed and do
not move on this model. Sand the horizontal tail
assembly for film covering.
Vertical Stabilizer:
) The vertical fin and the rudder can now be sanded smooth for covering.
Round off the leading edge of the rudder and the rear edge of the fin. The
hinge slots will be cut AFTER both pieces are covered. This will be explained
in detail during 'final assembly'.
Fuselage:
This section covers the construction of the fuselage assembly. Take your time and ensure that the fuselage is
straight and square. We have engineered into the MK II many features that will help you assemble a straight
airframe.
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Tech note : Before gluing the doublers, ensure that you are building a left and a right side, since the fuselage
sides and the doublers are identical it is possible to build two rights or lefts.
Use the tabs on F1 and F2 as alignment aid to properly locate the doubler on each fuselage side. Do not glue the
formers in place yet. When the doubler is in the correct position, remove F1 and F2 and allow the epoxy
securing the doubler to cure. Ensure the doubler does not move out of position!
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3) ocate the two 3/16 balsa fuselage sides, the
1/16 plywood fuselage doublers, and formers F1
and F2. Start by gluing the doublers to the
fuselage sides using 15 minute epoxy glue. Center
the doublers vertically on the balsa sides. You may
notice that the doublers are approximately 1/64”
narrower than the balsa sides on the top and
bottom of the doubler. This is normal. You can
use one of the lite-ply formers to align the slots of
the doubler to the slots in the sides but DO NOT glue any formers in place yet! Also notice that the doubler does
not go all the way to the forward edge of the fuselage side. This was purposely designed this way to
automatically align the firewall in a later step.
4) Decide which side of the fuselage you want the
rudder servo to be on. It does not matter but on the
prototype it is installed on the left side. Remove
the servo filler plug from the tail card sheet and
glue it into the servo cut out hole on the side you
DO NOT want the servo to be on. Use thin 'CA'
glue. You will need to just barely round off the
four corners of the plug.
5) Epoxy the rudder servo mount in place on the
inside of the other fuselage side (the same side the
fuselage doubler is on). Simply align the
horizontal edges of the mount with the horizontal
edges of the cut out in the fuselage side. Ensure
the 2 holes for the servo mounting ears are
centered, fore and aft, in the fuselage cut out when
viewed from the outside of the fuselage side ( i.e.
the other side of what is shown in this photo). You
do not want the servo mounting holes to be
covered up by the balsa sides. NOTE: see step 37
on page 15 for a picture of what this looks like from the 'outside'.
6) ocate lite-ply formers F-1 and F-2 and the birch plywood lower pylon
support and dry assemble the former cage as shown in the photo. DO NOT glue
any of these parts together!
5
7) Install the former cage on the inboard side of one of the
completed fuselage sides. The inboard side is the doubler
side. Ensure the pylon support is towards the bottom of
the fuselage. Before gluing the formers in place, ensure
the former tabs are fully seated in the slots and use a
square to ensure that F1 and F2 are perpendicular to the
fuselage side. Use thin 'CA' glue. Do not glue the pylon
support yet.
8) The other fuselage side is glued on next. Align the
former cage on top of the remaining side and ensure the
former tabs are fully seated in the slots. Before gluing
with thin 'CA' glue make sure the fuselage is square in all
directions. Do not glue the lower pylon support in place
yet.
9) The 1/4” plywood firewall is glued in place using 15
minute epoxy. Be sure to keep the fuselage assembly
square while the glue cures. Note that it fits into the space
formed where the plywood doublers end. Align the
firewall with the top of the fuselage sides. It will extend
slightly below the bottom of the fuselage and will be
sanded flush with the landing gear mount in a later step.
When the firewall glue has cured, epoxy the 1/4” plywood
landing gear mount in place. Note that it fits into the
notches cut out of the 1/16” plywood doublers. When the
epoxy cures for the firewall and landing gear mount, sand
off any 'squeezed out' epoxy and the lower edge of the firewall flush with the landing gear mount so that the
1/8” lite-ply wire trap will lie flush with the sides. Note that this picture shows both the firewall and landing
gear mount glued in place. It is recommended that each piece be glued in place separately, firewall first then the
landing gear mount. IMPORTANT NOTE: see step 24 on page 12 before gluing the firewall in place. It will be
easier to drill the air cooling inlet holes in the firewall before it is glued in place.
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10) The three 1/8” birch plywood hatch mounts are glued
in place with 15 minute epoxy. The mounts fit into the
notches of the fuselage doublers. Install each mount as
shown in this photo and ensure they are flush or slightly
below the top of the fuselage sides. They must NOT
extend above the sides or the formers!
11) Cut the 1/8” square balsa piece to length and glue in
place behind F-2 at the top of the former. Use thin 'CA'
glue. This piece will give support to the 1/8” balsa upper
fuselage sheeting which will be installed in a later step.
Now the lower pylon support can be secured with thin
'CA' glue.
1 ) The 1/8” lite-ply wire trap is glued in place with 15
minute epoxy. It is important to ensure the wire trap is
'square' to the fuselage since this will set the main landing
gear alignment. It fits even with the front of the firewall.
Note that the wire trap extends past each side an equal
amount. These 'extensions' will be sanded off flush with
the sides in a later step resulting in a perfectly spaced gap
for the main landing gear wires.
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13) The landing gear torque blocks and 3/8” balsa triangle
braces are installed next with 15 minute epoxy. This can
all be accomplished at the same time. The torque blocks
have a angle sanded in them to match the firewall down
thrust. et the triangle pieces extend slightly above the
firewall. They will be sanded flush with the firewall when
the glue cures.
NOTE: cut two each 2” long pieces from the balsa
triangle for the firewall braces. The remaining piece will
be used for the pylon support.
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Tech note: Draw a straight line on your building board approximately 36 inches long. This line will be used
to align the notches in the bottom of the firewall, F1, F2 and the rear end of the fuselage sides to help ensure a
straight airframe.
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Take your time with this step and build carefully. This is critical to a straight fuselage!
14) Place the completed fuselage sub assembly on the line you drew on your building board. Ensure that the
small notch on the bottom of the firewall and formers F-1 and F-2 are directly over the drawn line. You will
need to secure the fuselage so that it does not move off of the line. Heavy weights placed along each side of the
fuselage work well. Also ensure that the fuselage stays firmly on top of the building board. Do not let it rise or
twist off of the surface. Now carefully bring the two fuselage sides together and meet them directly over the
drawn line. Be sure to use one or two small 'squares' at the rear end of the fuselage before the sides are glued
together! Otherwise it would be very easy to build a twist into the aft section of the fuselage resulting in a 'tilted'
tail section.
15) Remove the tail wheel mount bracket from the 1/8” birch plywood
card. Glue it to the rear of the fuselage on the bottom side with 15
minute epoxy. Note that it is slightly oversize to allow for final sanding
to fit the fuselage.
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