DH 103 Hornet - A Building Guide: Fliteskin Products
DH 103 Hornet - A Building Guide: Fliteskin Products
DH 103 Hornet - A Building Guide: Fliteskin Products
Fliteskin Products
Scale: 1:5.4
100 Wingspan
Courtesy of www.StrictlyScale.com
Building Summary
Table of Contents
Item
Notes
Page
.
Nacelles
Wing
Stab / Rudder.
Fuse
Assembly
Finish
Flying
Building Summary
Notes
Building Summary
Qty
Description
Source
Est. Price
Engines
MVVS Netherlands
$600
Fuel Tanks
Hobby Lobby
$36
Spinners
Fliteskin Products
$166
Mufflers
Air Hobbies
Air Hobbies
$240
RC Showcase
$100
RC Showcase
$50
Dubro
Tower Hobbies
$25
Dymond Modelsport
$30
Maxx Products
$10
Maxx Products
$6
Radio Shack
$2
Radio Shack
$8
Radio Shack
$2
Building Summary
Qty
Description
Source
Est. Price
Nacelles
F/G Nacelles
VicRC
Inc.
set
Fliteskin Products
$275
Wing Tubes
TNT
$19
2+1
Fliteskin
Fliteskin Products
$170
Tower Hobbies
Sierra Precision
Hinges
Elevator Control Horns
$21
Landing Gear
Item
Qty
Description
Source
Est. Price
Wheels - Main
Tower Hobbies
$54
Retract - Main
Shindin Machine
$550
Retract - Tail
TBA
Wheel - Tail
Hobby Lobby
$8
Air accessories
Tower Hobbies
$34
Air accessories
Tower Hobbies
$13
Sierra Precision
$50
Building Summary
Qty
Description
Source
Est. Price
Fuselage
VicRC
$490
Canopy
Vanguard Vancouver
$40
Qty / Set
Description
Source
Est. Price
Plans
Rolled
Fliteskin Products
Photo CD
Pictures
Fliteskin Products
Pilot
eBay
Static Spinners
Fliteskin Products
$35
Solo Props
$33
Solo Props
$49
Navigation Lights
Electrodynamics
Electrodynamics
$100
Landing Light
Details4Scale
$50
G10 Details
Fliteskin Products
$29
Formed Parts
Vanguard Vancouver
Formed Parts
Wing Blisters
Fliteskin Products
$75
inc.
Building Summary
Qty
Description
Source
Est. Price
RX
Futaba - R148DP
Tower Hobbies
$130
Servo - Throttle
Tower Hobbies
$40
Tower Hobbies
$20
Servo - Rudder/Tailwheel
Tower Hobbies
$90
Servo - Elevator
Tower Hobbies
$32
Servo - Ailerons
Tower Hobbies
$63
Servo - Flaps
Tower Hobbies
$63
4.8V Battery
Tower Hobbies
$27
Building Summary
Building Summary
Building Summary
Fiberglass Fuselage
and Nacelles from
Fliteskin.com.
Building Summary
10
Building Summary
11
Aluminum Spinners
from Fliteskin.com.
Building Summary
12
Building Summary
13
Nacelle Construction
Nacelle Construction
begins with the layout of
all parts. If something
appears to be missing
contact Fliteskin.com.
Building Summary
14
Nacelle Construction
Note: When laying out parts and taping together, ensure you are
making one PORT and one STARBOARD nacelle.
On part N2 Inboard and Outboard, ignore the 5 small 1/8 dia holes near
the firewall. They were for potential engine mounts on the prototype.
Note incorrect location of
one of the servo tray slots,
resulting in an angled servo
tray. This tray alignment
has been correct and can
be repositioned or even
moved as the builder sees
fit. It is easier to mount the
throttle servo once the
engine is mounted to
ensure good alignment of
control rod.
Building Summary
15
Nacelle Construction
Nacelle boxes taped together to
check fit and plan internal
placement of components.
Building Summary
16
Nacelle Construction
Building Summary
17
Nacelle Construction
On my model I had to move the
firewall back. First mark out then
cut sides to suit. I also made new
firewalls out of Aircraft ply.
Building Summary
18
Nacelle Construction
Building Summary
19
Nacelle Construction
Building Summary
20
Nacelle Construction
Drill
Building Summary
21
Nacelle Construction
Fitting.
Building Summary
22
Nacelle Construction
Building Summary
23
Nacelle Construction
Building Summary
24
Nacelle Construction
Building Summary
25
Wing Construction
Building Summary
26
Wing Construction
Building Summary
27
Wing Construction
Building Summary
28
Wing Construction
Lengthen notch in W4 to
slide over main spar.
Pic shows one cut and
the second ready to cut.
Lengthen notch in W2 to
slide over rear spar.
Building Summary
29
Wing Construction
Trim front of W3 to
fit sq spar. Dont
glue yet.
Building Summary
30
Wing Construction
Building Summary
31
Wing Construction
Building Summary
32
Wing Construction
Four 1/8 ply flap
actuating tube
supports are made
and attached.
Glue one on each rib
closest to the ends
of both brass tubes.
Be careful not to get
any glue on the
aluminum tube.
Building Summary
33
Wing Construction
Here are a couple pictures of our
progress so far. Both sides of the
center section have the basic framing,
rear of the main spar, complete.
TIP: Install air tank now.
Building Summary
34
Wing Construction
Once the centers section is
framed up out to the outer most
ribs on the main spar, the outer
panels can be built.
Building Summary
35
Wing Construction
Building Summary
36
Wing Construction
Start framing the outer
panels using the lower spar
as a guide and gluing the top
spars in place.
Building Summary
37
Wing Construction
Once lower panels are framed up,
they are to be joined to the center
section. Carefully slide outer panel
in to center section overlapping
spars with the main spar.
Building Summary
38
Wing Construction
Once aligned and rear spars
tacked in place, add the 3/8 sq.
hardwood main spar cap. Also
epoxy the spruce sq spars that
overlap at this point.
Building Summary
39
Wing Construction
Building Summary
40
Wing Construction
The rear of each
nacelle box is
mounted with
two -20 nylon
bolts. Attached
pictures show
this arrangement
as well as the
tapped ply
blocks made up
to accept the
bolts.
Be cautious not
to glue the bolts
in when
attaching the
threaded blocks.
Building Summary
41
Wing Construction
With the nacelle boxes aligned
correctly open the three 1/8 dia
mounting holes to 3/16 dia.
Note, later I decided to add two more
6-32 bolts to this mounting scheme.
Read ahead to add this now.
Building Summary
42
Wing Construction
Building Summary
43
Wing Construction
Building Summary
44
Wing Construction
Building Summary
45
Wing Construction
The aileron
pivot wire and
tube is installed
next. First a
notch is ground
out in each rib
(1) to accept the
3/16 dia brass
tube. Nine
balsa blocks are
made (2) with
3/16 dia hole in
the center.
These are added
on the side of
each rib (3) as
shown and then
sanded smooth
(4).
Building Summary
46
Wing Construction
Now is a good time
install the retractable
landing light. Its
available from
Details4Scale.com and
has been modified for
4.8V power.
Building Summary
47
Wing Construction
I decided to drive to drive
the retraction off an air
cylinder. It will likely have
its own dedicated valve as I
want it to retract when the
flaps come down, and the
flaps are servo driven. With
the force of the air on the
lens I felt a small servo
would not be strong enough.
The on/off of
the light is
driven by a
micro switch.
Ill trigger this
with the end of
the air valve or
even servo
later.
Building Summary
48
Wing Construction
While the wing is
open its time to
hook up the flap
servo. A servo
tray is made from
ply and mounted
in the center of
the wing. The
aluminum torque
tube we installed
earlier is tapped
for a 6-32 bolt to
act as a control
horn. Note that
the pushrod is in
line with the
center of the
servo when at full
flap deflection.
Building Summary
49
Wing Construction
The outer horns on the flap torque tube are also drilled and tapped for 6-32
bolts. Its important to use loctite on the bolts and nuts to ensure they dont
come loose later. Note the wood dowel at each end of the torque tube. This is
to ensure the tube remains centered. A heavy-duty clevice is also tapped for 632 and shown in the right hand picture. Once the flaps are mounted the
pushrods will be made up and installed. This will also be shown later.
Building Summary
50
Wing Construction
There are two separate air valves in the wing. One for the retracts, and the other
for the retracting landing light. These are mounted on a piece of 1/8 ply as shown.
A couple hardwood rails are mounted on the underside to give the servo screws
something to bite into. Note the taper on one of the rails to avoid the spar.
Building Summary
51
Wing Construction
Light On
Light Off
Building Summary
52
Wing Construction
Before skinning the wing we need to do all the wiring/plumbing.
Building Summary
53
Wing Construction
Starting with the air system, I run the lines from the valves to the retract locations in
the nacelle bay, as well as the landing light out in the wing panel. I like to run my air
and servo leads in cardboard tubes. This keeps them all nice an bundled together.
Where there are no tubes I use small plastic ties to keep the wires together.
TIP: To help push wires through the tubes, use a piece of music wire with the lead taped to the
end of it. Feed the music wire through pulling the lead with it.
Building Summary
54
Wing Construction
Building Summary
55
Wing Construction
Building Summary
56
Wing Construction
I like to make all my own leads and use Ashlok connectors where I can to minimize the
number of connections. They are available in various pin counts from Ashtek Electronics.
This 12-pin connector is the only electrical connection between the wing and the
fuse. It carries the elevator and rudder servo leads, tail nav light, and
battery/switch connection (the RX is in the wing) all from the wing to the fuse.
Building Summary
57
Wing Construction
Five of the 6 pins in a 6-pin Ashlok
connector are used in the left wing
panel break for the aileron servo and
tip navigation light.
Building Summary
58
Wing Construction
Once the Twin Sync
is setup it really
shouldnt need to be
played with. In the
case it is needed to
be seen to trouble
shoot, Ive mounted
it in one of the open
wing bays and will
make a hiddden
hatch for access to it
once the wing is
skinned.
Again, note the use
of plastic ties on the
wiring to keep it in
order.
Building Summary
59
Wing Construction
The retract fill valve is mounted underneath the wing near the air
tank. The valve is set on a piece of 1/8 ply and attached just below
the surface of the wing. Once skinned, a hole will be cut in the wing
to access the fill valve.
Building Summary
60
Wing Construction
While there is
still access
inside the
wing, Ive
added some
balsa for the
carb intakes
between ribs
8 and 10.
These will be
carved out
later in the
build. Note
rib 9 needs to
be trimmed
back to allow
for the
balsa block.
Building Summary
61
Wing Construction
Building Summary
62
Wing Construction
Next 3/32 balsa shear webs
are added between the spars
as shown on the plans.
Building Summary
63
Wing Construction
Balsa leading edge is
added to the air intakes and
sanded round as shown on
the plans.
Building Summary
64
Wing Construction
Attention now turns to fitting out the nacelle boxes. First the mounting of the engines
and the main gear retracts (shown below).
Building Summary
65
Wing Construction
66
Wing Construction
Shown above are the manual remote glow (that you can plug into from your
flight box for starting) connection mounted on the side of the nacelle box. Also
shown is the Hobby Lobby pushrod transfer apparatus. Its designed to avoid
bending pushrods as they exit the fuselage. It will work well here, I hope, as the
carb arm is awkward to get to from the servo.
Building Summary
67
Wing Construction
Additional Engine control wiring. ** Note Ashlok connector
is used here as the nacelle box is made to be removable.
Ashlok
Connector **
Ground lead
on engine
mount
Lead to
onboard
battery
Lead to RPM
sensor
Onboard
glow control
module
Fuel line to
Carb.
Glow plug
lead
Building Summary
68
Wing Construction
Rechargeable on board
glow battery mounted to
nacelle box bulkhead.
Building Summary
69
Wing Construction
Building Summary
70
Wing Construction
The air inlets in
the wing are cut
and fitted from
1/8 ply.
Then they were
covered in
flitemetal (or any
smooth material)
and rubbed
smooth.
After painting
them flat black,
mesh wire form
was cut to
simulate the
mesh grills.
Building Summary
71
Wing Construction
Building Summary
72
Wing Construction
An important step in preparing the
wing for skinning is to sand all the
ribs and spars flush. A long sanding
bar works very will for this.
Building Summary
73
Wing Construction
Once sanding is complete its time to start
skinning the wing. For this we will use 0.010
thick Flite Skin and adhere it to the wing with
Elmers Nano glue.
Building Summary
74
Wing Construction
Building Summary
75
Wing Construction
Text
Building Summary
76