Table of Contents

iii

Introduction ......................................................................................... v a. How to use this manual .................................................................. v b. The manual definition .................................................................... v c. The target of the manual ............................................................... vi d. Author ........................................................................................ vi I. Step 1: Purchasing the Material ......................................................... 2 a. Where to find the base material ...................................................... 2 b. How to buy the controller, the motor and the battery ........................ 2 c. What tools will you need ................................................................ 2 II. Step 2: Cutting and shaping the styrofoam ......................................... 5 a. Making the wings .......................................................................... 5 a. Making the horizontal stabilizer ....................................................... 6 b. Making the rudder ......................................................................... 7 c. Making the body ........................................................................... 7 III. Step 3: Putting the parts together ................................................... 11 a. Connect the wing to the fuselage tail and stabilizer ......................... 11 b. Assemble Tail ............................................................................. 11 IV. Step 4: Connecting the electronic part to the plane ........................... 12 a. Installation of the servo ................................................................ 12 b. Programming the servo ................................................................. 13 c. Installation of the battery .............................................................. 13 d. Installation of the motor................................................................ 13 e. Connecting the plane to the radio controller..................................... 14 Conclusion ......................................................................................... 15 Index ................................................................................................ 17 Works Cited ....................................................................................... 17

Introduction

Introduction
a. How to use this manual
You will benefit in several ways from this manual. I believe everyone as a kid had some amount of fun making paper planes and throw it in the air. Flying is a mysterious feeling that you have to discover yourself. Making flying objects allows us to experience the joy of flying. This manual will guide you with step-by-step instructions as to how you can build your own RC aircraft with materials other than paper this time.

Caution: This symbol indicates the importance for you the reader to pay close attention as to avoid risks. Warning: This symbol indicates that you or anyone performing the assembly may injure themselves if extreme precaution is not applied.

b.

The manual definition

Elevator: is the aircrafts wing, located on the tail side that allows the plane pitch and dive. Fuselage: The fuselage or body of the airplane that holds all the pieces together. Propeller: is the twin blade that the motor spin to move the plane. Rudder: is the vertical wing located on the tail of the aircraft that give the plane a horizontal stability. It is also called vertical stabilizer (Tim). Servo: A servomotor is a rotary actuator that allows for precise control of angular position. Stabilizer: The stabilizer is a small wing, located at the tail of the plane, which control and maneuver the aircraft horizontally and vertically.

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How to build an RC Aircraft

c.

The target of the manual

This manual is intended for all those interested in building their very own mini-aircraft. As the pilot of your remote control mini-aircraft, you will control the machine using radio frequency technology. This project will allow you to have a quick glimpse into the life of a mechanical engineering student, and the amount of time and dedication that comes with this.

d.

Author

I am currently enrolled at the University of North Texas in my sophomore year majoring in Mechanical and Energy Engineering. I attended Richland Community College for two years and received my associates degree. I served as the secretary of the aviation club at Mountain View College, which helped build my knowledge of mechanical aircrafts, and the maintenance of many radio controlled aircraft. I found myself a great job at United Parcel Service that will help provide me the financial means for my engineering career. UPS is a worldwide delivery company that hires and trains its own computer engineers, main plan engineers, aircraft technicians and automobile technicians. I served as a volunteer for the Challenge Air for kids for three consecutives years. Challenge Air for Kids is a Program that gives a chance to kids with disabilities to fly. Helping those kids allowed me to connect with them on an emotional basis while teaching them something I love, aircrafts.

How to build an RC Aircraft

I.
a.

Step 1: Purchasing the Material

Where to find the base material
Its really cheap to build an RC aircraft. You will completely make the plane using styrofoam. You will need only one-sheet of Insulation foam 6 by 4 feet. You can pick up the Insulation foam at a store like Home Depot, Walmart or Lowes. You also need two metal strings as gear for the servos other components that are most likely have just sitting around the house.

b.

How to buy the controller, the motor and the battery

You will spend most of your money on electronics for the airplanes. You will find all the electronics parts in a RC hobby store. The hobby store will be able to you furnish everything you will need. Although, you will buy all my RC parts from the same Hobby, to ensure your part fit together. The size the motor isn't too important. You are quite likely to break a few propellers to order a couple extras. 20 amp brushless motor speed A 3-cell battery Control horns Controller Radio receiver systems Three servos

c.

What tools will you need

For the tool, which will help you manufacturing your aircraft, you will need to get. A meter A plastic gun A box cutter A sandpaper A tape A marker

Chapter II

II.
a.

Step 2: Cutting and shaping the styrofoam

Making the wings
- Step 1: Draw two perpendicular lines and cutting a piece of foam that is 28 inches by 14 inches (Figure - 1). - Step 2: You will use a drywall square to ensure you get a nice 92 be cuts (Figure - 2). - Step 3: Draw a rectangle with the with observances measure 14.5 inches down one side of the rectangle and 10.5 on the other (Figure - 3). - Step 4: Join the two marks and cut along that diagonal to obtain the shape for the wings (Figure - 5). - Step 5: Flip the first wing and place it on the foam sheet and trace an identical cut (Figure - 6). - Step 6: Put the wing together blew the wing tips in place so they have a slight angle (Figure - 7). - Step 7: Round these cuts as best you can with your knife and use the sand paper to make it smooth (Figure 8). - Step 8: Make a hole in connection part of the wing, for a stick entry (Figure 9).

b.

How to build an RC Aircraft

a.

Making the horizontal stabilizer

- Step 9: For the stabilizer you cut rectangle that is 12 by 2 inches (Figure - 8b). - Step 10: Now round two length corners (Figure 9b). - Step 11: On the 12 inches side, measure 4.5 inches and mark from either corner (Figure 10). - Step 12: On the opposite side, mark the center, from this point cut it into triangular shape, as the picture shows (Figure 11). - Step 13: Cut an angle of 40 degrees one side of the stabilizer (Figure 12). - Step 14: This angle will allow a horizontal elevation to the stabilizer (Figure 13).

Chapter II

b.

Making the rudder

- Step 15: Cut 8 by 8 inches square, then cut a rectangle that is 2.5 by 3.5 inches on one corner of the square (Figure 15). - Step 16: Cut a 2 by 1 inch rectangle to make an elevator for the tail. - Step 17: Then measure 1.5 inch from the opposite corners, round to the corners on this rectangle then now. - Step 18: Use a piece of light grit sand paper to wrap around the block foam to finish the round edges (Figure 16).

c.

Making the body

- Step 19:From the sheet of foam make a cut 3 feet on the edge, and then repeat the action three more time (Figure 17). - Step 20: Use one of the long pieces and stick it to another using the hot glue (Figure 18).

- Step 21: Stick the third piece with the bottom piece (Figure 19).

- Step 22: Use the sandpaper to make sure all the cuts and edges are flush or rounded (Figure 20).

Chapter III

11

III.
a.

Step 3: Putting the parts together

Connect the wing to the fuselage tail and stabilizer
Step 1: insert the metal stick onto control horns one of the wing as the picture shows (Figure a). Step 2:attach the second wing while fixing both to the fuselage as shown on (Figure b) and (Figure c). Figure - a Figure - b Figure - c

b.

Assemble Tail
Figure d

Step 1: Apply the glue to the horizontal stabilizers and while putting it the tail side of the body hold it in position until it sets (Figure - d). Step 2: Apply the glue on the vertical stabilizers, place it on the horizontal stabilizers and press it on until it sets (Figure - e).

Figure e

12

How to build an RC Aircraft

I suggest you reinforcing the part of the tail that will drag on the ground with some piece of wood or metal, to prevent damage of the foam. Second you will. (Hobby)

IV.
a.

Step 4: Connecting the electronic part to the plane

Installation of the servo
Figure - f Use hot glue to install the metal string to the rudder on the right wing and connect it to a servo that you will safely glue on the bottom of the wing (Figure - f). Then you will repeat this process for the left wing. You will glue a panel to the rudder vertical stabilizer so you can set another metal string (Figure g), which will be connected to a servo that you will fix it to the fuselage. Finally insert all wire into the fuselage

Figure - g

Chapter III

13

b.

Programming the servo

Connect the servos to the receiver by Inserting in the following table: The servo of the rudder is channel 3 (Figure - h) The servo of the elevators is channel 2 (Figure - i)

The servo of the wings is channel 1 (Figure - j)

c.

Installation of the battery

You will put the battery into the front of the fuselage, and then plug its wires into the general receiver. (Figure - k)

d.

Installation of the motor

Step 1: Glue the motor directly to the front of the airplane; moreover, I recommend you to clean the baseplate of the motor before you install it (Figure - l). Step 2: Make a hole for the wires of the motor to pass through into the fuselages and plug into the receiver. Then install the propeller by using the propeller nut (Figure - o). Figure - l Figure - o

14

How to build an RC Aircraft

e.

Connecting the plane to the radio controller

Make sure you have your finger of the propeller. Make sure the right stick of the controller is pointed down and all the servo receiver bottoms are on normal. Be careful and hold steady the plane when you want to set up the controller. (Figure 1a)

- Step 1: Turn on your controller and it will be automatically connect to the radio receiver in the plane. Figure 2b The right stick of the controller will allow the plane to accelerate and decelerate. - Step 2: Ensure that the elevator goes down when you push the left tick of the controller up, which makes a plane climbed (Figure 2b). - Step 3: Ensure that the elevator goes up when you move tick down; this will make your plane dive (Figure 3c).

Figure 3c

Conclusion

15

Conclusion
Once you have created your own mini-aircraft you should make sure that it would fly. Turn on the radio frequency that will send a direct signal to the motor to start the propeller. Your mini-aircraft will take off high fly, while you maneuver the toy aircraft using your remote control device.

Index

17

Index
Rudder, v Elevator, v

Servo, v Fuselage, v

Propeller, v

Stabilizer, v

Works Cited
Hobby, Banana. bananahobby. 4 April 2012. 8 November 2013 <http://www.bananahobby.com/>. Tim. Youtube. 9 February 2013. 8 November 2013 <http://www.youtube.com/watch?v=KOixZFAyoik#t=245>.