Final Assembly - Kavan FunStik Bauanleitung

8. Glue the outer leading edge 13, trailing edge 17 and corner gussets 7 (top
and bottom) in place.
9. Glue together the wing tip consisting of parts 5, 6, 22 and 23.
10. Sand the outer wing end flush with the edges of the outer rib 4.
11. Glue the wing tip assembly in place and sand flush with the wing.
12. Glue together the aileron servo box consisting of parts 24-27.
13. 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.
14. Glue the aileron servo cable leading stick 28 in place.
15. Glue together the two aileron parts 18; sand them in the shape once
the glue has cured.
16. 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.
17. Assemble the other wing half in the same way. CAUTION! Keep in mind
you are building LEFT and RIGHT wing halves.
18. Epoxy the wing joiner 12 into one wing half.
19. 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.
20. 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.
21. 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.
22. The wing is ready to covering now.
Tail Feathers
23. Glue the reinforcement sticks 69 into the horizontal stabilizer 67.
24. Once the glue has set, sand the entire horizontal stabilizer using a san-
ding block with No. 180-220 sandpaper; round the leading and trailing
edges. Sand the elevator 68 in the same manner as well.
25. 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.
26. 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 trai-
ling edges. Sand the rudder 66 in the same manner as well. Prepare the
rudder hinges in the same way you did with the elevator.
27. Fine sand the entire empennage using a sanding block with No. 400
sandpaper - the tail feathers are ready to covering now.
Fuselage
28. Prepare all the plywood/liteply parts of the fuselage and the bottom
balsa plate 53; sand to fit if necessary. Check if the rudder and eleva-
tor servo tray parts 42 and 43 fit the servos you intend to use. Modify
the servo trail parts as needed or make a new ones from 3 mm liteply
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.
29. Pin down the fuselage bottom plate 53 to a flat working surface protec-
ted with a sheet of thin plastic film.
30. 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.
31. Epoxy both two liteply sides 51 and top brace 50 in place.
32. Now it is the right moment for preparing the engine/motor mount insta-
llation. Draw horizontal and vertical centre lines on the front face of the
firewall - they will help with the correct alignment of your engine/mo-
tor mount. The recommended downthrust (-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 sidethrust 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 moun-
ting 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.
33. Glow Engine: Install the engine mount and your motor with silencer.
Mark the position for the throttle push rod outer tube opposite to the
carburettor lever on the firewall and drill 3 mm hole.
Insert your fuel tank into the fuselage in order to check it could be placed
in the correct position in relation to the needle-valve/carburettor rotor
as recommended by the manufacturer of your engine.
Electric Motor: Install your motor and mark the position of an opening
for the motor cables in the firewall. Cut the hole.
34. Glue the fuselage longerons 60 in place.
35. Sand the fuselage sides and glue balsa sides 52 in place (white glue
recommended).
36. Glue the elevator and rudder push rod outer tubes in place.
37. Glue the tail tip 63 in place and then, one by one, the top fuselage balsa
sheeting 59 (cross-grain).
38. Glue the trailing edge plate 58 in place, the undercarriage plate 72 and
the top nose sheeting 54 in place. Carefully sand the entire fuselage
including the fuel tank/battery hatch clean using No. 180-220 sanding
paper/sanding block and then with No. 400. The fuselage is ready to
covering now.
39. Glue together the tail skid consisting of parts 61 and 62; sand and cover it.
Covering
• Thoroughly sand the surface of all parts with No. 360-400 sandpaper and
carefully vacuum all the dust (the iron-on film does not stick well to a
dusty surface; the dust also contains hard grains released off the sand-
paper capable to ruin the smooth coating of your sealing iron quickly).
• Use as light iron-on film as you can get (transparent Oracover, Oralite etc.
– not supplied in the kit). Follow the instruction manual supplied with
the covering film of your choice please.

Final Assembly

40. Cut the covering film over the opening for the fuel tank/battery hatch 55
in the top nose sheeting 54. Glue the pin 56 along the front bottom edge
4