Aeroworks 100cc Edge Build Thread

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Aeroworks 100cc Edge Build Thread - 4/9/2010 4:16 PM

Jake Ruddy

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Good morning,

Well it appears the flying season is finally here once again. We (like most) had the longest and most snow ever this winter and I happy to say the sun is back and temps are up. It has been very windy so far but I am hoping the season evens itself out.

With that in mind it's time for me to start a build thread for my new toy. I am doing a review on the new(er) 100cc Edge from Aeroworks.

Parts to be used:

DA 100 (old style)
MTW 75 cans
3 x 8711s
4x 8611s
1 x R922 Powersafe receiver
2x 2300 A123s
1 x 1600 NiMh

I have started the unboxing and will be sharing actual pictures over the next few days but here are some teaser pics...

More soon!!!

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RE: Aeroworks 100cc Edge Build Thread - 4/9/2010 5:09 PM

Andrew Bird

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Great looking plane! Look forward to the pics.

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RE: Aeroworks 100cc Edge Build Thread - 4/9/2010 6:06 PM

phantomdriver

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Jake, Oregon still getting snow here & 12 degrees this morning.
I just recieved my 100cc edge and will be watching your build as well.
Orange or yellow? interetsed in the cg when finished. I plan on using
the new da 120 when they get released. I have the 50cc version flying
now and love it. Looking forward to your build.

Mike C.

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RE: Aeroworks 100cc Edge Build Thread - 4/10/2010 4:46 AM

Jake Ruddy

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Thanks guys.. I have a yellow one and purchased the decal kit. It's a pretty impressive decal kit, I think it will look great in person once I get it done.

We had just over 80" of snow here this winter which was a new record, last was 67" back in the 20s or something. Normally we get about 30" in a season. They are saying its going to be a bad summer for storms too so will be interesting to see what happens. I know so far it's been windy nearly every day. Last night we had winds of 50mph for about an hour as a storm came through.

I was hoping for a DA120 as well for this project but it wasn't possible so I am using my 100 from my 260. I have heard some good things about this plane so I am looking forward to getting her in the air and putting it through the paces.

I will be getting up early tomorrow to start the build and if all goes well I will spend majority of the day on it.

Expect lots of pics tomorrow.

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RE: Aeroworks 100cc Edge Build Thread - 4/13/2010 4:49 PM

Jake Ruddy

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My bad, I couldn't find my cable to my camera!

I will be posting a bunch of pics tonight.

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RE: Aeroworks 100cc Edge Build Thread - 4/15/2010 10:52 PM

Jake Ruddy

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Alright, crazy week with work. So now I am working and posting pics at the same time. I have to work all this weekend but next weekend will be the maiden and I will shoot some video then as well.

As you can see she arrived a little beat up, UPS didn't do me any favors. Since I have had several AW planes I knew it would be doubleboxed and wood would be in there as well so things would be safe...

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RE: Aeroworks 100cc Edge Build Thread - 4/15/2010 11:01 PM

Jake Ruddy

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Lets take a look at what some of the included parts and a closer look at the plane itself...

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RE: Aeroworks 100cc Edge Build Thread - 4/15/2010 11:11 PM

Jake Ruddy

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Now we will start on the wings. I started with the basic tools needed and first sealed the wings.

It's very important that you go over an entire plane with a heat gun and iron when you get it. Edges need to be sealed and all covering fit tight to the frame. It doesn't matter if there is no wrinkles or not, it's a step well worth the time and it gives you extra time to closely inspect things.

Next get your servos, arms, and extensions ready.

You will notice there is string run through the wings already for you. Simply break the piece of wood free and then tie your servo extension end to the string and pull it through.

Once you have the servo leads run you can dry fit the servos in place and prepare to predrill the servo mounting screws. Use a 1/16" drill bit and predrill your holes. Once you have the holes drilled you then need to harden the holes with thin CA.

After the CA has dried properly mount the servos to the wing.

*NOTE* Be careful with the CA, it can drop to the covering below and you will see it on the top of your wings.

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RE: Aeroworks 100cc Edge Build Thread - 4/15/2010 11:24 PM

Jake Ruddy

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Now we can mount the control arms and finish the servos.

Aeroworks uses aluminum control horns that are attached by 3 screws on each side. The holes are pre-drilled and these are simple to install. I pre-drilled just the top of the already drilled holes just to make the screw sit in easier. I then just used my drill to screw in the screws.

The big thing to remember here is to use some medium CA on the control horn screws so they stay secured.

There are servo linkages included along with a wrench to make adjustments.

*NOTE* Pay special attention to how the linkages are assembled and remember the root end of the control link uses the bottom hole and the wing tip end of the control horn uses middle holes

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RE: Aeroworks 100cc Edge Build Thread - 4/15/2010 11:30 PM

Jake Ruddy

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Lets move on to the stabs...

Same same basic steps apply here as they did for the wings. I will let the pictures do the talking.

*Cool Feature* One thing I forgot to note on the ailerons is the use of 2 hinges at the wing tip which I thought was a great feature. You can see here the stabs have it as well.

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RE: Aeroworks 100cc Edge Build Thread - 4/15/2010 11:31 PM

Jake Ruddy

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More soon!

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RE: Aeroworks 100cc Edge Build Thread - 4/22/2010 6:11 AM

Jake Ruddy

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Hey guys, haven't forgotten about this. Work has been super busy the last 2 weeks, conference all weekend and this week has been rediculous. Been on the go for the last 17 hours and calling it quits for today.

If I can find time I will wrap it up before Sat. if not Sat is def. a building day, not much left now!

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RE: Aeroworks 100cc Edge Build Thread - 4/24/2010 7:38 PM

Jake Ruddy

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I just finished installing the rudder... now it has to dry for a few hours.

Before you begin make sure you go over the rudder and tail section with a heat gun and iron.

I mounted the control horns first, I dont think I mentioned this before but when using the control horn screws the small ones are for the rudder. Also don't forget the medium CA on the screws like the other surfaces.

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RE: Aeroworks 100cc Edge Build Thread - 4/24/2010 7:39 PM

Jake Ruddy

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I like to use Gorilla Glue on hinges, basically I put some painters tape over the hinge hole, cut out the hole and then slice the tape in half so it's easier to peel from both sides after everything dries. For the hinges I put a dab of Gorilla Glue on a toothpick and cover the inside of the hole with the glue. I also buy the small bottles of Gorilla Glue and slice of the top slightly so a hinge will fit in there fairly tight. I do this so I can get an extra thin coating on the hinge itself as well.

As you can see in the pics I like to use a small dab of oil as well on the hinge. Do it over paper towel so it can suck up any excess oil quickly and not get on the rest of the hinge.

For the 15 mins or so the glue will expand and you will have to clean it up around the hinges. After that tape the rudder in place so the expansion doesnt cause a larger gap then you would like.

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RE: Aeroworks 100cc Edge Build Thread - 4/24/2010 7:46 PM

Jake Ruddy

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More soon... have to let things dry. We have rain coming in soon so I have to go cut the grass because it's suppose to rain for the next 5 days

My plan is to have this finished by tomorrow night and then be ready for 2 days of flying next weekend. I will be also shooting video so will have some in flight pics and video to share then as well.

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RE: Aeroworks 100cc Edge Build Thread - 4/25/2010 6:33 AM

bipeguy03

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Keep the pics commin! I'm building a 100 cc ultimate and looking for ideas on this size plane everywhere!

GREAT IDEA with the masking tape on the hinge points! Gonna have to give that a try!

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RE: Aeroworks 100cc Edge Build Thread - 4/25/2010 7:07 AM

SunShyne

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nice work Jake, great thread and a gorgeous bird. Look forward to seeing it done!

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RE: Aeroworks 100cc Edge Build Thread - 4/25/2010 7:24 AM

JOHNS3D

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nice job Jake as always.

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RE: Aeroworks 100cc Edge Build Thread - 4/25/2010 6:17 PM

Jake Ruddy

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Thanks guys... and we continue.

Remember I sliced the tape in half after cutting out the hinge holes? This is so you can peel it off easier deom each side. Once you peel it off you will have some left over tape and Gorilla Glue to remove. Use a #11 blade and get out all of the tape can cut away any excess glue around the hinge points. Any glue that is there is going to cause your surface to slightly bind and effect your throw.

Your surface should be able to move to max throws very easily.

Once you have all the tape/glue removed you can take a small drop of 3-in-ONE oil and put it on the hinge points.

**CAUTION with the oil, you only want a small drop on the hinge point itself. If you get oil on the surface when you go to seal the hinge gap the material will not stick.

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RE: Aeroworks 100cc Edge Build Thread - 4/25/2010 7:42 PM

Jake Ruddy

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On to the pull pull rudder system...

The manual calls for 2 x 180oz torque servos. Since I am using an 8711 I am going to use one to start with. I do have a Smart-Fly 3D EQ here and another 8711 if I decide to add another one. I am pretty happy with 1 8711 in the tail of my H9 260 and I can do KE loops coming out 5' from the deck with no feeling of blow back. This rudder is a typical Edge rudder and is a lot taller. I may compare 1 vs 2 down the road just out of curiousity.

The manual calls for a 3-3.5" arm. I had a 3" arm here that I thought was 3.5" I used the middle holes in the control horns which are 3" apart and was able to get full throw no problem. If you use a 3.5" arm make sure you use the outside holes so you get 1 to 1.

First I mounted the servo like any other servo, pre drill hole, thin CA, wait till it dries, and mount.

Then I ran the cables into the fuse and started the first servo end.

The the big thing here is making sure the loop of cable goes through the brass swag TWICE there should be a loop so it can't pull back through again. I give a light crimp first, then use some thin CA, then use diag. cutters and put 4 crimp spots on the swag so it can't come loose.

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RE: Aeroworks 100cc Edge Build Thread - 4/25/2010 7:53 PM

Jake Ruddy

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continued...

Get all 4 ends of the pull pull installed and semi tight before you fine tune it. You won't be able to get it perfect in one shot. That is why each end has an adjustable connection at the ball link.

After you have it close adjust each end at the ball link until it is tight. It should be fairly tight but doesnt have to be guitar string tight.

After everything is done don't forget to put the servo screw in with some blue loctite. You will see in the pics I haven't done that last step yet, dont forget!

**Remember - The pull pull cables will become loose over time, you should check these often and tighten as neccessary.

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RE: Aeroworks 100cc Edge Build Thread - 4/25/2010 8:28 PM

Jake Ruddy

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Now we move on to the tailwheel.

All the holes are pre-drilled so this is a pretty quick step. I put some medium CA on the screws and in the holes to harden up the wood a bit and keep the tailwheel on for those harrier landings.

Make sure the springs are tight but do not over tight them.

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RE: Aeroworks 100cc Edge Build Thread - 4/25/2010 9:24 PM

Jake Ruddy

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Now we move on to the main gear.

One thing I forgot to mention is that you can't tell in any pics online or these ones but the black is actually metalic which looks really sharp. I had forgotten about that until I unpacked the wheel pants and noticed the nice job on them. I am a firm believer that AW has some of the best wheel pants out there. You can tell there is a lot of care taken with them, they don't flex like a lot of other companies, and they are pre drilled which is an added bonus.

Something else to note is you can see that AW did some work to the main gear to make them liter which is a nice touch as well.

The gear goes on straight forward, there is a gear plate to be removed first, then mount the main gear, the tires, and the wheel pants. Couple key things here is blue loctite, and using a file to make a flat spot on the axle. Also make sure you have the wheel centered in the pant to make sure there is no rubbing.

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RE: Aeroworks 100cc Edge Build Thread - 4/25/2010 9:26 PM

Jake Ruddy

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finished up..

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RE: Aeroworks 100cc Edge Build Thread - 5/1/2010 7:20 AM

Jake Ruddy

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Slowly working towards the maiden this weekend around a hectic work schedule I did make some progress tonight.

Got the engine mounted up and a rough start on the venting.

Mounting the engine was easy thanks to the templates provided. I am using my trusty old DA 100 with standard mufflers. I was planning on using my MTW cans until I realized I didn't have the right headers on hand. So in a panic I hurried and found my standard mufflers instead.

To open the vents I jumped through the process using a soldering iron. I still have to remove the exhaust plates and clean them up from the inside now.

So far so good. Tomorrow will be an early morning finishing up the cowl, plumbing the tank, installing elevators, and setting up the radio.

More pics tomorrow...

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