IAF-Zukit-Fouga Magister (RCJC)
 

IAF-Zukit-Fouga Magister-build thread.

Hello,

I present to you some pictures and information of my IAF-Zukit building process. The model was developed for few years by RCJC team and it is manufactured by FB jets according to the RCJC team specification.

More info can be found in the RCJC web site and here at RCU in theFouga Magister Is On the Market.

The majority of the information here is based on my personal experience.

I have no business relation with RCJC and this kit was bought by me for my personal use. Over the time I needed some support from RCJC and FB jets and got a good service from them.

Why this Jet?

Being a scale enthusiastic in general and for warbirds in specific I always liked special planes. For about 12 years I am building and flying mainly scale warbirds. For me the CM170 Fouga Magister was always one of the more elegant and graceful airplanes I ever knew. When I first started with RC Jets about 20 months ago I knew I'll have one sooner or later and being an IAF veteran it will definitely be the Israeli version called Zukit.

I was looking for a relatively big, easily noticeable scale jet with pleasant flight characteristics. Budget and storage place were also arguments so all in all I came to porches one beautiful Zukit directly from RCJC local inventory here in Israel.

General overview of the model Jet itself

Manufactured by FB Jets the overall quality is good. You will hardly find nasty or hidden issues. The hardware supplied in the kit is also from good quality and complete. The model was manufactured some time ago so in today's latest material and manufacturing technology there are products that combine even more lightweight materials to accomplish lighter weight.

Fuselage is made from Fiberglas reinforced with carbon areas and strips. The formers are from medium grade wood with part of the main formers reinforced with carbon doublers.

Scale details such as panel lines rivets and air vents are well made and noticeable. The kit comes with bags containing a lot of scale parts that will upgrade the scale appearance of the complete jet.

The paint job including weathering is done at the factory the quality is good with an even and drops-less paint coating. Although the finish is too shiny not as the real life planes it still looks good. Unfortunately some areas have too much sealer/primer/paint so panel lines and rivets are lost under it. This is also the case in other areas of the wings.

Front gear with its door is very scale like and factory installed. The front wheel is scale like with the unique groove in the middle originally designed to rout water from entering the air inlets. The wheel has the Goodyear logo on them like the real plane had. Remarkable.

V-tail is beautiful. One of the Fougas "trade marks". Made from main and rear spars-don’t know the material- covered with load bearing composite. It comes with flight surfaces hinged. Feels very strong but heavy. Later on ill inform of some must to do points regarding the tail section.



Wings are divided into 3 parts/sections. Center section is a part of the fuselage and forms one solid platform for the main gear and containing one of two flaps each side. 2 External sections are about 2/3 of each wing and have the external flap, aileron, air brake and wing tip fuel tank (not functional in the RC plane). Flaps can be either scale fowler type or semi scale asymmetrical hinged style. Choose your preferred type when ordering the model.

Same as the fuselage the wings are well detailed, ailerons already hinged. Scale like main gear with doors is air operated and factory installed. Brakes are also there.

All in all the first impression was it is a good solid quality product.



Assembly or better to say building an ARF

Yes, you can take it straight out of the well packed box and after few days/evenings have it ready for maiden. I had other planes.

Learning from previous personal experience I took all parts out of the box and assembled to see if everything matches together and if no missing parts. Other than the tail wheel all was there and all fitted nicely. It looks great and very impressive.

IAF-Zukit-Fouga Magister (RCJC)
 

https://cimg5.ibsrv.net/gimg/www.rcu...965f43dbcd.jpg
Out of the box. Nice touch to the living room.

IAF-Zukit-Fouga Magister (RCJC)
 

https://cimg3.ibsrv.net/gimg/www.rcu...159771b11f.jpg
The original rear fuselage is made from fiberglass reinforced with carbon strips. It is strong enough however combined with the narrow jet outlets, engine working and hot external temperatures as we have during summer the area might become soft/mellow
https://cimg4.ibsrv.net/gimg/www.rcu...aa3f3373ab.jpg
To better cope with hot climate and the tarmac in our summer days I decided to reinforce the rear fuselage with additional carbon. Later it was thermal treated with heat shield. The 180 grams weight increase worth it and the final result is very good.
https://cimg5.ibsrv.net/gimg/www.rcu...e0c780c264.jpg

IAF-Zukit-Fouga Magister (RCJC)
 

The above treatment is not mandatory and there are similar jets flying very well without this treatment.

IAF-Zukit-Fouga Magister (RCJC)
 

https://cimg1.ibsrv.net/gimg/www.rcu...39be13a851.jpg
Applied BVM heat shield for thermal protection.
https://cimg2.ibsrv.net/gimg/www.rcu...19952d9bd4.jpg
https://cimg3.ibsrv.net/gimg/www.rcu...6485deccff.jpg

IAF-Zukit-Fouga Magister (RCJC)
 

https://cimg9.ibsrv.net/gimg/www.rcu...be53da6178.jpg
The new air lines routed together.
https://cimg9.ibsrv.net/gimg/www.rcu...8a96bfb6c1.jpg
Fuselage main section also treated with BVM Heat shield. It is not mandatory for the heat in this area isn't too high. I did use it to give some protection to the body in case of fuel leakage and i just love the white finish in airplanes internal areas...

IAF-Zukit-Fouga Magister (RCJC)
 

https://cimg8.ibsrv.net/gimg/www.rcu...0ce2af0988.jpg
Wiring heat protection. There are several kinds in the market, I prefered this one since it has a higher declared temp resistance and it was already in my workshop.
https://cimg0.ibsrv.net/gimg/www.rcu...fd291bc797.jpg
https://cimg1.ibsrv.net/gimg/www.rcu...89605af30.jpeg
Tie wraps are secured to bases each 25 cm and in direction changes.
https://cimg2.ibsrv.net/gimg/www.rcu...e434dfbf41.jpg
Rear harness completed with servos wiring and future lighting system wiring.

IAF-Zukit-Fouga Magister (RCJC)
 

https://cimg3.ibsrv.net/gimg/www.rcu...7980b32b84.jpg
The hole for the wiring was made to prevent the wiring from "skipping over" the front and rear fuselage contact surface. This will not harm the structure.

IAF-Zukit-Fouga Magister (RCJC)
 

https://cimg3.ibsrv.net/gimg/www.rcu...27076b6470.jpg
The two fuselage sections are originally attached with 4 screws and blind nuts. I added 3 more. 2 on the sides and one on top. A forth bottom can't be used because of the exhaust pipe. 2 of the 3 are in this picture.

IAF-Zukit-Fouga Magister (RCJC)
 

https://cimg3.ibsrv.net/gimg/www.rcu...d93786151d.jpg
Front gear is very scale. Remarkably detailed to reality. Note the unique retract mechanism.
very important to thread lock all bolts. I disasembeld the entire retract mechanism and the air cylinder to make sure everything is in good condition and air leaks free.
The wheel itself is relatively heavy and solid.
The 2 metal rods use to center the gear at up position must be secured otherwise the gear might go up not centered and jam itself with the door.
I took them out and glued them in place.

IAF-Zukit-Fouga Magister (RCJC)
 

https://cimg1.ibsrv.net/gimg/www.rcu...a82e91cf47.jpg
Same as the front gear the mains are solid good quality and beutifull. I also took them entirely apart to verify mechanical and pneumatic operation. Again all bolts and nuts must be thread locked. Note the "spacer" made from several nuts...i guess they have too many at the plant... I added the nuts to my inventory and made a new spacer from a fuel tube.
https://cimg6.ibsrv.net/gimg/www.rcu...89a95d7c13.jpg
New spacer from fuel tube.
https://cimg2.ibsrv.net/gimg/www.rcu...662e428c97.jpg
Brakes where disassembled for inspection. The o rings are in good shape, all metal parts without chipings or dents. All was tested, lubricated and reinstalled. Again, thread lock.

Amazing job Avi, thanks for sharing.

IAF-Zukit-Fouga Magister (RCJC)
 

Thank you Drorso.

IAF-Zukit-Fouga Magister (RCJC)
 

Moving forward to one of the challenging subjects in this jet. The flaps.
The original CM170 was redesigned from a glider. Its weight to drag ratio is fabulous along with the long wing span and low wing load you get a kind of a jet glider. Never the less it need flaps. At the RCJC site you can choose between 2 types of flaps. the first is scale alike fowler type consists on the flaps with bearings running on rails. The second is the sport type with asymmetrical hinges. Both types consists of 2 flaps per wing, one flap in main section and the other in the external wing itself. Both types have options for actuation by one or two servos. Either one of the option you choose they will aerodynamically do the work well.

After some doubts about the fowler scale type I decided to go for it.

IAF-Zukit-Fouga Magister (RCJC)
 

https://cimg7.ibsrv.net/gimg/www.rcu...51c8c35170.jpg
Inner flap is a part of the fuselage/wing main section. The outer flap and aileron are part of the wing. Functional air brakes are also there so you have a pretty complex jet at your hands. Fun!

IAF-Zukit-Fouga Magister (RCJC)
 

So how it works?
Must admit that the idea is simple and smart.
Option 1 one servo for 2 flaps.
The inner flap is operated by a servo connected to a crank on a torque rod. The crank is connected to the inner flap. The crank task is to generate the desired angle for the flap to move. Without the crank there isn't enough height inside the wing to get the travel for generating the desired flap geometry.
The torque rod tasks are to first transfer the servo movement to the inner flap and second to transfer the rotation movement to the outer flap through a second crank.
Important note is that both cranks are positioned in the center of each flap to insure proper force to each flap in order to eliminate uneven movement.

Confused? Don't be, have a look at the pictures.

IAF-Zukit-Fouga Magister (RCJC)
 

https://cimg2.ibsrv.net/gimg/www.rcu...695f648e49.jpg
Here are the inner flap with its crank and rods. The hole in the crack is for the torque rod. All original clevices and threads where replaced with Sulivan hardware.

IAF-Zukit-Fouga Magister (RCJC)
 

https://cimg4.ibsrv.net/gimg/www.rcu...d33a122680.jpg
Obtaining the right connecting rods adjustment last long with a lot of coffee and bear. Or bear and coffee... All is secured with aero safety wire.

IAF-Zukit-Fouga Magister (RCJC)
 

https://cimg6.ibsrv.net/gimg/www.rcu...e78959ba5a.jpg
This is a view from the air brakes mechanism location on the crank and torque rod of the outer flap.
https://cimg2.ibsrv.net/gimg/www.rcu...b44edd3913.jpg

IAF-Zukit-Fouga Magister (RCJC)
 

https://cimg6.ibsrv.net/gimg/www.rcu...1205858c53.jpg
The inner flap mechanism with 2 connecting rods and the crank.

IAF-Zukit-Fouga Magister (RCJC)
 

https://cimg7.ibsrv.net/gimg/www.rcu...2f5b92294f.jpg
https://cimg6.ibsrv.net/gimg/www.rcu...e4f4f8f2d4.jpg
https://cimg1.ibsrv.net/gimg/www.rcu...5e38f4732c.jpg
The servo is mounted into place at the rear of the main landing gear. It is "slided" into rails so it can be removed for service.

IAF-Zukit-Fouga Magister (RCJC)
 

https://cimg2.ibsrv.net/gimg/www.rcu...6c5270b047.jpg
https://cimg8.ibsrv.net/gimg/www.rcu...4c29e6833b.jpg

IAF-Zukit-Fouga Magister (RCJC)
 

https://cimg9.ibsrv.net/gimg/www.rcu...c1346f081f.jpg
The movement to the outer flap is through the outer sife of the torque rod. This idea is simple and smart. I hope it will last since the joining points could be made from more hardened aluminum or better steal.

IAF-Zukit-Fouga Magister (RCJC)
 

The other option for the flaps operation is same as described but there is no connection between the two torque rods. The outer flap is operated with a servo connected with rods and crank similar to the inner flap.
This demands allocating a high torque mini servo as the flap operator in such way that it is impossible to get it out for service without scrapping or tracking the servo mount.
Add to it the servo weight and this was way I have decided to use one servo option.

It is however doable and was done by others.

IAF-Zukit-Fouga Magister (RCJC)
 

V tail.
The complete V tail is made from one section. It arrives with the surfaces already assembled nicely without slops or free movement. High quality but unfortunately heavy. In my opinion with today's updated materials adhesives and with more meticulous manufacturing proccess one could save about 50% of the entire section. Obviously reducing so much in the rear will have positive outcome in the front. Other then that It aligned and fit perfectly to the fuselage with 2 aluminum duels and one 6 mm bolt.
One nasty thing i came to find totally by chance was during one of the test runs i did to the plane. During disassembling of the beautiful V tail i thought i felt some movement in one of the 2 aluminum duels. Came back to the shop and using a plier i found that actually it was loos and about to leave his duty ...
I used my dremel to exposure the front part of the V tail and found out that the original glue wasn't spread properly. On the other hand it was a good opportunity to take a limited look inside of the V tail section. It is very well designed and build with high quality materials. Heavy but high quality.