Foamboard Aircraft Parts Upgrade Kit – Level 1
$4.70 Foamboard Aircraft Parts Upgrade Kit – Level 1
3D
Published 2019-10-07T16:29:40+00:00
A 3D printable parts kit to upgrade a mid-size profile model aircraft with a wingspan of 1 to 1.5 meters (~39 to 60 inches), built from foamboard, cardboard, or balsa.
The kit consists of 4 different robust control horn styles, with large mounting bases to minimize control surface flexing, a motor mount suitable for many 450, 480 and power-10 size motors, with a built-in 1.5 degrees trust offsets, both downward and to the right, and a tailwheel assembly with a 20mm tailwheel designed to be mounted to an ~8mm (5/16”) thick rudder.
The kit was originally designed to upgrade a “Hummer” for my club’s 2019 pylon racing season. The upgraded aircraft flies true at much higher speed than stock, without flutter and with positive control on all surfaces, using a power 10 size motor – 1250kv, 3-cell, 600 watts power system, turning an APC 9x9E propeller.
The parts should work well with most other foamboard kits, where a decent size motor with adequate offset trust is desired, along with precise positive controls such as 3D aerobatics and/or faster flight.
The parts can be easily 3D printed, without any support, on a modern inexpensive 3D Printer. They can be printed with a variety of materials, including PLA, PETG, ABS and many other types of printable materials.
PLA works well for most of the parts, except for the motor mount which must be printed with a more heat tolerant material such as ABS or PETG. This is because the motor mount will likely be exposed to high temperatures during flight or immediately afterwards, exceeding ~55 C (~ 130 F). At such temperature, PLA will likely deform, warp or even separate, thus causing loss of control of the model.
Further, should the model with the upgraded parts be left in a parked car in the summer, the same thing could happen. Therefore, I strongly recommend using PETG or ABS for all the parts.
I have successfully used these upgraded parts since early 2019. They solved many issues I encountered with the flimsy hardware normally included in many foamboard kits.
Recommended print settings with a .4 mm nozzle:
Control Horns and Tailwheel (Plate 1)
- Layer Hight: .150 ~.160 mm, depending on motors and gearing
- 2 perimeters or shells (~0.9 mm)
- 6 bottom layers (~0.9 mm)
- 6 top layers (~0.9 mm)
- Infill 15%~20%, depending on infill type
Motor Mount and Tailwheel Fork (Plate 2)
- Layer Hight: .150 ~.160 mm, depending on motors and gearing
- 3 perimeters or shells (1.2 ~ 1.5 mm)
- 8 bottom layers (1.2 ~ 1.3 mm)
- 8 top layers (1.2 ~ 1.3 mm)
- Infill 20~30%, depending on infill type
Additional items needed for assembly
- 1 M2x16 screw to mount the tailwheel
- 1 M2 nut
- 2 M2 flat washers (optional)
- Medium CA or another suitable adhesive
Assembly Instructions
I recommend using medium CA, with or without accelerator, to glue the individual parts to the model. However, feel free to use any other suitable adhesives you are comfortable with.
The holes in the control horns may be slightly undersized for your pushrods and/or clevis. For a precise fit, ream/drill them out to the correct size for your hardware.
Motor Mount
1 - The motor mount consists of 2 separate parts - the X-Brace at the rear and the 1.5 degrees Offset at the front. The two parts should be glued together back to back using medium CA, to make one assembly. When completed, the engraved writing should be visible on the front side.
2 - Cut a 42.5mm high X 45mm deep opening in the front of the model for the motor mount, centered along the longitudinal axis or desired trust line. Make sure that the opening is not cut too large.
3 - The motor mount assembly is installed with the engraved writing facing upward - “up” should be in front and be oriented towards the top of the model. If mounted up-side-down, the offset trust angle will be in the wrong direction.
4 - Dry fit the motor mount assembly by orienting it properly in the opening with the long rails facing forward, and the short rail pushed all the way to the back of the opening that was cut in the step above. It should be a snug fit, not a tight fit. If necessary, carefully trim the opening in the foamboard.
5 - Once satisfied with the fit of the motor mount assembly, remove it and apply medium CA (or epoxy) in the motor mount assembly rails, then re-install it in the model to set the glue.
Note: The motor mount assembly is designed with the correct offsets for a clockwise rotating propeller when viewed from inside or the rear of the model. This is the standard in North America and many other countries around the world. Some models may require counter rotating propellers. In that case, the correct offsets should be to the left and down. This can be achieved by mirroring the 1.5 degrees offset part along the “X” axis prior to printing. Unfortunately, this will also mirror the engraved text in front of the part, making it difficult to read. However, the direction arrows will remain pointing in the correct direction.
Tailwheel Assembly
1 - The tailwheel is mounted in the tailwheel fork with the M2x16 screw.
2 - First, partially insert the M2 screw into one of the pre-threaded M2 holes located on the fork, to the point where it protrudes just past the inside of the fork.
3 - Optional - Install one M2 flat washer between the inside wall of the fork and the wheel.
4 - Install the wheel.
5 - Optional - Install another M2 flat washer on the other side of the wheel
6 - Continue tightening the M2 screw into the pre-threaded hole on the other side of the fork, to the point where it is just tight enough to prevent play but allows the wheel to turn freely.
7 - Secure the screw with the M2 nut. Only apply enough torque to the nut to seat it properly. DO NOT OVERTIGHTEN!
8 - Apply 1 drop of CA glue to the end of the M2 screw to prevent the M2 nut from loosening.
Notes: To assist holding the parts in place during assembly, partially tighten the M2 screw after Steps 3, 4, and 5.
The optional M2 flat washers are used to reduce potential friction between the wheel and the fork. I made tailwheel assemblies both with and without the washers. Since I do not taxi my model aircrafts very far, it did not seem to matter much. “Your mileage may vary!”
| Date published | 07/10/2019 |
| Precio | $4.70 |
| ¿Cuándo tiempo lleva? | 150 - 400 minutos |
| Cantidad de filamento | Plate 1: 13.1 grams - Plate 2: 15.7 grams |
| Sin apoyo | YES |