DG 800 S Instruction Manual F.W. 28/7/2014 Vers.1.
Thank you very much for purchasing the CARF Models DG-800S high performance glider. Before you get started building and setting-up your new aircraft, please make sure you have read this instruction manual, and understood it. If you have any questions, please don’t hesitate to contact your Rep, or CARF-Models directly. Below are the contact details: Email: techsupport@carf-models.com Or call your CARF Rep by phone!!! He will be there for you.
Important/General Notes Elastic Hinges: The ailerons, flaps and elevator are all hinged already for you - laminated in the mould and attached with a special nylon hinge-cloth, sandwiched between the outer skin and the foam. This nylon hinge is 100% safe and durable. You will never have to worry about breaking it, or wearing it out. There is no gap at all on the top side of the surface, and there is a narrow slot in the bottom surface, where the control surface slides under the skin during ‘down’ throw.
Take Care: Composite sandwich parts are extremely strong, but fragile at the same time. Always keep in mind that these composite airplanes are designed for minimum weight and maximum strength in flight. Please take care of it, especially during transport, to make sure that none of the critical parts and linkages are damaged. Always handle your airplane with great care, especially on the ground and during transport, so you will have many hours of pleasure with it.
When sanding areas on the inside of the composite sandwich parts to prepare the surface for gluing something onto it, do NOT sand through the layer of lightweight glasscloth on the inside foam sandwich. It is only necessary to rough up the surface, with 80/120 grit, and wipe off any dust with acetone or denatured alcohol (or similar) before gluing to make a perfect joint. Of course, you should always prepare both parts to be joined before gluing for the highest quality joints.
General information The wing of your CARF-Models DG-800S is a so called all carbon wing. The skin has several layers of carbon fibre as well as the C-spars. These are laminated in separate molds, all carbon, of course. The fuselage is made from various glass fibre layers, responsibly and well engineered with Kevlar reinforcements in the canopy and fin area. This extensive use of high end materials is unique in the industry and responsbile for the incredible strength and overall performance of the aircraft.
Liste Der Enthaltenen Bauteile Material Name Piece Threaded end M3 with hold for steel cable 2 PULL PULL WIRE DIA 0.8MM 2 x 2 Meter CRIMP TUBES DIA 2MM 4 Clevis M3 2 ALLEN SCREW M 3*12 2 WASHER M3 6 SHEET METAL SCREW 2.9*13 4 hinge wire 2mm 400mm 1 For What Ruder Ruder Ruder Ruder Ruder Ruder Ruder Ruder Counter sunk M5x 60 Clevis M 3 ALL THREAD M3 x 20 mm WASHER M3 SHEET METAL SCREW 2.
milled wood parts and hardware Rudder servo tray Retract Servo tray Cockpit tub and parts Retract mounts milled parts for RC equipment Milled instrument panel
Milled wood parts and hardware Horizotal Stab Rudder Retract Wing Tow release 20mm (standard size) servo mount parts 16 mm (mini size) servo mount parts
Horizonal stab installation Install a standard size high quality elevator servo with the included 2.9 x 13 mm self tapping screws. Use washers if necessary. The elevator linkage is assembled from the 20 mm M3 all thread and 2 spring steel clevises. NOTE: Since space is very tight, these clevises must be secured with LOCTITE after the final elevator setting is adjusted.
Horizontal stab installation Extend the servo wire, either by soldering an extension or connecting a pigtail socket. Secure the extension so that it cannot disconnect under any circumstances. It is helpful to use the tailwheel opening to feed the wire forward. Use cable sockets to secure it to the fuselage wall. Make sure that it is not rubbing against retract and carbon formers. The horizontal stab is readily built and can bolted on immediately with the included M5 x 40 mm counter sunk bolts.
RECENT UPDATE! Note: During countless test flights it has been noticed that the stab incidence should be reduced by 0.7 degree in order to maximize the performance of our DG-800. Even though the plane is flying very well with the incidence out of the box in slower thermal flying, the faster you want to fly, the more you feel you need to trim down elevator. Please sand or grind the spacer highlighted on the photo down to zero thickness at the rear.
Rudder servo installation The rudder servo tray is already assembled and holes for the servo are drilled. Use 2.9 x 13 mm self tapping screws and washers to install your standard size servo (preferrably of the same type as the elevator servo) Then bolt the servo tray from the rear against the landing gear former.
Rudder installation The spar with the hinge posts is already installed and glued securely. Also the rudder has the hinge pin sleeves and the cutouts preinstalled. It can be attached to the fin immediately. Attach the steel wires by looping them through the control horns and crimp them with the included crimp sleeves.
Rudder installation Trial fit the hinge pin, either conventionally from the top (where you can always see it) or from the bottom, like shown in the photo. In that case it is important to secure the pin against accidental loss. Bend the end approx.
Tail Wheel Installation The tail wheel axle can be made from either M3 or M4 bolt, 35 mm long, depending on the wheel used. The predrilled hole might have to be adjusted slightly to fit.
Wing Servo Installation The wings are completely finished. The slot cover tape is attached, control horns are installed and the speed brake cover is precisely attached.
Installation of 16mm Aileron Servos Important Note: A 16mm Servo can be used if it is one of the newest high end servos with a torque of 10+ kg/cm. This is sufficient if not flown under extreme conditions with oversized jet turbines. It is recommended, however, to install a standard size servo, if the very top performance and speed is desired. A special servo cover and mount for standard size servos is optionally included in the kit! For the installation of the aileron servos please use the 2.
Installation of 20 mm standard size aileron servos If you decided to use the standard size servos, you will use the flat frame from 6mm plywood. Grind a recess for the servo horn as shown on the photo. Then insert the M3 blind nuts and glue the frame on to the skin. Note: Sand the skin surface thoroughly with coarse sand paper and use a little playdow (or similar) to fill the threads of the blind nuts. Use a good 30 min epoxy or thickened laminating resin to glue the frame in place.
Installation of 20 mm standard size aileron servos
Spoiler and flap servo installation The installation of Flap and Spoiler servos is identical to the method of the 16mm airline servos. Use the 2.9 x 13 mm servo screws included in the kit. Mount the hatches with the 1.9 x 10 mm sheet metal screws. The flap linkage is built exactly like the aileron and elevator linkage. For the spoiler linkage please use the 2mm threaded end and one M2 spring steel clevis. The limited space requires a Zbend on the servo side. Do not experiment with this linkage.
Wing attachment For the wing servo wire connection we recommend to use larger connectors. You can glue 2 against each other. There are many ways and preferences, you might have your own style. It is important that the wires don’t rub against the edges of the cut-outs. The “floating spar” wing mount is completely finished. Install the massive 30x30 mm carbon connector. Glue the knurled plastic nuts on the M6 bolts and you won’t need any allen key to assemble your plane at the field.
Gear door and retract installation Create hinge pins from the 2mm welding rod and install the gear doors. Glue stops from scrap plywood and trial fit hooks for two rubber bands. Even though this seems a very simple method to keep the gear doors closed, it is a very efficient one. The retractable gear is designed to open the doors against the spring loading with the steel loop in front of the wheel.
Gear door and retract installation Mount the wooden servo mount with the M4 x 12 allen bolts to the aluminum frame of the retract. As usual, use the 2.9 mm sheet metal screws and washers to mount the servo in the frame. As linkage use the M3 all thread and two spring steel clevises. You might have to adjust the length of the linkage to work properly.
Gear door and retract installation Slide the retract unit into the slots of the two formers and secure it with the two wood boards, bolted on with each two of M3 x 16 allen bolts, as shown on the photos above.
Remaining equipment installation The front part of the fuselage is used as equipment bay. The photos show only a sample installation, since most have their own ideas and methods how to install receiver, powerbox, batteries, switches…. The photos also show an easy way to install the tow release servo.
Canopy hinge and cockpit tub The photo shows the gas spring mount of the canopy hinge, which otherwise is already completely installed. Up to 1.5 kg of lead must be glued into the nose in order to balance the DG-800. Make sure that the cockpit tub still fits the fuselage after you installed all your equipment and balance weight. Cut a slot in the rear part of the cockpit tub so that you can compress it sideways to insert it under the lip of the fuselage.
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