Opitec Windflyer II User manual

E102056#1

Windflyer II

102.056

Technical data:

Wingspan 735 mm

Length 625 mm

Wing area 9,19 dm2

Tail area 1,75 dm2

Total area 10,94 dm2

Weight 120 g

Wing loading 6,9 g/dm2

Building time as a group project, approximately 10 hours

Recommended for pupils 10 years old plus

Please Note

The OPITEC range of projects is not intended as play

toys for young children.They are teaching aids for young

people learning the skills of Craft, Design and Technolo-

gy.These projects should only be undertaken and tested

with the guidance of a fully qualified adult.

The finished projects are not suitable to give to children

under 3 years old. Some parts can be swallowed. Dan-

ger of suffocation!

1. Product information

Article: Flying model in construction kit form

Conditions: For flying in still or very light winds

Use: With pupils aged 10 plus

2. Material information

2.1. Material: Balsa wood (Technically a tropical hardwood, soft and light)

Beech wood (Hardwood)

Pine wood (Soft wood)

Plywood (Multi layered, glued crosswise)

Working: Wood can planed, sawn or sanded

Joining: Glueing

Finish: Wood varnish (Base coat plus finish- also in spray form)

Staining (Water based - finish with clear varnish)

2.2. Material: Depron, thermoplastic

Polystyrol hard foam (PS) white

Working: Cutting with a modelling knife

Joining: DO NOT use any any glue containing solvent

Finish: No special finish is necessary

3. Tools:

Saws: Use a PuK saw from our catalogue for sawing small strips of wood and dowel

Note! Hold the work in a clamp

Cutting:: Use a modelling knife

Note! Be careful with your fingers the blade will be sharp!

Sanding: Use a block and glasspaper for all flat areas and edges

2E102056#1

E102056#1

4. Material list

Part Material Quantity Size Part no.

Body Plywood 1 8 x 80 x 300 mm 1

(Fuselage) Pine strip 1 6 x 8 x 495 mm 3

Nose sides Balsa 1 2 x 50 x 250 mm 2

Pre-cut Balsa 1 2 x 100 x 500 mm 4/12/13

Wings Abachi strips 2 8 x 10 x 374 mm 10

Balsa strips 2 5 x 15 x 374 mm 11

Pine strips 2 3 x 7 x 374 mm 9

Tissue paper 1 255 x 760 17

Fixing Rubber bands 2 60 mm dia 18

Beech dowel 2 3 dia x 150 mm 5/6

Joiners Card 1 160g/m2 14/15/16

Tail Foam 1 3 x 114 x 410 mm 7/8

Trim lead lead shot 1 34 g 20

5. Parts list for ready made components

Part No pces Material size in mm

1 Nose 1 Plywood 8 x 55 x 255

2 Nose sides 2 Balsa 2 x 48 x 95

3 Fuselage boom 1 Pine strip 6 x 8 x 495

4 Wing support 1 Balsa 2 x 20 x 125

5 Wing dowels 2 Beech dowel 3mm dia x 125

6 Fixing dowels 2 Beech dowel ca. ø 3 x 25

7 Tailplane 1 Foam 3 x 80 x 250

8 Tail fin 1 Foam 3 x 80 x 90

9 Main spar 2 Pine 3 x 7 x 374

10 Nose strip 2 Abachi 8 x 10 x 374

11 End strips 2 Balsa strip 5 x 15 x 374

12 Wing ribs 14 Balsa, pre-cut 2 x 13 x 102

13 End ribs 6 Balsa, pre-cut 2 x 13 x 102

13a Supports 4 Balsa 2 x 12 x 18

14 Joiner, upper 1 Card 45 x 125

15 Joiner,lower 1 Card 45 x 125

16 Middle, strengthener,upper 1 Card 15 x 125

17 Covering paper 1 Tissue 255 x 760

18 Rubber bands 2 Rubber 60 dia

20 Trim lead 1 Lead shot 34g

Also needed to complete this model is:

Shrinking dope 50gm

Thinner 15gm

Wood glue (Ponal express) 20 gm

Paste

4E102056#1

6. The layout of the balsa pre-cut ribs, sheet and Depron

62,5

13a 12

Pre-cut balsa ribs etc

Balsa sheet tailplane

Depron sheet

Note: Do not alter the layout due to the cutting direction!

E102056#1

7. Instructions

General notes:

Keep to the drying time for the glue, otherwise you may have difficulties. Other parts can be made whilst the glue

is drying.

Use white glue, check that any glue you use does not melt the styropor / Depron foam.

Use a block and glasspaper for sanding all flat surfaces (sanding block is not included) Use an all purpose glue

to fix the sandpaper to a block.

Tick off the steps as you go along

The shortened form 'Sk' means sketch. A number in brackets (4) means part eg.4

Use mapping pins, most normal pins will bend or break under pressure!

Planning overview

7.1 Fuselage (body)

7.2 Tail plane and fin

7.3 Wings

7.4 Cover wings, spray with water and then dope

7.5 Colouring

7.6 Balancing

7.7 Flying

7.1 Fuselage

7.1.1 Assemble the building plan (Pages 15/17/19/3 pages) by cutting the plans along the broken lines and sello-

tape them together.

Note: Note the markings

7.1.2 Cut out the pattern for the nose (see plan) and using dabs of glue fix it to the 8mm plywood. Drill the 3mm

hole for the front dowel (6)

7.1.3 Carefully saw out the shape of the nose. Do not forget the 20mm and 25mm lead chambers (The openings

for the chambers will be drilled later)

7.1.4 Cut out the pattern for the nose cladding (2/plans) and trace it twice on to the balsa wood sheet, cut out the

shapes with a modelling knife.

7.1.5 Start by firstly gluing on one side of the cladding (2) and then the other

Apply the white glue in a circular motion to the nose (1). Make sure the edges that the edges are particulary

well covered. Rub the cladding on to the nose until the glue starts to 'pull' then press it into the final position

once more!

Cutting lines

Esq 1

Bead of glue

6E102056#1

7.1.6 Fit the boom spar (3)into the nose and glue it into position.

7.1.7 Drill the 5mm dia holes into the lead weight chambers (These holes will be covered with sellotape at a later

stage)

7.1.8 Cut two 25mm lengths from the dowel 3 dia x 150mm. Use a modelling knife (roll the dowel under the

blade) Using the plan as reference glue one dowel at the front end of the nose and the other at the end

(see plan)

Note: Do not cut both of these pieces from the same length of dowel!

7.1.9 Sand the nose and then chamfer the cladding edge at 45 degrees (See sketch)

7.1.10 Mark and cut out the wing carrier (4) as shown on page 5 and glue it in position (see diagram)

Note: Note the direction of the grain

7.1.11 Glue the side dowels (5) 3 dia x 125mm ( remainder from step 6.1.8) in position as shown in the diagram

45°

62,5

125

Esq 2

E102056#1

7.2 Tailplane and Fin

7.2.1 Cut out te pattern for the tailplane (7) (Plan 8). Apply spots of glue to the rear of the pattern and lay it out on

the foam sheet 3 x 114 x 410 (See page 4). Firstly cut out the 3mm slot in the Tailplane using a steel ruler

and sharp modelling knife (7) and then the remaining contours.

7.2.2 Cut out the Fin (8) and remember the lower fixing tab.

Note: The directional (long) flap is cut after the plane has been flown

7.2.3 Sand the curves of the Fin and Tailplane to shape with a block and glasspaper.

Note: The underneath of the Fin (8) must not be sanded!

7.2.4 Ensure the Fin fits in the slot in the Tailplane.

7.2.5 Glue the Fin into the slot in the Tailplane and leave to dry

Note: The Fin must be at right angles to the Tailplane

7.2.6 Mount and glue the Fin and Taiplane on the Fuselage (3) and leave to dry!

Note: Make sure that it is mounted squarely with the Fuselage otherwise the flight pattern will be

affected!

Do NOT sand the

underneath of the

Fin (8)

This long cut for the

flap is cut after the first

flight

8E102056#1

7.3 Wings

7.3.1 Cut out the patterns (Pages 21) and glue them together

Note: Make sure that the joins are accurate

7.3.2 Place a strip of sellotape (broken lines) over each of the ribs so that the glue from the wing does not stick to

the plans

7.3.3 Press out the ribs ( 12 /13) from the pre-stamped balsa sheet, clean them up as necessary

7.3.4 Place all the ribs( 12/13) together on the main spar (9) and sand them from front to back with a block and

glasspaper. Any irregularities can be removed on the top or bottom of the ribs can be smoothed in this way.

7.3.5 Cut out the patterns for the angled wing supports (13a) from the plan. Use the patterns on the balsa sheet

and cut them out.( See page 4)

7.3.6 Make up two sets of 3 ribs (13 / rib packet) and glue them together

Note: Use a spar to make sure that they are in line

These ribs must NOT be glued to the spar!

After these have dried for a few minutes remove them from the spar.

7.3.7 Shape the middle spar/ leading and trailing wing edges ( 9 + 10 + 11) where the meet in the centre of the

wing ( appox 11 degrees)

Note: This angle must be accurate !

45°

105

Cutting lines

Esq 3

Esq 4

13a 9

7.3.8 Selloptape the plans to a building board.

Note: The minimum size of building board should be approximately 10 x 150 x 400mm (Large enough

for one wing half)

7.3.9 Pin the main spar to the board

7.3.10 Lay out and glue the ribs in position along the main spar.

Press the ribs down so that they are flush with the board. ( Fix with pins) The middle ribs (A) must not be

glued.

7.3.11 Glue the angle supports (13a) against the second rib and leave to dry thoroughly.

7.3.12 Place the middle rib (A) on the end of the main wing spar and lean it against the wing angle support.

Note: This will give the V angle between the wings at a later stage

7.3.13 Glue the leading edge strip (10) in position against the ribs

7.3.14 Glue the trailing edge strip ( 11) to the ribs

Note: Leave the wings to dry overnight

7.3.15 Lightly sand the top of the ribs with a block and glasspaper

13a

Middle rib (A)

10 E102056#1

7.3.16 Carefully remove the wings from the board, sand the edges ( see wing diagram)

7.3.17 Sand the angled middle wing ribs

7.3.18 Trace the patterns for the wing joiners (14/15/16) on to the 160 gm white card and cut them out using a mo-

delling knife and a steel ruler. Cut the side slot on the joiner (15)

Note: The printed shapes on the card are not accurate, cut the joiners to the plan!

7.3.19 Glue both halves of the wing to the middle joiner (14) only apply glue to the ribs and spar. The middle line

on the joiner must be just visible. Rub the joiner on the glued area and leave to dry for approximately 1/2

hour

7.3.20 Weight one half of the wings down on a building board and apply glue to the V gap in the middle

7.3.21 Raise the other wing half from the board so that the tip is 140mm high (see diagram on page 11)

Note: Leave to dry overnight

7.3.22 Glue the top wing joiner (15) in position, apply the glue to the ribs and spar, leave to dry for approx 3 hours

7.3.23 Glue the middle joiner/strengthener (16) in position

76.3.24 Clean up any excess card

15 20 20 20 20 20 10

125

454515

E 1 : 1

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