Pilot 107" Sbach/DLE-111/canisters build

[swk550]

I ordered the 107" Sbach/DLE-111/cansiters combo directly from Pilot-RC.com.
To my suprise, the plane shipped almost on time. Tony has redisigned the wing box so DHL would not crush them. Attached are some pictures of the cartons. Minor box damage, but all arrived in good shape.

I built the plane with a rudder control modification:
* JR-8711 rudder in the tail for direct control (eliminated the pull pull cables)

[swk550]

Installing the control horns

Mix some 30 min epoxy and thin with denatured alcohol. I use an epoxy syringe to inject the epoxy into the control horn slots. Don't forget to roughen up the root of the truss horns with sand paper.

[marksextra]

This is going to be great. Looks good so far. Keep them coming.

[rick dazzler]

awesome.I love this airplane

[Rick1999]

Looking like my next project

[pilot-rc]

thank you so much. you work very fast on the plane. only 6pcs sbach in US now.
I am afraid the tail heavy for the rudder servo.

[cjgillette]

Nice looking plane - I've been watching these. Is there a 150 cc version as well?

C

[pilot-rc]

will test 150cc sbach on weekend. then release it.
tks.

[swk550]

Engine firewall installation

It is very important that you trial fit the firewall and engine first to make sure the spinner alligns up with the cowling. This will also allow you to decide the length of spacers you need from the engine backplate to the firewall. The airplane kit comes with triangle stock to glue to the firewall front and motor box. I substituted 5/16" square spruce. I attached the firewall and aluminum to the engine box using 30 minute epoxy mixed with milled fiberglass. Then clamp or use masking tape to hold everything in place until the epoxy cures. As turns out, you need to notch out the spruce to clear the engine spacers.

[swk550]

Control linkages

Pilot supplied very good quality ball links and turn-buckles for the control linkages. The turnbuckles and ball links are metric. I prefer to use the SWB aluminum control horns on the aileron and elevator servos. The threads on the horns are for #4-40 screws. I simply threaded a Dubro heavy duty 4-40 ball link on to the right hand tthread side of the turn-buckle. Every thing aligned perfectly. The direct drive control horn is a Hangar 9 (from the 35% Extra 260 parts kit) heavy duty control horn threaded on to a #10-25 flat head screw. I simply inserted the screw 0.5 inch (12 mm) below the truss horn cut-outs. The screw is held in place by bleeding fast cure CA into the threads. This also hardens up the balsa in the rudder post. I use this method on my 42% plans also. Do not forget to seal the control surfaces hindge gaps with either clear covering or matching Ultracote.

[swk550]

Tail wheel installation

For the tail wheel installation, I used a common spring tied to the tail wheel tiller and screwed to the back of the rudder bottom.

Throttle servo installation

There is plenty of clearance to install the throttle servo thru the motor box bottom.
I did cut the throttle arm return spring so there is no excessive tension on the throttle servo. I have burned out digital servos when I left the spring return engaged. You need to keep the spring installed as this keeps proper spacing for the throttle plate. The throttle arm uses a #2-56 soc head cap screw. The linkage is #4-40 rod ends and a carbon fiber rod (from Central Hobbies). I use JB weld to secure the titanium rod ends to the carbon fiber rod.

[swk550]

Canister Installation

Shown are pictures of the canister installation. Do not forget to fuel proof the bulkhead mounts. I install a #2 or #3 pan head sheet metal screw thru the Teflon coupler into the stainless steel header. I cover the pan head with the spring clamp. This keeps the Teflon coupler from slipping off the header when heated up.

[swk550]

Oops I forgot the clamp picture

[3Dguy]

I'm sure you're aware of this, but is there a reason you mounted the standoffs and the blind nuts backwards? Was it for clearance, because it looks like you had to cut wood away anyway...

[learnedinuk]

My guess is it was for mock-up only.