User Manual
Carelully
twist the
tube to
and
lro
unlil
it is released
from the
wing skin.
Do not use
lorce under any
circumslances.
The
bowden
cableoutercan
now be shifted
as
required
Take
great
care
nollo
pullit
outloo
lar, as
it is exceedingly
difficult
lo
push
it back
into the
wing again.
Set
the bellcrank
to
ils neutral
position,
long shank
parallel
with lhe
fuselage centreline,
and
mark where the
threaded
pushrod
37 crosses
the
sealing slrip
when
the
rod
is
at
right-
angles
to
the aileron
leading edge,
in line with the
connec-
ting
point
on
the shorter
bellcrank
shank.
Using a
pointed
round
file, cul a
tunnel
from the sealing
slrip through
the
foam to
the bellcrank
well, removing
as
litlle foam as
possible,
to avoid
unnecessarily
weakening
the
wing.
Screw
the
clevis 35
onto the lhreaded
pushrod,
and
bend
lhe
rod as shown
in
lhe drawing.
Pass it through
the tunnel
and connect
the clevis
to the bellcrank,
as
shown
in the
drawing.
Hold the
aileron against
the
wing,
with equal
clearance
at either
end, and
mark the
position
of
the aileron
horn
29
(bored
1 .7 mm).
File
out
the
horn
slot
in
the aileron
until
the top
skin
is
exposed.
Apply strips ol
tape
round the
slot
to avoid soiling
the surface
with
glue,
then
glue
the
horn
inlo its slot, using
plenty
of epoxy.
The
position
olthe
horn
-
and
in
particularthe
positionollhe
linkage
hole relative to
the
hinge line
-
must be
identical on
both
ailerons,
otherwise
they
willnot have equalmovement.
The 60 degree
bellcranks
provide
approximatelylhe
conect
amount
of aileron
dilferential
rnovement:
when lhe
pushrod
at the
wing rool
is moved equal
distances
lrom centre,
the
aileron
deflection
should
be
greater
up than down.
Glue
the bellcrank
mounl into the
wing, using
plenty
of
epoxy.
Checkthatthe
mount is sufliciently
deep
inthewing,
and that
no
glue
gets
onto the bellcrank
pivot.
Temporarily
hinge the aileron
to the
wing
with
strips
of tape'
and oin
it
at
neulral. Set
the bellcrank
to
neutral also.
Mark
the
point
al which the
pushrod
crosses
the
horn, and bend
the
rod at
right-angles at
that
point.
Cut the
angled end
down
to a
lenglh of
10 mm
and
conlect
it to the
horn.
The
entire aileron
linkage can
now be checked
for correcl
ooeration.
The threaded
pushrod
must
move freely
inside
its
lunnel.
The aileron should
be able
to dellect about
30
degrees
up
and
1
5 degrees
down,
and
must not
iam
or
rub
at any
point.
Adjust the
linkage
where necessary
until this
is
lhe
case.
The bellcrank
well is
sealed
with the
well
cover
21
. lmpor-
tant:
the
grain
of the cover
must run
parallel
with the
wing
leadingedge.
Take care to
glue
the
loint
soundly.
Whenthe
glue
has set
hard, sand
back the cover
llush with the
wing
skin.
Installing
aileron
servos
in
the
wings
We canonly
provide generalguidelines
here,
as
servosvary
so
greatly
in size
and
mounting
provisions.
You mustdecide
at the
outset
whetherthe
hatch overthe
servo
well is to be
removable or
glued
in
place.
A removable
hatch severely
weakens
the
wing, and
it is essential
to
remedy this
by
installing
reinlorcing
webs in a spanwise
direction.
We
recommend
spruce or
plywood
strips of appropriale
size.
ln
practice,
a
permanently
sealed servo
well has
proved
an
excellent
altemative.
Servo
failure
i6
extremely
rare, and
if
this should
happen the
hatch can easily
be cut
out and
replaced
with
a
new one.
This
method is
much
simpler
and
does
nol weaken lhe
wing significantly.
Rernove lhe
very minimum ol
foam, to avoid
a
weak
point
in the struclure.
Installing the servo
extension
lead
is very simple,
as the
bowden
cableouter
is lreeto
move insidelhewing
Pullthe
outer
out
of the servo
well slightly,
cut olf the
end ol the
exlension
lead
at
an angle
and
glue
it into the outer
with a
drop
ol
instant
glue.
Now
pull
the
bowden
cable outer
out
of the
wing
lrom the
rool
end
and the
lead will be
pulled
through
the
wing
with il.
We strongly
advise
the use of
separation
lilters
il
you
intend
installing servos
in
the
wings.
The filter should
be
lilted at
the
wing
root
end
ol the
lead, as close
to lhe
receiver as
Dossible.
The MULTIPLEX
extension
lead set
including
separation
lilter
is
available
under
Order
No.8 5138.
The linkage between
aileron
servo
and aileron
is completed
with a threaded oushrod
with
a
clevis
fitted at the
horn end'
to
provide
a
means
ol adiustment.
Use
long servo
output
arms and
long horns, as this
minimises the etfects
ol any
lost
motion in the
linkage.
Connecting
lhe
airbrakes
fhe DG 500/22
ELÄN is
tactory-fitted
wilh twin-blade
"
super-aiörakes
as standard;
allyou
need to do
is mmplete
lhe
linkage and
fit
the
blades.
Thread the
clevis
35 onto lhe steel
rod
38,
roughen up
the
end
and bendthefinal2
mm at
right-angles. Slidetheclevis
back
to the end
and solder
it to the
rod.
Rotatelhe
airbrake
leverstolhe
upright
position,
pulling
the
actuating
mechanism
towards lhe
wing
root to
raise
the
end
lever.
Thread
lhe
pushrod
into the airbrake
mechanism,
positioning
the
rod u nder the
lront-facing
pins
on the
levers.
This is essential
if the brake
unit
is
to
lunction correctly.
When the airbrake
is closed,
these
pins
hold the
pushrod
in
Dosition.
Thread
the
rod into the bowden
cable outer
and
connecl lhe
clevis lo
the
lug
on
lhe actuating
mechanism
Check that
the brake
functions
correctly.
The brake blades
46
can
now be
fitted using
the screws
40:
first the
lower blade, then
the upper
blade.
Please take
particular
care
al this stage;
it is essentialthat
the shallow
flange on the
screw
head engages
in
the
brake blade,
-
otheMise
the
brake unit
will not operate
reliably,
without
iamming.
Because
of the lhinness
ol the screw
head,
be
sure
to use a screwdriver
with a
perfectly
square
blade tip,
and
work carefully.
Take
care
also
nol lo bend
ordistorl the
blades.
They can easily
be straightened
if
necessary.
Check that
the brake
system
works correctly.
Cut
lhe brake
cap 55 to
length, trim
lo
lit,
and
glue
it to the
airbrake
with
contact
adhesive.
Do not use
5-minute epoxy
lor
lhis
joinl,
as
you
risk
gluing
the
airbrake
mechanism
to
the
wing,
which
invariably resulls
in serious
damage lo
lhe
struclure.
Sand
the brake
cap lo
section, using
no more
than
rnoderate
pressure.
The use ol lhe
screws
40 as
pivols
allows
you
lo
remove the
brake blades
and
replace them
a
few times,
which can be
very
useful
at lhe
tinishing stage.
Nevertheless,
always
take
great
care, and
never use
force.
wingtips and
plug-in
wingtip extensions
Seal one
end of
the brass tubes
48
and
49,
either by
soldering
or squeezing.
Push the brass
lubes
-
4 mm
diameter at
the
front,
3mm
diameter
al lhe
rear
-
belween