Construction / tuning:
With a normal Twin Star 2 plane (a Multiplex kit) I bought an
additional spare wing set plus two additional motor mounts!
- take one set of wings (eg. both left wings) and leave the channel cover in place. First wing cap at the beginning of the ailerons (this will be the inner part - connecting with
the other wing and the body of the plane). As the wing has a straight end you may use a 90° tool to mark the exact cuts. Cut the wing with slow & precise cuts with an
- cut the 2nd (left) wing at the end of the center holder (5 cm from the inner part - you may also use the wing connection moulds on the top of the wing as a measurement -
these you need to cut off!)
- put now both wings in line with each other (on its belly) - use the end of the wings as a measurement that they are 100 % straight. Glue both together with a little super
glue! Let it dry.
- apply a heavy duty tape (in my case white) on the top of the joint of both wings! Then turn the wing on its upside.
- now from the bottom side you may apply ample super glue! Ensure that the wing lies flat on the work surface! Let it dry well. If you have some gaps use a filler (in my case
I used some 5 min epoxy - that is actually not recommended for gluing, however for filling I am sure it will work!
- at the bottom of the cable channel push a 2 mm CFK rod - 15 cm long - into the other wing stub (before you may sharpen the tip of the rod with sand paper) - insert it half.
Then use super glue to fix it to the bottom! Make sure that both wing parts are flat on the work surface (... and that you have a flat surface :-) )!!
- Then use a 3 mm CFK rod - 20 cm long - as an additional connection between both wing halves. This one I inserted in a trench what I cut out with the scalpel. Use ample
super glue to fix it in place! Later on you may cover this black connection with a white strong tape (give additional strength too).
- Now start with the 2nd wing set (eg. both right wings)
- Note: In my conversion I have exact 235 mm distance between the center of both motor mounts (future prop center)! That is enough space to run 9" props on each motor
(so I can use 2 cell lipo to save weight). Between the props will remain exactly 10 mm apart! Lets see how that works in practice.
- Now follow the instruction manual for the motor & servo installation! Note: as you run now 6 (!) motor cables through the channel quite some carving away is necessary!
But don't worry, that is not too difficult!.
The wing servo installation:
- The servo extension cable needs to be woven in order to avoid interferences (cable is now quite long)! Note: the soldering of all the extension cables takes longer then
the actual wing extension (2x motor connection, 2x BEC, 1x aileron-servo) x 2 wings ! :-(
- Fuselage completion - glue it together as per instruction manual! Follow it and nothing can go wrong!
- BEFORE you glue in the rudder & elevator wing - decorate the fuselage, the rudder and elevator wing! Now it is much easier then later! See below my mods that I have
applied (sorry - but I am Austrian, so the rudder got our national colours)!
The placement of the receiver:
- Here the completely assembled fuselage with rudder and elevator wing (both installed as per instruction manual)!
- Now you can see for the first time the full size of this plane by putting the wings next to the completed fuselage - massive!
- The installation of the motors:
My motors did not fit fully into the supplied motor holders, so I looked up some forums and found a solution: cut them a bit shorter and fit them so that the back mounted
outrunner fully inserts into the motor gondola. See pictures below....
Afterwards I fixed the motors to the
mounts and glued them in place.
With lots of cyan glue.....
Finally the running direction of the motors were checked and adjusted and the BEC installed (held in place by a CFK rod - 3mm - which I glued in place with a hot glue gun.
- The finishing of the wings:
Next I started to lay the cable connections ... what a work! And finally I fixed the covers of the cable channels
in place. But before I needed to cut and sand away quite a bit to be able to hide all the cables and
connectors. The whole proceedure took almost 2 hours to complete.
Before you finally close all the covers make sure you double check all motors, their running direction, the
BECs and again all connections! All must work pefectly - only then glue the covers in place!
Ad BEC: I left only the outer right motor BEC intact (all three connectors to the receiver) - on all others I have
disconnected the RED cable in order to have one BEC focusing on the cut of voltage of the battery.
Now it was time to fix the props and do the first test runs. Here I hade some vibration problems and it turned out that on two motors the prop holders were not 100 %
centered! Another 30 minutes later and all motors run perfectly.
Now I could tape over the still visible connection CFK rod where both wing parts met (with white strong tape).
Next I fixed the wings and started the test run of all four engines a 3 cell lipo with 3300 mAH - the planned accu pack. The battery did not even get warm (the motors were
using 29,5 A at full power altogether. That promised a long flight time! We will see.
Finally the assembly of the plane and picture taking during a sunny window during this rainy Sunday - enjoy these pictures:
June 2010: first flight done! Well, actually by now several flights. The plane flew extremely well as of the first throw (I had to do ist myself as nobody was at the field).
Surprise I was with the sailing abilities - despite the four porps it flies and glides like a EasyGlider!
At the beginning I used the 3 cell Lipo, but after a few flights using just about 30 % of the throttle I decided to go to the two cell lipo. Now I use approx. 50 % to keep the
plane level, but the weight is much less and the A usage even less. 22 minutes was the longest flight (despite the 4 motors). Unfortunately I have some vibrations from the
motors which I still need to locate. On the workbench all motors & props performed well, however mounted I get vibrations. Well, this needs to be fixed because only then I
may show you the on board videos (I did one, however it looked totally hazy from the vibrations).
Well, more news to follow soon.
Update: March 2012:
After several experiments to get rid of the vibrations I installed 3-bladed props - Master-Airscrew with 8 " dia -
left and right running props.
But the results were equally poor an the vibration did not cease! Hours I spend on fine ballancing the props,
but without success.
Update: May 2012:
After unsuccessful attempts to get rid of the vibrations I invested in 4 new motor sets - this time the same
sets I successfully use since almost 2 years in one of my other Twin Stars - the TS Styria. These sets are
the same as for the small Multiplex Merlin plane: Himax 2216 motors - on folding props!
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