Construction - Basic Electric Trainer Airplane with Coroplast and Balsa wood - Part 1

Make an Electric Trainer Airplane in 01 day.

  • This basic Trainer Plane is the conversion of famous SPAD design, the LC-40 (IC Engine) into Electric Trainer Plane.
  • Please go through the SPAD Tips and Hints link from the SPAD main page before starting construction(http://www.spadtothebone.net/resources.htm).
  • For the full construction details of IC Engine version please go through this link - http://www.spadtothebone.net/freeplans.htm 
  • I will be explaining the changes required to convert the IC Engine version into an Electric Trainer and how we can make use of locally avialiable materials.
Materials and Hardware required.
  • Coroplast sheet – 02 (6x4’) - For fuselage and wing.
  • Balsa sheet 5mm – 02 (100mmx1m) - for making spar and reinforcements.
  • Balsa strips 5mm – 06 (5mm x 10mm x 1m) - for reinforcing fuselage.
  • Aluminium strip 1.5/2mmk – 01 (1.5/2mm x 0.5m) - for making main LG.
  • Hard wood dowels/carbon fibber rod 4mm – 04 (5mm x 1m) - for making wing attachment.
  • Cycle spokes 2mm – 04  or  MS wire 2mm – 1m.- for control rods.
  • Moped or Motorcycle Wheel Spokes 4/5mm - 02 - for main wheel axle and nose gear.
  • Control Horns (ready made or self made) – 04.
  • Clevis – 10 (optional).
  • Cello Tape or fibre tape 1” – 1 roll.
  • Colored Tapes – 2/3 colors as required for decoration.
  • Masking Tape – 01 roll - for keeping the things in place during construction.
  • Flex Quick (any cyno based glue) 15ml -  02 bottles - for gluing the coroplast and balsa wood.
  • Nut and Bolts 5mm x 30mm – 04 (for LG).
  • Nut and bolts – 04 (for motor mount).
  • Ply wood 04mm – 1pc (100mm x 100mm) - for motor mount and LG support.
  • Small screws or nuts and bolts as required for servo mount and control horns.
  • Light weight Foam Wheels 50mm - 03pcs. (If you want steerable nose wheel, you have to buy one).
  • Bullet connectors (4/5mm) - 05 pair.
Tools Required
  • A good quality paper cutter with spare blades.
  • Steel rule (1m / 1.5m).
  • Fitters Square / instrument box tools for angle measurement.
  • Scissors.
  • Marker pen .
  • All basic tools in a work shop.
Electronics Required
  • BLDC Outrunner Motor - 01
  • Propeller - 01
  • ESC with BEC - 01
  • Servos - 03
  • LiPo Battery - 01(2200-4000 mAh)
  • Minimum 04 channel Tx-Rx.
My configuration -
I made 03 LC-40 Trainers, for each one I used different motors, ESC, LiPo and Servos were same.
  • BLDC Motor - 
  1. Turnigy D3536/6 1250KV, Battery: 2~4 Cell, Max current: 34A ,Max power: 500W, Weight: 102g (including connectors), Diameter of shaft: 5mm, Prop size: 7.4V/10x5, 14.8V/9x4.7,  Max thrust: 1270g.  
  2. Turnigy 2217 16turn 1050kv 23A Outrunner, Peak Current: 23A, Weight: 73g, Test Data 11.1V     18.6A   1047   1090g/ 11.1V     19.5A   1060   1020g.
  3. EMAX GT2215/09 KV1180 (C2836) Outrunner, No. of Lipo Cells : 2-3S, Max Watt : 312W, Max Current : 28A, Weight : 70g, Max thrust : 1250g, Recommended model weight : 600 - 1100g, Recommended ESC: EMAX 30A, Recommended Propeller : EMP 10x4.7SF, EMP 10x5E @3S LiPo 
Best Performance given by Turnigy D3536/6 1250kv motor.
  • Propeller - 10 x 5
  • ESC - HK 40 Amp ESC with BEC.
  • Servo - Model: CS929MG, Operating Voltage: 4.8V / 6.0V, Stall Torque: 2.0kg.cm /2.2kg.cm, Weight: 12.5g, Ball bearing: MR85, Gear: Metal, 
  • Tx-Rx - Avionic RCB6i
  • LiPo - ZIPPY Flightmax 3000mAh 4S1P 20C, Discharge: 20C Constant / 30C Burst, Weight: 313g (including wire, plug & shrink wrap), Dimensions: 139x46x25mm, Balance Plug: JST-XH, Discharge Plug: XT60.
Coming Next - Construction Sequence.