Author Topic: Pulsar 4.0 Pro , My latest project  (Read 279 times)

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Offline wizzard363

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Pulsar 4.0 Pro , My latest project
« on: August 23, 2017, 05:05:19 AM »
I have gone away from foamies for a while now , I just love the quality of balsa and composite models .
In this purchase I have gone with a combination of both .
The Pulsar 4.0 Pro , as the name suggests , is a 4M wingspan thermal soaring glider .
It is not a cheap kit but the quality is awesome .
The first thing I noticed when the postie handed me the box was just how light this thing is , even in the shipping carton . Take it out and the lightness is incredible
The build should not take long but the fit out will be done with the care and quality this air frame deserves
Ingredient list is as follows
Pulsar 4.0 PRO - kit
AXI 2820-14 motor
40/5mm precision spinner (Graupner}
42mm centrepiece (Graupner)
13x6.5 folding blades - (Graupner)
4 x KST 135MG servos - flaps and ailerons
1 x Hyperion DS11-AMB servo - Elevator
1 x KST DSX08H servo - Rudder
All up cost me around AU$2K
The hardware that comes with the kit has all control rods/horns , servo covers etc .
The only thing I have had to buy is servo wire and multiplex plugs for the wing harness .

Build progress so far is

Rudder servo mounted
One side of centre wing panel harness fitted
Boom glued to fuse  (tricky job getting that lined up , lucky I have a good eye for level)
Motor mount holes drilled

Still to go .

Mounting wing servos . Cutting slots in wing for flap control rods (yes , I have to attack wing with a scalpel)
Cut slots and glue in control horns .
Mount elevator servo .
Cut out and fit servo covers .
Bolt wing to fuse .
Mount motor , esc , bec and rx
Program the DX9 (this will be done as I fit each servo)
Throw in air and fly

Pics so far
Kit laid out in lounge room.
http://i.imgur.com/eZg81LM.jpg[/img]]
Wing centre panel
http://i.imgur.com/TiDDmsN.jpg[/img]]
Carbon fibre boom fitted to fuse
http://i.imgur.com/1lLxvRt.jpg[/img]]
Rudder servo fitted
http://i.imgur.com/goqydwN.jpg[/img]]
Close up of the carbon/Kevlar leading edge . Note the carbon fire strips on each rib , it is a quality kit
http://i.imgur.com/KYuKHKJ.jpg[/img]]

Should be finished within the next 10 days

« Last Edit: August 23, 2017, 05:11:16 AM by wizzard363 »

Offline Rumblecloud

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Re: Pulsar 4.0 Pro , My latest project
« Reply #1 on: August 23, 2017, 07:45:40 AM »
That is a glorious looking plane. 4 meter wingspan?
Are those 12 inch tiles it is laying out on? Take your time, !0 days is not a long time.

Top speed?

Offline wizzard363

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Re: Pulsar 4.0 Pro , My latest project
« Reply #2 on: August 23, 2017, 09:43:07 PM »
Yes it is a 4 meter wingspan and the tiles are about 12 inches. 
The build is not complex but I need to do it with care .
Got a flap servo test fitted yesterday and the first control rod exit slot cut in the top of the wing . Control rods for flaps run internaly  throught the wing . I will attach a few more pics later . Here is a link to the Esprit site that has some detailed pics including diagrams of control surface setup . These diagrams are the only guide there is for assembly . There is no build manual for this model
http://file.espritmodel.com/airplanes/star_flight/pulsar4e-pro-det3.jpg
« Last Edit: August 24, 2017, 06:22:33 AM by wizzard363 »

Offline wizzard363

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Re: Pulsar 4.0 Pro , My latest project
« Reply #3 on: August 24, 2017, 06:22:02 AM »
Continued the flap servo / control horn installation tonight.
Did  test fit
http://i.imgur.com/uKbKEt5.jpg[/img]]
http://i.imgur.com/cSKbMhL.jpg[/img]]

Then took the plunge and finished the cutting and glued in the control horn
http://i.imgur.com/qmE0mb2.jpg[/img]]
http://i.imgur.com/WhLAj4n.jpg[/img]]

one down , 3 to go
Measured the tiles tonight , they are 400mm or in old school 15 3/4 inch .

Offline AKPhill

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Re: Pulsar 4.0 Pro , My latest project
« Reply #4 on: August 25, 2017, 12:25:13 AM »
Very Nice  Sail plane it is huge  :t2980:
Goi for a speed record with that one should do it  :winky:

Offline wizzard363

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Re: Pulsar 4.0 Pro , My latest project
« Reply #5 on: August 26, 2017, 11:11:38 PM »
Yesterday i finished the servo install in the tail ,  elevator and rudder servos are mounted and connected .
To keep weight in the tail boom to a minimum I only ran 4 wires through the boom to power both servos .
The + and - wire is shared by both servos , they are "Y jointed" in at the tail end of the boom with a solder joint just below vertical stab . Then there is a single signal wire for each servo . At the RX end the elevator has a standard connection into the RX with all 3 wires (this provides the + and - for both servos and signal for elevator) but the rudder only has the signal wire plugged into the RX , the other wires have been removed ,.
The wing works similar with the flap providing the + and - for both flap and aileron servos , this means there are only 4 wires running through the first part of the centre panel up to were the flap servo is and then from the to aileron servo there is the standard 3 wires (signal runs all the way to RX but + and - Y into the flap servo wire)
This save the weight of 2 extra wires running through centre panel .
It has been one of the trickiest wiring jobs I have ever had to do on a model but this way I have save about 1.5m of servo wire weight being added .
The idea of these models is to keep them as light as possible so any weight saving is a bonus.
Progress pics so far , you will notice I purchased a bicycle maintenance stand , it makes setting up so much easier .

Elev servo
http://i.imgur.com/EVy1rD6.jpg[/img]]

Wing harness to RX connection
http://i.imgur.com/hVWbYuN.jpg[/img]]

This is the plug that is in each end of the centre panel for connecting the aileron servo wire when the ends of the 3 piece wing is attached . It is the female plug from a servo extension lead that is epoxied into place . The  aileron wire has the male end of the servo lead soldered on with the outer case removed exposing the pins . This makes the connection small enough so the wire can be threaded through the wing without having to enlarge the holes in the ribs.

http://i.imgur.com/rzCz2gL.jpg[/img]]

Setting up for test fit
http://i.imgur.com/ZRwHAro.jpg[/img]]

« Last Edit: August 27, 2017, 06:16:30 AM by wizzard363 »

Offline wizzard363

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Re: Pulsar 4.0 Pro , My latest project
« Reply #6 on: August 30, 2017, 06:28:13 AM »
Almost finished .
Set it up for final testing and programming radio .
I will set up 3 flight modes on a 3 way switch
 Central position on switch will be Launch mode , in this mode all surfaces will be at neutral position .
Switching up will be Speed mode , in this position the ailerons and flaps will raise slightly (2-4mm) adding a bit of reflex to the wing , this will help it cut through the wind when traveling up wind without power and get it from A to B a bit quicker .
Switching down will be Thermal mode , in this mode the aileron and flaps will go down slightly adding a bit more camber to the wing and this can improve lift . as this model has an airfoil designed for maximum lift I do not think its needed but i will see how it goes .
I have also set up crow breaking on a separate 3 way switch , in this mode  have flaps down and ailerons going up to act as a brake on final approach , it can also help to kill lift and get the model out of a strong thermal that may carry it too high .
I would also like to mix flaps with ailerons so they act as an extension of the aileron  and also ailerons to rudder as recommended by the manufacturer .
Should be a black belt in DX9 by the time I am finished .
A few pics showing how the outer wing panels plug into the centre wing panel to connect the aileron servo wires and also showing it set up on the stand for testing .


http://i.imgur.com/zE4bc4s.jpg[/img]]

http://i.imgur.com/gFAzPSV.jpg[/img]]

http://i.imgur.com/iK76Jjz.jpg[/img]]

http://i.imgur.com/rrGu5yU.jpg[/img]]

http://i.imgur.com/1W9PJnn.jpg[/img]]

For reference , that is a 52 inch tv


« Last Edit: August 30, 2017, 06:30:53 AM by wizzard363 »

Offline Rumblecloud

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Re: Pulsar 4.0 Pro , My latest project
« Reply #7 on: August 30, 2017, 08:06:27 AM »
It looks so very fragile with th e thin fuse down the middle and the huge wings. Beautiful though.

Offline wizzard363

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Re: Pulsar 4.0 Pro , My latest project
« Reply #8 on: August 31, 2017, 05:57:32 AM »
Fragile it is , this is not a model for high G aerobatics but can still do some lazy loops 
Got the programming sorted tonight so all that is left to do is fit servo covers install the RX and see what the smallest battery is I can use and still get C G . hope to get it to balance with a 1500mah 3S pack . Big packs are not required as I should be able to get 20 mins + out of a couple of 30 second motor runs . In good thermal conditions 60 +min flights are not uncommon from a single 30 second climb to altitude .
I will post final pics in the next day or 2

Offline wizzard363

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Re: Pulsar 4.0 Pro , My latest project
« Reply #9 on: September 02, 2017, 02:38:10 AM »
Ready for maiden  :t2030:

Very happy it balanced at 95mm CoG with a 1500mah ,this will keep the AUW low , the wire weight saved in the tail has paid off .

Final pics before flight vid in a couple of weeks when I head to my mates farm for the maiden .

https://i.imgur.com/IiKFUqo.jpg[/img]]

https://i.imgur.com/f2gm1JP.jpg[/img]]

Offline Rumblecloud

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Re: Pulsar 4.0 Pro , My latest project
« Reply #10 on: September 06, 2017, 08:31:56 AM »
You really don' realize just how big it is until thatlast pic -- at least I didn't realize it --  :b0703:

Good thing you have a large living area to accommodate the balancing act. Even transporting it would be difficult without a proper carrier - fragile too I would imagine.  :t2030: :t2030:

 















Offline wizzard363

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Re: Pulsar 4.0 Pro , My latest project
« Reply #11 on: September 07, 2017, 04:30:39 AM »
Transport is easy , the wing breaks down into 3 sections , you can see the black line of the RH wing join just above my left hand the other join is the first black line above the fuse. I will be building a box to store and transport it as it is very fragile.
I can fit it in the back of the car with the centre panel still fitted .  At the field you just slide the outer panels on , connect the servo plug and apply a bit of tape to the wing join to stop them falling off , its easier to set up than some of the foamies I have . For long trips I will break it down completely to transport in its box but that still only adds 2 minutes to the setup time as the centre panel is 2 plugs for connecting the servo wiring and 3 screws
Maiden in a weeks time weather permitting
« Last Edit: September 07, 2017, 04:34:30 AM by wizzard363 »

Offline wizzard363

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Re: Pulsar 4.0 Pro , My latest project
« Reply #12 on: September 11, 2017, 06:59:56 AM »
Transport/storage box almost finished , just need to panel it with light 3mm ply

https://i.imgur.com/xB6h2uS.jpg[/img]]
https://i.imgur.com/WogxahC.jpg[/img]]
https://i.imgur.com/mycncMt.jpg[/img]]

Offline Rumblecloud

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Re: Pulsar 4.0 Pro , My latest project
« Reply #13 on: September 11, 2017, 07:55:49 AM »
Looks to be a decent way to store it as well. Nice job. :t2030:

Offline Davesheli

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Re: Pulsar 4.0 Pro , My latest project
« Reply #14 on: September 19, 2017, 07:27:36 AM »
I converted 4m to about 12 feet and thought, no way something is wrong... Well, the last Pic tells the story, Huge it is....,

Very nice, camera should be able to follow that a long way away...  :b0201: :t2030: :t2030: :t2030:



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