rafale construction guide - jetworks.online

Construction Guide

Parkjet

Dassault

© 2019 Craig Clarkstone. All rights reseved

4th Generation Jet Fighter

Rafale History

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© 2019 Craig Clarkstone. All rights reserved.

Tthe Dassault Rafale (French pronunciation: [ʁafal], literally meaning "gust of wind", and "burst of fire" in a more military sense) is a French twin-engine, canard delta wing, multirole fighter aircraft designed and built by Dassault Aviation.

Equipped with a wide range of weapons, the Rafale is intended to perform air supremacy, interdiction, aerial reconnaissance, ground support, in-depth strike, anti-ship strike and nuclear deterrence missions. The Rafale is referred to as an "omnirole" aircraft by Dassault.

In the late 1970s, the French Air Force and Navy were seeking to replace and consolidate their current fleets of aircraft. In order to reduce development costs and boost prospective sales, France entered into an arrangement with UK, Germany, Italy and Spain to produce an agile multi-purpose fighter, the Eurofighter Typhoon.

Subsequent disagreements over workshare and differing requirements led to France's pursuit of its own development program. Dassault built a technology demonstrator which first flew in July 1986 as part of an eight-year flight-test programme, paving the way for the go-ahead of the project. The Rafale is distinct from other European fighters of its era in that it is almost entirely built by one country, involving most of France's major defence contractors, such as Dassault, Thales and Safran.

Many of the aircraft's avionics and features, such as direct voice input, the RBE2 AA active electronically scanned array (AESA) radar and the optronique secteur frontal infra-red search and track (IRST) sensor, were domestically developed and produced for the Rafale programme.

Originally scheduled to enter service in 1996, the Rafale suffered significant delays due to post-Cold War budget cuts and changes in priorities. The aircraft is available in three main variants: Rafale C single-seat land-based version, Rafale B twin-seat land-based version, and Rafale M single-seat carrier-based version.

Introduced in 2001, the Rafale is being produced for both the French Air Force and for carrier-based operations in the French Navy. The Rafale has been marketed for export to several countries, and was selected for purchase by the Indian Air Force, the Egyptian Air Force, and the Qatar Air Force.

The Rafale has been used in combat over Afghanistan, Libya, Mali, Iraq and Syria. Several upgrades to the weapons and avionics of the Rafale are planned to be introduced from 2018.

Photo’s used in this manual are copyright of their respective owners.

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Designers notes

Tthe Dassault Rafale being a delta wing has a range of really nice handling characteristics. An attractive yet unusually shaped plane, with the wide fuselage, ‘T’ sectioned forward fuselage and underslung side mounted air intakes. Not the simplest to replicate in flat foam sheet.

Take it step-by-step, and it is possible to generate the lines of this remarkable plane. With Optional 3D printed parts available to help generate the shape and increase durability, both the single and twin seat variants and both EDF and Pusher powerplant options, you can build this plane to suit your own flying style.

Adhesives> For the majority of construction : - UHU Creativ for Styrofoam (also called UHU POR) - 3M 77 Spray adhesive.>For wing spars and motor mounts : - Epoxy. (5 and 15mins cure times are the most convenient) micro-baloons can be added to reduce weight.> For servo’s / and quick grab : - Hot melt glue gun - Caution if the glue gets too hot it will melt foam - test first!

Tapes> For holding parts tightly together whilst glue sets - Low tack masking tapes> For leading edges, hinges, general strengthening - 3M Gift tape (Purple - not green one!) - I prefer lightweight plastic hinges.

Cutting parts1. Print the plans, 2. Cut around each part using scissors - allow a border of approx (1/4”) 6mm 3. Use either 3M spray mount or a very light coat of 3M 77 to the back of the parts and stick in an economical layout on the Depron foam.4. Using a safety rule and craft knife over a cutting mat - important! use a fresh blade otherwise it will drag and spoil the foam. (I find the stanley knife perfect) make the straight edge cuts, then the curved parts freehand.5. Once the parts are cut-out, keep the template stuck to the part until just before needed to help identify the parts.6. After use, I find it helpful to keep all the used tempates in case replacement parts need making. (the glue eventually dries and they don’t stick together!)

Glueing parts together.1. Ensure a really good fit - this will reduce the amount of adhesive used. The Bar Sander is a great tool for this. 2. Follow the adhesive instructions closely. 3. Use ordinary steel head pins to help keep the parts located whilst epoxy sets.4. Use objects as weights such as paperweights to apply pressure whilst adhesive sets.5. Use masking tape to apply pressure whilst adhesive sets. Also use masking tapeto along the slots for the wing spars whilst gluing the carbon rod spars into the wings. This prevents the glue protruding and gives a nice finish.

IMPORTANT Wherever the plans call for marking guidelines onto the depron, please ensure that you do otherwise it can cause problems later on. I suggest you use a Sharpie Fineliner to transfer the lines.

Before you start.

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Using masking tape to prevent spillage, glue the carbon spar into the wing.

Put masking tape over the top of the joint and lay in a flat place, preferably with a weighted object such as a book to keep it flat while the glue sets.

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Pusher only

EDF only

All versions

All versions

Gently bend the cockpit sides (inner) to match the shape of the Forward fuselage contoured sides (#1) then glue the cockpit sides to them.

Use the table edge method to add the gentle bend.

Cockpit sides (inner)

Cockpit sides (outer)

Forward fuselage contoured sides (#1)

Gently bend the Forward fuselage contoured sides (#1) to the cockpit side assembly then glue together.

Use the table edge method to add the gentle bend.

Adding one Forward fuselage contoured side piece at a time, build up the two contoured side assemblies as shown.

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All versions

FF contoured sides (#2)






Glue bulkhead 1 and bulkhead 2 to the assembly to connect the pieces together.

All versions

Bulkhead 1

Bulkhead 2

Glue the wing and the forward fuselage assembly together using the tab on bulkhead 2 in the wing slot.

Ensure the assembly is not warped by ensuring all the centrelines of the foam parts align with a straight line drawn on your workbench.

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All versions

Glue Pusher bulkhead 4 to the assembly.Pusher Bulkhead 4

Pusher only

Trim the bulkheads to suit your particular EDF unit. This model can take between a 64mm and 70mm EDF unit.

Test-fit the two EDF bulkheads.

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Glue the EDF bulkheads to the airframe assembly with the EDF unit dry-fitted inside.

Position the EDF unit, then glue in place using either silicone sealant (to reduce noise) or Hot-melt glue.

EDF only

EDF only

EDF bulkhead Rear

EDF bulkhead Rear

EDF bulkhead Front

Glue the EDF exhaust bulkhead to the assembly.

Please note that if a birfurcated 3D printed thrust tube is used, then the hole shown will be different.

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Glue the Upper fuselage corner reinforcers together and then to the airframe - ensuring that the wing is completely flat.

EDF only

EDF only

EDF Exhaust bulkhead

Glue the two pieces of the Motor mount panel together, the n glue the stick motor mount in place using hot melt glue - ensure that the stick is perfectly aligned.

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Glue the Motor mount assembly to the main airframe. slide in place using epoxy glue (sparingly)

EDF Exhaust bulkhead

Pusher only

Hobbyking - SKU:OR004-00602

3DPrinted

Part

3DPrinted

Part(optional)

Pusher only

Pusher motor mountpanel (x2)

Glue the Pusher exhaust panels on.

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Pusher only

Pusher only

Pusher exhaust panel (x2)

Glue the Upper fuselage corner reinforcers together and then to the airframe - ensuring that the wing is completely flat.

All versions Glue the Upper fuselage sides to the assembly.

Upper fuselage sides

All versions Pre-curve the Lower forward fuselage sides, mark a line on the wing with a pencil (as indicated on the plans).

Glue the pieces along the edge of the contoured forward fuselage sides, and according to the line.

Lower forward fuselage sides

Align to the edgeof the contoured forwardfuselage sides

All versions Glue the Forward fuselage belly (upper) to the assembly.

Forward fuselage belly (upper)

All versions

Forward fuselage belly (lower)

Glue the Forward fuselage belly (lower) to the assembly.

All versions Glue the Servo support pieces to the assembly.

Holding the drill bit with your fingers, twist and gently drill out the cable route for the canard servos using a 8-10mm bit. Use the hole in the bulkhead as a pilot hole.

EDF only

ESC

RX

Install all the electronics as shown. The ESC will be glued to the underside of the upper fuselage in a later stage. Solder and heatshrink all joints. Using Hot melt glue, glue the RX to the wing and the servos in place.

PARTS ‘CUT AWAY’ FOR ILLUSTRATION PURPOSES

Install all the electronics as shown. Recess the ESC>MOTOR wires into the leading edge of the motor mount. Mount he ESC on its edge as shown using Hot melt Glue. Fix the RX and servo cables as per the EDF version (previous page). Solder and heatshrink all joints. Using Hot melt glue, glue the RX to the wing and the servos in place.

Pusher only

ESC

EDF only

EDF only

3DPrinted

Part

3DPrinted

Part(optional)

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Cut the thrust tube from thin plastic sheet. Join the seam with nylon reinforced tape. Glue in place carefully with hot melt glue - not too hot to melt the plastic sheet.

Print the thrust tube to suit your particular EDF size. Use a soldering iron to create the hole to feed the motor wires through. Glue in place using Uhu Por.

Glue the Belly panel (EDF variant) to the assembly.

EDF only

Pusher only Glue the Belly panel (Pusher variant) to the assembly.

x

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All versions

All versions

Using fine drill bits twisted in the fingers, cut a path between the identified Entry and exit positions - indicated by the notch and hole.

Start with 3mm drill bits, and work up to 6-7mm.

Push aluminium tube through. Glue the exterior of the tube with epoxy to hold in place. Allow the tube to protrude 1-2mm to create a shoulder for the canard bushing to sit against.

Using the same method as the wings. Glue 6mm Carbon tube to the canards. Fit a drilled out prop-saver adaptor as a bushing and slot into place.

Use a drilled-out standard size servo horn on the end of the canard shaft. Use a twin piano wire Z-bend as shown to connect the canard to the servo.

Use friction to hold in place for the moment as the canards will be removed for sanding the fuselage.

Entry

ExitFit drilled outprop adaptor

EDF only

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Pusher only

Glue the Fuselage top (EDF variant) to the assembly.

Glue the Fuselage Top (Pusher variant) to the assembly.

3DPrinted

Part

3DPrinted

Part(optional)

All versions

All versions

Choose whether you want the twin canopy or single canopy Rafale version, and choose the nosecone accordingly. Glue the Nosecone pieces together as shown.

OPTIONAL : Choose whether you want the twin canopy or single canopy Rafale version, and 3D print the Nosecone accordingly. .

All versions

All versions

First glue in place the Nosecone aligner, then glue the Nosecone to the assembly.

Remove the canards and use the Sanding jigs to help create the shape of the Rafale. Use photos of the real plane to help. Please note that the nosecone sits proud at the top, do not sand this off.

All versions

All versions

Choose either the twin or single canopy variant, then construct the Turtledeck so that it conforms to the shape of the fuselage, but allows you to remove it to sand it to shape.

Use masking tape over the fuselage and a few drops of glue to pin it to the tape. Add a layer at a time. Once assembled remove it to shape. Ensure that the pieces are correctly aligned to the centreline of the plane then Glue in place.

Glue the Vertical stabiliser to the assembly using Epoxy glue to ensure a gap-filling bond.

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3DPrinted

Part

3DPrinted

Part(optional)

All versions

All versions

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Glue all the pieces of the canopy together or print out a 3D Printed version.

Single seat canopy shown here

Ensure a good fit to the plane.

3DPrinted

Part

3DPrinted

Part(optional)

All versions

All versions Glue all the pieces of the canopy together or print out a 3D Printed version.

Twin seat canopy shown here

Ensure a good fit to the plane.

Build a tongue using a piece of scrap depron and 3mm liteply at the front of the canopy.

Attach the magnets to the magnet panel

Epoxy the magnets to rear of the canopy so that the canopy is removable but holds firmly in place when mounted.

1. press magnet into depron to impress shape. 2. Dig out a recess for the magnetusing a sharp knife.

3. Apply glue into recess andpush magnet into it.

5. When fully cured, remove tapeand put adjoining magnet on top

6. When correctly aligned, press adjoining depron onto the sticking up magnet to impress shape.

7. Repeat steps 2-4 for the upper part.

4. Whilst still wet, lay masking tapeover the area.

IMPORTANT.Before glueing the upper magnet in, check that the magnet is the right way around!

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Single seat canopy Twin seat canopy

Assemble the tail-cone jig and glue together. Wrap 3mm depron around the jig, taping together on the side of the jig. Apply uhu Por to the visible side. Stick the outer 3mm depron in place. Trim and sand flat to the flat surfaces of the jig. Trim away areas that encroach onto EDF ducting or Pusher motor and stick to the exhaust bulkhead as shown below.

TapeAll versions

Print the correct exhaust cone for your chosen power method.

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3DPrinted

Part

3DPrinted

Part(optional)

EDF - Birfurcated Thrust tube versionEDF - Sheet Thrust tube version

Pusher version

EDF only EDF only

Pusher only

3DPrinted

Part

3DPrinted

Part(optional)

3DPrinted

Part

3DPrinted

Part(optional)

3DPrinted

Part

3DPrinted

Part(optional)

All versions

All versions

Cut 2 pylons from balsa and glue to the edge of the wing using uhu Por.

OPTIONAL : Print out two Pylons, cut a notch out of the wing for the ‘snag’ protector and glue to the wing.

The holes on the side of the pylons are for attaching missiles to.

All versions

All versions

BEFORE you start, sand the inside edge of the fuselage (inside the air intake to be a smooth airflow)

Construct the air intakes using the 3mm liteply template. Glue together all parts (including a corner reinforcer) and sand to the shape of the plywood.

OPTIONAL :

BEFORE you start, sand the inside edge of the fuselage (inside the air intake to be a smooth airflow)

Print out a mirrored pair of intakes and glue to the assembly.

3DPrinted

Part

3DPrinted

Part(optional)

All versions

All versions

Glue either the plywood or 3d printed Refuilling probe as shown here with Epoxy.

Stick the two 3mm depron antenna parts onto the vertical stabiliser.

3DPrinted

Part

3DPrinted

Part(optional)

Congratulatoins your model is now complete! Either fly it as it is or finish it in a paint scheme of your choice!

Use Google images to help complete the final shaping of your plane. Use lightweight filler to help with the concave radii on the fuselage. There are lots of paint schemes to choose from - simply look on google images!!

rafale construction guide - jetworks.online

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