Infineon EPP Build Log - Thanks Firetrappe and MrFlash!

Step 1 Printing and Cutting Parts

If using the tiled plans then tape the sheets carefully together making sure that they
line up perfectly. Once I had the plan assembled I cut the plan down into smaller
areas (ie. Wing, tailplane, fus etc) and used double-sided tape to temporarily stick
them to the EPP sheets so that they didnt move while I cut parts out. Most of the
cuts can be made using a straightedge (ruler) and the more accurate the cuts are to
90, the easier it will be to build nice and straight.
For parts that needed producing in multiples (ie. Wings, fuselage sides and formers)
I was able to remove the paper from the cut parts, leaving the double-sided tape
attached to the paper, and then re-use the templates again.
Once all the parts are cut I recommend doing a test fit as seen below to make sure
that all the pieces fit in their respective slots. Any slots that need enlarging are
better done now rather than when covered in glue!
Notes:
The plans are drawn assuming 9mm EPP is used for the centre cabane, although 2
pieces of 5 or 6mm could be used instead. I cut the servo holes at this point
however, plans are drawn assuming a Hitec HS-55 is used for ailerons and 2x Blue
Bird 306s are used for rudder/elevator.
Attached Thumbnails
Parts cut from plans 52.6 KB Views: 2046

Test fit main parts 90.3 KB Views: 1609

Step 2 Bevel Hinge Areas and Fit Carbon Fibre

Next, the trailing edges of the wings, horizontal and vertical stabs need the bevels
cut/sanded to 45. I used a steel rule and the edge of my cutting mat as guides and
cut the bevels using a sharp blade. While I was in bevel mode I also cut the bevels
on the rudder, elevator and ailerons.
The carbon fibre can now be glued to the areas shown in the photo below. 0.5mm x
3mm strip was used for all areas except the centre cabane. I applied contact

Infineon EPP Build Log - Thanks Firetrappe and MrFlash!

adhesive to the foam and the cf, allowed it to go tacky and then stuck the two
together. The cf was taped to the wing to hold it in place while drying. The cabane
used a 2mm CF rod which I sharpened to a point on one end and then pushed
through the foam (rotating the rod at the same time) to embed it. The point was left
exposed by about 2mm to aid alignment of the upper wing during final assembly.
Slots were cut in the outer struts and reinforced with 0.5mm x 3mm CF strips.
Note :
The photo shows the CF rod exposed on the bottom of the cabane. This needs to be
cut off flush before gluing in place. Also, the cf on the leading edges is in 3 pieces,
the main centre section and two additional pieces for the tips.
Attached Thumbnails
CF strips and rod glued in place 39.7 KB Views: 1893

Step 3 Glue in Centre Crutch and Firewall

The two firewall pieces were next glued together. Once dry, the top and bottom of
the firewall were bevelled using the top and bottom spacers to work out the angles.
The firewall was glued to the fus side with approximately 3 of down and right thrust
built in. The centre crutch was then trimmed to match the angle of the firewall and
glued in position from the firewall until it begins to taper.
Once dry, the nose was supported and the rear end of the crutch was glued into
place as shown below.
Attached Thumbnails
Centre crutch and firewall glued at front - top view 35.7 KB Views: 1544

Centre crutch and firewall glued at front - bottom view 85.5 KB Views: 1304

Infineon EPP Build Log - Thanks Firetrappe and MrFlash!

Centre crutch glued to rear with nose supported 86.7 KB Views: 1353

The top of the fus and upper former can now be glued in, taking care to make sure
everything stays nice and straight. Make sure to put some glue around the sides of
the cabane cutout, I nearly forgot! This also helps the top of the fus keep its shape
while drying.
Once dry, the nose can be supported again and the rear former and servo tray can
be fitted. Both the tray and the former were trimmed to size (using the centre crutch
as a guide) before gluing. You may want to position the servo tray further forward if
you are using heavier servos to keep the weight forwards. The further forward the
servos are however, the harder they will be to access once the wings are fitted.
Attached Thumbnails
Top front spacer, upper former and cabane fitted 78.1 KB Views: 1418

Servo tray and rear former fitted 81.1 KB Views: 1577

Step 5 Make and Fit Motor Mount and Install Radio Gear

I made a motor mount from a piece of fibreglass printed circuit board (lightweight
ply would be a good alternative). Before glueing to the firewall I drilled holes for the
motor shaft, wires and mounting screws. Matching holes for the shaft and wires were
made in the EPP firewall.
To avoid using servo extension leads I mounted the gear as shown in the photos
below. The rx was fixed to the centre crutch using velcro (the velcro in contact with
the EPP was sprayed with 3M 77 to ensure it had a strong bond). This allows me to
change the xtal in the rx without too much trouble.
I prefer using a velcro strap to secure my lipos, so I added pieces of strapping tape
to both sides of the centre crutch (to avoid the foam tearing on heavy impacts!) and
cut slots so that I could loop a strap over the cf. I sandwiched the esc wires between
a piece of spare EPP to keep them out of the way and provide a solid base for the
lipo to lie on. This also keeps the weight of the lipo as close to the thrust line as
possible.

Infineon EPP Build Log - Thanks Firetrappe and MrFlash!

The servos were glued into the tray and then the lipo was connected to make sure
they were centred (and everything worked). While I still had good access to the
inside of the fus I routed a Du-Bro micro pushrod snake through the rear former
and fus. Doing this now allowed me to keep the angle of the pushrod as shallow as
possible to prevent any unnecessary strain on the servo.
Attached Thumbnails
Motor mount cut from fibreglass PCB board 47.2 KB Views: 1313

Motor mount glued to firewall and motor installed 87.3 KB Views: 1569

Radio layout and lipo strap fitted 50.4 KB Views: 2173

Step 6 Attach the Other Fuselage Side and Hinge Surfaces

The second fuselage side can now be glued in place. I found it best to work from the
back of the fus to make sure the horizontal stab slots lined up and work my way to
the front.
While the glue dried I used Blenderm tape to hinge the ailerons, elevator and rudder
using the standard shockie method. Prior to hinging the ailerons I cut the holes for
the aileron control rods to make sure the holes in the connected ailerons would be in
line with each other. (see step 12 for more details)
Attached Thumbnails

Infineon EPP Build Log - Thanks Firetrappe and MrFlash!

Second fuselage side fitted 70.7 KB Views: 1400

Bottom of elevator and rudder hinges 57.2 KB Views: 1360

Top of elevator and rudder hinges 52.6 KB Views: 1139

Step 7 Join Top of Fuselage and Attach Tail

The top of the fuselage can now be completed. I started by gluing the edges of the
canopy and the edges of the top of the fuselage that needed joining. Once the glue
was tacky I fitted the canopy piece starting from the front and worked my way back
to the tail ensuring that the fuselage stayed straight. I then pinned the top of the fus
in several places to hold everything in place while the glue dried.
Once dry, the horizontal stab/elevator and vertical stab/rudder can be glued in place.
Test fit and trim/sand the slot and top of the fuselage if necessary to help keep
things square. Again, pin as required while the glue dries.
Attached Thumbnails
Side view 65.8 KB Views: 1490

Top View 75.7 KB Views: 1296

Step 8 Install Rudder Pushrod and Attach Lower Wing

Infineon EPP Build Log - Thanks Firetrappe and MrFlash!

The fuselage was now placed upside-down, and I installed the pushrod for the
rudder. This can run parallel with the bottom of the fuselage, passing through the
rear former and out through the fuselage side, again preventing undue strain on the
servo.
At this point the second fus lower former was trimmed and glued into the fuselage in
front of the rx. A hole is needed in this former to allow the wires from the esc and
aileron servo to pass through to the rx.
I then glued the lower wing re-enforcing plate to the lower wing, making sure that it
was at 90 to the hinge line and that the servo holes in both parts lined up. Once
dry, the wing was glued to the fuselage.
Attached Thumbnails
Rudder pushrod installed 45.2 KB Views: 1612

Lower wing re-enforcing plate fitted 75.5 KB Views: 1231

Lower wing fitted 89.6 KB Views: 1344

Step 9 Attach Control Horns, Outer Struts and Upper Wing

I used Du-bro micro horns and light ply for the control horns (matching the control
rods). The ply had a small hole drilled in it to allow the barb of the horn to pass
through and pierce the foam. The horns and ply were glued together using epoxy
and positioned inline with the previously installed pushrods. I added a blob of glue to
the tip of the barb on the opposite side of the control surface to further secure the
horns.
The aileron horns were positioned on a slight angle so that they were lined up with
the aileron servo. It is a good idea to fit the aileron servo at this point and connect it
to the rx while you have easier access. I did not glue the servo in at this point
however, so that it could be removed and placed inside the lipo bay, allowing the
fuselage to sit flat for fitting the upper wing.

Infineon EPP Build Log - Thanks Firetrappe and MrFlash!

Next the outer struts were glued into the slots on the lower wing. The upper wing
was then slotted onto the struts and glued in place using the carbon protruding from
the cabane to help hold the wing in position.
Attached Thumbnails
Rudder and elevator horns installed 89.5 KB Views: 1536

Aileron horns installed 79.8 KB Views: 1287

Struts and upper wing fitted 82.2 KB Views: 1408

Step 10 Landing Gear Construction

The landing gear was made by sandwiching 2x 2mm diameter carbon rods between
the two remaining formers. I made grooves in the formers using a soldering iron and
then glued in the carbon. The two formers were then glued together and left to dry
with a weight compressing the two halves.
The axles were made from piano wire bent to shape as shown below. This allows the
spats to be glued to the axle to add that finishing touch. The axles were then glued
with epoxy and bound with to the cf rods. Notice the notch cut in the top of the
formers to allow the esc wires to pass through.
Attached Thumbnails

Infineon EPP Build Log - Thanks Firetrappe and MrFlash!

Front formers with grooves 53.0 KB Views: 1090

2mm cf rod glued to formers 67.2 KB Views: 1139

Axles bound to carbon undercarriage 60.9 KB Views: 1365

Landing gear complete 62.3 KB Views: 1309

Step 11 Complete the Bottom of the Fuselage

I next connected the pushrods and routed the aerial wire through the rear former
and out the rear of the fuselage just above the tail skid. If you are confident that you
will not need access to the rear servos or rx, then the bottom of the fuselage can
now be glued in.
I opted to add an access hatch below the servos. I added some extra pieces of 3mm
EPP to the sides of the fuselage and cut the bottom rear spacer to create a hatch
similar to the lipo bay hatch at the front.
The bottom rear spacer was then glued in place. The hatch was secured with
strapping tape at the narrowest point and velcro was used at the other end to hold
the hatch closed.

Infineon EPP Build Log - Thanks Firetrappe and MrFlash!

The landing gear and front spacer were then glued in place. Note, I bevelled the
front spacer to make the front of the nose square. The lipo bay re-enforced sides
were then trimmed to fit and glued in.
The lipo bay hatch was attached using 2 wide strapping tape running from the front
of the front spacer to the leading edge of the lower wing. The tape was trimmed to
fit around the LG struts and velcro was stuck to the overhanging tape and between
the LG struts to hold the hatch closed. Lastly, the aileron servo was glued in position
and the control rods connected. I used a pushrod kit identical to the set used for the
rudder and elevator. The outer tubing was cut to size and slid over the thin wire rods
to reduce flexing.
Attached Thumbnails
Aerial routed to rear of fuselage. Control rods connected to servos 47.3 KB Views:

1450
Control rods connected, aerial secured and bottom glued in position 45.9 KB

Views: 1211
Landing gear, front spacer and lipo bay sides installed 45.7 KB Views: 1439

Hatches open 48.5 KB Views: 1563

Infineon EPP Build Log - Thanks Firetrappe and MrFlash!

Hatches closed 48.3 KB Views: 1336

Step 12 Fitting Aileron Control Linkages and Wing Braces

The upper and lower ailerons were linked using 1.5mm diameter cf rods. To secure
each end of the rods you need 4x 1 lengths of rigid plastic tube with an inside
diameter of 1.5mm. I found that the ink tubes from ballpoint pens were perfect! I
made a hole near the end of each tube using a pin and then used the offcuts from
the Du-Bro pushrods to pin each tube into the four holes in the ailerons. The four
pins were glued into the ailerons, taking care not to get any glue around the tubes so
that they could easily pivot on the pins. The carbon rods were then cut to fit (leaving
them slightly short so that they could be adjusted in the tubes). Once I was happy
that each pair of ailerons were level with the wings I glued the carbon into the tubes.
The wing braces were made from 2mm diameter cf rods. I used a length of pushrod
wire I had left over from the ailerons and inserted it through the lower wing at about
45 just behind the aileron servo. The thin wire was pushed through the foam
towards the outer strut. This was done a couple of times until I got the correct angle
so that the wire lined up with the point where the outer strut joined the upper wing.
Because very thin wire (pushrod) was used, only tiny pinholes were left where the
wire had pierced the foam. The tiny holes and tunnels that the wire made were
enough to be able to guide the cf rod on the correct angle first time. The photos
below give you an idea of where the cf rods exited through the sides of the fuselage
to create the perfect angle. The first brace was glued in place and then the same
procedure was carried out for the opposite brace.
Attached Thumbnails
Bottom aileron control linkage 74.7 KB Views: 1524

Infineon EPP Build Log - Thanks Firetrappe and MrFlash!

Top aileron control linkage 65.0 KB Views: 1217

Wing braces upper view 42.6 KB Views: 1472

Wing braces lower view 97.6 KB Views: 1403

Step 13 Airbrakes and Decals

Many of the latest indoor pattern and freestyle planes use fixed airbrakes. These are
used to slow the downline speed of the model so that it is easier to perform
manoeuvres keeping a constant speed. Flash has experimented with various brake
ideas on the Infineon, the most effective being 40mm wide strips of 5mm EPP
attached to the rear of the outer struts. I bevelled the top and bottom edges of the
brakes so that they followed the curve of the outer struts and fitted flush against
both wings. If intending to fly the model outdoors then it is probably better to leave
the brakes off initially, they add drag and reduce the forward speed of the model
significantly if flown in breezy conditions.
I designed the decals in the photo below to add a bit of character to the model
without adding too much weight. The decals were inkjet printed onto 5 sheets of
11x17 waterslide transfer paper and then attached to the model using 3M77
adhesive. For detailed instructions see my mini how-to thread here :
http://www.rcgroups.com/forums/showthread.php?t=582939
As the majority of people don't have A3 printers I have produced pdf's for the
Infineon and Mini Infineon suitable for Letter sized transfer paper. These are in a
tiled format and I recommend you print them on normal paper first to check they fit
your model. Once you have confirmed that they are the correct size then print them
onto transfer paper one page at a time to avoid paper jams. The pdf's can also be

Infineon EPP Build Log - Thanks Firetrappe and MrFlash!

opened in Photoshop and the colours can be changed by adjusting the hue of each
page.
Infineon Blue Decals - Letter Tiled (27Mb)
Mini Infineon Purple Decals - Letter Tiled (17Mb)
Well, thats about it
Thanks for reading, and if you have any questions regarding the design or build then
MrFlash and myself will do the best we can to answer them.
Happy Building,
Si.
Attached Thumbnails
Airbrakes fitted 70.8 KB Views: 1544

Waterslide decals added 50.0 KB Views: 1637