So, if I have convinced you, let's start with the parts.
Oh, and please vote for this project! :) Every vote helps a lot.
Step 1: Parts - RC Plane
Fuselage - http://www3.towerhobbies.com/cgi-bin/wti0001p?&I=LXFRU7&P=ML
***It seems as if this fuselage has been discontinued. You can by the RTF version here: http://www3.towerhobbies.com/cgi-bin/wti0001p?&I=LXFXV0&P=ML and change out the motor.
****There is also a substitute frame that you can buy here: http://www.hobbyking.com/hobbyking/store/__16544__Hobbyking_Bixler_EPO_1400mm_ARF_.html
If you buy this plane, then you don't need to buy a motor or servos. It comes included.
Magnets - http://www.hobbyking.com/hobbyking/store/uh_viewItem.asp?idProduct=8288
CA accelerator - http://www.hobbyking.com/hobbyking/store/uh_viewItem.asp?idProduct=8456
CA glue - http://www.hobbyking.com/hobbyking/store/uh_viewItem.asp?idProduct=8443
Hinges - http://www.hobbyking.com/hobbyking/store/uh_viewItem.asp?idProduct=8424
Propellors - http://www.hobbyking.com/hobbyking/store/uh_viewItem.asp?idProduct=8006
Carbon Fiber (x2) - http://www3.towerhobbies.com/cgi-bin/wti0001p?&I=LXJDN9
Carbon Fiber (x2) - http://www3.towerhobbies.com/cgi-bin/wti0001p?&I=LXJDP4
Foam sheeting...you can find it at your local hobby + crafts shop
ESC - http://www.hobbyking.com/hobbyking/store/uh_viewItem.asp?idProduct=2165
Servos - http://www.hobbyking.com/hobbyking/store/uh_viewItem.asp?idProduct=662
Motor (doesn't have to be this one, but something close) -http://www.hobbyking.com/hobbyking/store/__15190__S2858_2630_Brushless_Inrunner_2630kv_.html
Battery - http://www.hobbyking.com/hobbyking/store/uh_viewItem.asp?id
Charger - http://www.hobbyking.com/hobbyking/store/uh_viewItem.asp?idProduct=7028
Power supply for charger: http://www.hobbyking.com/hobbyking/store/__20968__Hobbyking_60w_Power_Supply.html
Safety charger pack - http://www.hobbyking.com/hobbyking/store/uh_viewItem.asp?idProduct=4134
XT60 connector - http://www.hobbyking.com/hobbyking/store/uh_viewItem.asp?idProduct=9572
Battery monitor - http://www.hobbyking.com/hobbyking/store/uh_viewItem.asp?idProduct=14627
Insane RC controller - http://www.hobbyking.com/hobbyking/store/uh_viewItem.asp?idProduct=8992
Y harness - http://www3.towerhobbies.com/cgi-bin/wti0001p?&I=LXSGN3
Step 2: Parts - UAV
Step 3: Lay Out the Parts
ESC - controller for the brushless motor.
Brushless motors - Ok, here's a crash course in a sensorless brushless motor. Brushless motors are better for a few reasons, they are more energy efficient and more controllable than brushled motors, hence why we use it on a long duration flying UAV. First, how a brushed motor works: it has a stator on the outside which consists of magnets and a rotor on the inside that has a coil of wire. When you run electricity through the coil, it creates a magnetic field which pushes against the stator spinning the rotor 180 degrees. Once it has spun 180 degrees the coil is now atracted to both sides of the rotor and doesn't want to spin. So, we flip the voltage in the coil flipping the magnetic field and spinning the rotor 180 degrees. In a brushed motor, the spinning rotor flips the magnetic field mechanicaly by use of brushes. In a brushless motor, the magnets are spinning, so we can't flip the magnetic field mechanically. Hence why we need a brushless controller, the controller pulses the magnetic field correctly to spin the motor.
Brushless motor rating - This is the little complex part. There are a few ways to rate brushless motors, but the most important for us is the kV value and the amps that it draws. the kV rating tells you the sed that the motors turns depending ont he voltages. The amps that the motors draws in pretty self explainatory... To find how long the plane is going to fly, take the maH of your battery and divide by the the amount of amps your motor wil draw (that will give you a rough estimat of duration-of-flight).
Servos - These aren't just great for RC planes but for anything robotics. Servos are a great way to get presice motion. There are three wires, black is negetive voltage, red is positive voltage and yellow/brown/orange is the signal wire. The signal is a pulse sent from the receiver that tells the servo what position to go to.
RC - Radio Control. Pretty self explanatory. We have a transmitter (the thing with joysticks) and the receiver (the little box that goes inside of the plane). I personally have a 9 channel transmitter, but you will only need a 5 channel transmitter (4 for flying the plane, and one shutoff channel for the autopilot).
Step 4: Cut Out Holding Areas
Step 5: Layout Carbon Spars
For the front of the plane:
There is one center spar and two spars on the outside. For the spars on the outside, I just stabbed the carbon spar into the foam and pushed it in as far as possible. For the middle spar, I tapped it in place then ran an exacto knife along the edge of the carbon spar. I then pushed the carbon spar into the goove and glued it in place using CA glue and then spraying it with CA accelerator.
For bottom of plane:
This is harder...You want to cut grooves the same size as your carbon spars along the inside edge of the plane. In other words, you want the spar to run along the inside (interior side) of the fusalage. I installed them to run along the edge of the cuts that we made for extra storage (look at the last picture below). Again, you want to glue these in place by putting CA glue in the foam cut and spraying the spar with CA accelerator.
Step 6: Cut Out Spaces for Wires
Also make a slot on either side of the back of the cockpit (first picture) You want these slots to be pretty wide, but they don't need to be that deep. You will be running the power and signal cables to the ESC.
**Ignore the magnet stuff in the picture. That's for the next step, just ignore them**
Step 7: Insert Magnets and Handle
Now move on to the next picture.
We now have to glue magnets into the main cabin cover. Do the same thing as before, glue the magnets into the main cabin cover then snap magnets on and mark and glue those magnets into the fuselage.
Lastly, we want to create a handle for the hatch to the extra compartments. To do so, I use a bent paper clip and some tape, but you can use really anything.
Step 8: Install Motor
Step 9: Glue Sides Together
Oh, and contrary to the manual, run the wires of the motor out through the ventilation hole (look at picture below).
Step 10: Solder Connectors
1. Put ball of solder on the motor wire
2. Hold down gold connector somehow....I use a pair of second hands
3. Stick wire with ball of solder into the gold connector (look at first picture to see which side, there's a finished one in the background).
4. Then solder! You might want to put in a little extra solder once it if in place...you don't want this to fall out.
Now for the battery connector:
1. Grab a XT60 connector (in picture below)
2. Take the red and black wire coming out of the ESC and solder them in place according to the pictures (make sure that the wires are correct!)
Step 11: Modify + Install Stabilizers
Ok, now install the elevator (as per the instructions). Install the servo horn in the elevator as per instructions. Install the servo horn into the rudder by making a slot for the bottom of the "T" of the plastic (look at picture). Then put CA accelerator on the foam, CA glue on the plastic horn, and shove in into place. Make sure that the holes are facing the front of the plane.
Step 12: Install ESC
Step 13: Install Servos
Step 14: Build the Wing
Tip: spray paint the wings a bright color. Not only will this make the plane look awesome, but it will help you see it while flying.
Step 15: Install Battery Safety Lights
Step 16: Install Flight Electronics
****Make sure that when you install the battery you check the CG of the plane*** To check the CG, put the wings on and balance the plane on your finger right on the back edge of the foam piece that you installed into he wing (feel for the seam). Move the battery backward and forward to make sure that the plane is balanced. If you ever install more electronics into the holding bins, make sure that you recheck and fix the CG.