BVM F-100D Jet Kit

Specifications
LENGTH: 83.5"
WING SPAN: 69"
WING AREA: 1200 + sq. in.
WEIGHT: 29-31 lbs

The model is sized to operate with a JetCat P-120 or 160, AMT Pegasus, or RAM 1000 engine and weigh about 27 to 29 pounds. Wing area is over 1,200 square inches.
We reverse engineered a real bone yard F-100D to produce an exact scale outline model - something that any scale jet enthusiast would be proud to own.
The F-100D is very easy to assemble and service and despite its size, it completely disassembles to fit into the BVM JET-CASE, making it very easy to transport.

See how the first flights went on the F-100.

Major Kit Components

All components are composite except the flaps. Flaps are built at the factory with hinges installed. Leading edge slat tracks are factory installed for easy finishing. Stabs are checked for perfect alignment on a surface plate and shipped bolted together as shown above.

F-100 Super Sabre
Super Scale Feature
The Cockpit

Since the BVM F-100 airframe and landing gear reflect improved technology, we wanted the cockpit to be able to "measure up" to this new standard.

F-100 customers have been very pleased with what you see here. It is technically accurate and very detailed. The casting resin system is the best we have seen. The parts are not warped and are reasonably light in weight. The instruction package shows step-by-step assembly and painting, even including the correct F.S. (Federal Standard) numbers.

This pilot figure (1/7th scale) was hand made with clay and molded in a plastic resin to fit specifically in the F-100.

F-100 Super Sabre
Scale Outline Accuracy is important

The real test for "accuracy of outline" is placing your model in front of Top Gun judges - they rarely miss a detail.
Most of these judges have years of experience at Top Gun making them the most critical and yet consistent in the business. That is why we are very pleased with their comparison of the BVM F-100D to the 3-view drawings as printed in the War Paint Series #4 book on the North American Super Sabre.
The model received 29.25 out of a possible 30.00 points for accuracy of outline. This means that the basics are there for a serious scale enthusiast. An owner of a BVM F-100 can feel confident that his efforts to finish and detail his jet will not be in vein when it's time to put it in front of the judges.

The Inlet opening

The relatively small opening and sharp lip of the F-100 inlet prohibited its accurate scale modeling prior to turbine power. This and other details like the 20mm gun recesses are faithfully reproduced in the BVM moldings. Note also in this low angle view how prominent the leading edge slats are in the extended position.

The inlet of the F-100 must be right or the whole front of the fuselage suffers. Since we had access to a real F-100, we actually put a plywood plate, covered with poster board, over the front of the aircraft's inlet and traced it. We then used our "Faro" digitizing arm to record the X-Y components into our AutoCAD system and accurately reproduce it to the 1:6.857 scale of the BVM model.

The Boneyard F-100

Serious scale modelers would give anything to have access to the real thing - especially one that was disassembled. We were lucky to find an F-100D in just this condition in Florida, and we visited the site 4 times with camera's, measuring equipment, a ladder and drawing supplies to be able to reverse engineer the airframe.
This investment of time at the onset of the project pays off in the long run because the investment in the production tooling is secure.
Customer confidence and satisfaction that he has an accurate model is the ultimate reward.

F-100 Flight Scores
The highest in Designer Scale

Jeff Foley (1st with an BF-109E) and Nick Ziroli Jr (2nd with an Avenger) had the edge in static scoring and they deserved it. The time and experience these guys put into their models must be matched if you want to beat them because they both fly very well too.
The top 3 places in this tough category were separated by less than 1/4 of a point as shown by their scores 1st - 191.541, 2nd - 191.375, 3rd - 191.333.
I was pleased that the F-100 could score so well in the flight category - it has the smoothness and performance to be a winner, especially in crosswind conditions.

F-100 Super Sabre
Super Scale Feature
"Thin Flying Surfaces"

The F-100 was the first operational jet fighter for the U.S. Air Force that was designed to operate supersonic. Experienced gained by the early X plane development programs allowed North American to design and build very thin, low drag flying surfaces that could also withstand the stresses of MACH 1 plus flight.

We had access to a boneyard F-100 that we reverse engineered to design the BVM model. When we first measured the thickness (or better, the thinness) of the flying surfaces, we knew we had a challenge.

We also knew that to build them "fat" would certainly be easier, but not scale or authentic looking. Our philosophy was; why go to all the trouble and expense to build the tooling and then have to look at a fat wing, stab and fin with disappointment.

As we mentioned earlier, the scale NACA 64A007 airfoil was used for the wing along with operational leading edge slats to make the thin wing act like it is fat for take-off and landing.

The fin, fin base on the fuse and the stabilators offered some special challenges to duplicate those sharp leading and trailing edges and the overall thinness ratio of the surfaces.

Thanks to super materials like Carbon Fiber and Titanium we were able to meet the engineering challenges and produce light weight, truely scale, supersonic looking flying surfaces that have demonstrated their air worthiness many times at 200+ m.p.h. speeds.

"Thin is in"
on a real jet fighter

F-100 D Fine Feature

Super Scale Undercarriage

Every truely scale jet needs a scale landing gear made exclusively for it or it just won't look convincing or function properly. That's what we have learned over the years at BVM.

The capability to design and manufacture such items can only come from a mature company that has acquired the skills and equipment to do so. This beautiful and functional landing gear system for our F-100D reflects that capability.

Flight testing has allowed us to fine tune the design and present to the customer a system that he will be proud to own.

Since we all occasionally "prang one in", parts and service are extremely important. Again, it takes a mature company to be able to back up the product for many years to come.

F-100D Structure highlights We designed it so that you can transport it
The removable wing panels are all composite molded with every panel line faithfully reproduced. Two full depth and very strong carbon fiber spars carry the landing gear and flight loads (similar to the BVM F-4) and bolt to the carbon fiber bulkheads that are factory installed with accurate fixtures that guarantee perfect alignment. Putting the wing on the model at the field is a 10 minute affair. Access to the wing bolts is through the main wheel well openings.

Each leading edge slat rail has been custom fitted at the factory into the precision machined tracks that are built into the wings. The L.E. slats are molded of carbon fiber and have the "D" tube spar factory installed. The modeler does a very little bit of hand fitting, glues the slat to the rails and installs the operating servos. Leading edge slats have never been this easy and accurate.
The fin removes by loosening (2) set screws. With the wings and fin removed, the BVM F-100 transports and stores very conveniently even though it is a rather large model.
BVM makes a special "Jet Cradle" for the F-100 and our other kits to assist you in building the model and attaching the wings at the field. Jet Cradles can also serve to hold the model during transport. All of the components of the BVM F-100 have been extensively flight tested. Where we found need for improvement - we did so, before we released the kits. At BVM, our factory team pilots and reps fly alot so we can stay ahead on the learning curve. If we find a way to make your F-100 better, you can be sure that you will be informed.
Match molded Landing Gear Doors and Speed Brake

Beautifully detailed inside and out these match molded Epoxy resin and glass cloth molded parts are also very light weight and stiff. The hinge and actuating arm locations are marked on the parts making installation very easy and accurate.

F-100 Wing Fences
optional parts

Most F-100D's had wing fences applied to the upper outboard sections. The exact location is determined by the molded dots in the top wing skin.

BVM has machined the fences and a base strip from .030" poly ply and provided a plan and brief instruction sheet to make the installation easy. The fence base strip is attached with 4 panel screws each allowing removal for Jet Case transport.

Available now - BVM #9735 $18.50

F-100 Refueling Probe & Pitot Tube

F-100's had both straight and bent refueling probe's. To replicate the bent version, apply an extension spring (tight winding) to the O.D. of the tube. Use the drawing (included) to locate the bends.

BVM #9737 $24.00

F-100 in a Jet Case

It took some planning in the early stages of developing the F-100 to allow it to be transported in our UPS and Airline acceptable "Jet Case". Notice that the aft fuse section fits over the nose of the forward section and that the wing flaps are removed. Even the aft wing spars were shaped to conform to the molded fiberglass container.

Careful wrapping of the parts in a high density foam allows all but the hot section tailpipe to be safely air freighted to your destination. A separate cardboard tube can be used to send the tailpipe and external stores.

Transportability is another great reason to own a BVM F-100D.

F-100
Airframe Directive (A.D.)
And other helpful notes

Large Fuel Cell Transfer Tubes
Replace Brass with Stainless Steel
(4/20/06)

There has been one case where the brass tube that transfers fuel through a hole in the fuel cell baffle experienced a razor saw-like cut. The engine flamed out because the remaining fuel below the tube was unusable.
The most likely cause of the brass tubing failure was many miles of trailer transport of the model with the fuel cells empty.

The Fix

BVM now supplies Stainless Steel tubes with the large baffled fuel cells i.e., KingCat, F-100, F-4, Rafale, F-86 (80"). Retrofit parts are available. Ask for part #PSTU003 (quantity 2) price $5.00 for the pair mailed within the USA.
To be honest, we don't know how many travel miles the brass tubes will withstand. It could vary quite a bit. BVM is converting our factory demo models as time allows. Our prototype F-100D is 6 years old, has at least 300 flights and more trailer miles than we can count. We inspected the brass tubes and found minimum wear. We changed them to the Stainless Steel variety anyway.

Wing Pylon Mounting

Locate drill locations per plans.
Drill pilot holes with 1/8” bit. be sure to align drill vertically with respect to ground stance of model. (not surface of wing skin).
Re-drill with 3/16 bit, then with 13/64” bit. (hole size is critical for proper installation of brass insert.)
Install brass insert onto 4-40 socket head bolt. Slowly thread insert into hole. Maintain vertical alignment to avoid braking maple block loose in wing.
Remove bolt from insert, if insert does not release, place a drop of water into hole to swell maple block around insert. Wait 10 minutes, then try to remove bolt again. If needed, a drop of ZAP can be used to hold insert in position in block.

F-100D & F
Stab Servo Arms

The details and instructions on the top view of the fuse plans show and emphasis that the stab pushrod clevises are connected to the 2nd hole from the center of the JR 215 heavy duty arms. THIS IS CORRECT.
The photo on page 54 of the "D" model and page 63 of the "F" model should be replaced with this image.

Trailer Transporting
the "Heavy Jets"

It is convenient to transport the F-100 and F-4 gear down and strapped to shelves in the trailer. However, we are seeing some wear and tear on the wing mounting formers in the fuselage. The #10-32 bolts are working loose and even stripping the threads on the carbon fiber threaded discs. Of course, occasional stiff landings further aggrivate this problem.
Supporting the model on foam rubber on the trailer shelf should greatly alleviate the problem.
To fix a stripped out receptacle we made some aluminum threaded inserts. See photo's for how to attach.

To add the threaded aluminum inserts (BVM #2880) to the rear wing mounting formers, first scuff with #80 grit, tack with slow CA, then surround with Aeropoxy.

Use a 90° Dremel tool and a Perma-Grit RF-5C to open holes in the forward wing mount former to accept the aluminum insert shaft. Accomplish one at a time, checking alignment with wing attached.

You should also periodically check the 4-40 bolts that attach the main gear to the carbon fiber wing spars.

F-100 Rudder Trim

It is hard to observe at a glance because of the scale bulge in the fin at the top of the rudder and because the rudder is thicker than the fuse fairing at the bottom. Take a close look before take-off.

F-100 Tailpipe Cooling Shroud

A few of the very early kits may need to have this part updated. The correct exit diameter at the rear of the outer pipe is 3-3/4". If yours is less, return it for a no charge upgrade. The upgrade deletes the need to wrap the outside of the pipe with the heat blanket. The new system runs cooler.

F-100 Flap Geometry Improved

A second look at the flap linkage produced better results. It uses all of the same parts but realizes a better advantage in both the up and full down position.
As with any control surface linkage system, be sure that the surface will travel freely beyond the prescribed limits so that the servo is not under heavy load while commanding the desired deflection. For the F-100 flaps, this means that the inboard ends do not bind on the fuselage sides. Use a volt/amp meter to check for excess servo power drain.
The system shown has been thoroughly flight tested in our F-100F.

Note servo arm angle with flaps full up. Clevis is in 1st hole of JR heavy duty servo arm and the 2nd hole on the metal flap horn. Do not neglect the wood shim, flaps up stop (arrow).

Note angle of the servo arm in the flaps down position.

Installing the Slats

Steven Ellzey is a super precise craftsman as well as being an Aerospace engineer, so I am sure F-100 builders can benefit from his slat technique.

Steven says:
I finished up getting the slats on the Hun, and they turned out working very smoothly (if you pick the wing up leading edge down they will fall on the floor). I thought I would pass on what I did, should it be of any help.

For fitting and gluing, a layer of masking tape was applied to each side of the rails where they go into the wing. This forced the rail to the center of the slot. The opening into the spar on the slat was made a bit over sized, and the top of the rail, where it meets the slat, was cut back a bit extra (1/64"). This was done so that when the slat was held in place it would not touch, and possibly bend, the rails. The slat was held in place by several pieces of balsa, CAed to masking tape (see attached photos). This made sure that the OML (outer most layer) of the slat matched the OML of the wing on the top. I also applied a thin layer of CA to the edges of the rails where they go into the wing and polished it with 600 grit. I did this after the fact on one side and it seemed to help a bit when the slat was loaded vertically. On the other side, I CAed and polished before I glued them in (much easier). Other than the CA and polishing on the first side, no work was done on the rails after being glued in.

The only problem I see so far is that the slats are a bit thinner than the wing. Since I made the upper surface match as is, I will putty the lower surface to match the lower OML of the wing, which should be fairly easy to do. So far this looks like a very slick piece of machinery.

Steven Ellzey

Inlet / Fuse Joint

The forward inlet/fuse joint can be strengthened to reduce distortion during high power static and low air speed run-ups and to prevent damage while handling the model. This can be accomplished during construction or on a completed model.
Once the forward inlet duct section has been glued in according to the instructions, position the fuse nose down onto a flat surface (cover with wax paper) and pour a mixture of resin and micro-balloons through the openings of F-1.
Use one and one half ounces of Pacer Finishing Resin mixed with micro-balloons to form a thickened, but still pourable slurry.
Allow to cure with fuse in vertical position.

F-100 Stabilator Control Horns
some were tapped 4-40 vs 5-40

Our vendor for this part misread the print and we did not catch the mistake prior to shipping some of these units.
Check that the part in your kit is properly setup for the #5-40 bolts that mount the pushrods. If it is not, return it for a replacement. If you have a #38 drill and 5-40 tap, you can correct the part in your shop.
Sorry for the inconvenience.

F-100 Wheel Brakes Retention

Note that the wheel brake hub is retained to the axle with (2) "dog end" set screws that seat into a hole through the wheel axle and are locked in place with secondary set screws.
After several flights you can check the security of these screws with a 5/64" hex wrench.
We have observed that after about 80 flights on our "D" model, the "dog end" set screw is slightly bent but still functional.
Spare set screw sets are available - a nice addition to your spare parts kit. Add it to your next order and save on the postage.

Package #5828 contains:
(4) dog end 8-32 x 3/8"
(4) set screw 8-32 x 1/4"
Price: $4.00

F-100 Slat Servos

JR has discontinued the 3321 servo that we call for in the instructions for use on the slats.
The replacement digital variety #3301 are temporarily out of stock. The Airtronics 94141 (metal gear) makes an excellent substitute. Two standard and two reverse units are required. These servos allow manual operation of the slats. We always like to see the slats extended for static display. See your Airtronics dealer. F.T.E. has these units in stock - call 561-795-6600.
BV's new F-100F utilizes the 94141's on the slats.

F-100 Speed Brake / Wheel Brakes
mix on the JR 10X

We mixed the speed brake to the wheel brakes and assigned the control to the Aux 3 channel.
The first 90% of side lever travel provides proportional braking for taxi control. The last 10% activates the speed brake air valve servo control servo.
I prefer to fly the final approach with the speed brake deployed so that the glide slope and touchdown point is very precisely controlled with power. Touching down with the brakes "on" will yield a short roll out of about 200ft. If this is not desired, move the Aux 3 lever just a bit prior to touchdown to release the "full on" brakes and hold the nose high for a full flare landing.

For Futaba 9ZAP users there is a device called the electronic switch that will help free up a channel. BVM rep Paul Bageman has some experience with this item.

Landing Heavy
and Fail Safe setup

I had one occasion at Jets over Deland (Jan '01) where the radio was indicating fail safe conditions shortly after take-off.
I always set the fail safe as follows:
Engine to idle, gear down, and a slight amount of up stab.

The "Hun" was on the downwind leg when I saw the gear extend, so I immediately entered the landing pattern, dirtied up and set the power appropriately for a heavy landing.
With about 90% of the 4.8 Liters of fuel remaining the slatted wing handled the extra 5-6 pounds of fuel (above a normal landing) very well - just keep the power on.
This experience confirms that we can add a few extra pounds worth of missiles and bombs and enjoy the ultimate airborne appearance. Plenty of reliable power is all that is needed.

Stab Servos - shim

To keep the servo cases from interfering with the bottom fuse skin, it is necessary to add 1/8" ply shims to the inboard faces of the stab servo mounts. BV's model has the bottom of the servo cases protruding very slightly to keep a close check on servo temps after flight. So far no problems, holes in the bottom of the fuse are not necessary.

Stab Control Yoke

A very few parts may have been shipped out with 4-40 threaded holes vs. the correct 5-40 threads. Contact BVM if you received a 4-40 set.

3-View Drawings

We used the drawings from the War Paint Series #4 booklet. 11" x 17" copies of the top, side and front view of the F-100D are available from BVM.