Beechcraft Bonanza User Manual

Before beginning construction ofyour Bonanza you should
make
these following corrections:
Fuselage Plan The correct site of the rudder/fintip block
(BON9S08)
is: 5/8" x
x 6-1/4'
Page
57,
step 7-ChangeF2to F1
A.
Page
57,
step
9
-
Change F2toF1A.
Page
58,
step
17
-
Change
".
.along the cut lines .
."to".
.about
l/l6"
inside the cut lines.
"
Page
58,
step
2
-
Change ".. Phillips head
.
to
.
Socket Head Cap Screw. ."
Page
60,
step
4
-
Change1"x 1-3/4"X2"
-3/8'x1-3/8'
x 1-1/2'
Page
62,
step
15
-
Change Fuselage to "cowl
"
Page
64,
step (wing)l-Add"as"after the word"such
"
Page
68,
step10-
Ad d sure"after the word "make
"
Page
69,
control throw chart-Trim mixing section change references to
"
Down
"
to
"Up"
WARRANTY.
....
TOP
Flite Models guarantees this kit to be free of defects in both materials and workmanship at the date of purchase. This warranty does not cover any component parts damaged by use or modification. In no case shall Top
Flite's liability exceed the original cost of the
purchased kit. Further, Top Flite reserves the right
to
change or modify this warranty without notice.
In that Top Flite has no control over the final assembly or material used for final assembly, no liability shall be assumed nor accepted for any damage resulting from the use by the user of the final user
-
assembled product. By the act of using the user-assembled product the user accepts all
resulting liability.
If
the buyer is not prepared to accept the liability associated with the useofthis product, the
buyer is advised to immediately return this kit in new and unused condition to the place
of
purchase.
I
J
Top
Flite Models
P.O.
Box
788
Urbana,
IL
61803
Technical Assistance-Call
(217) 398-8970
READ THROUGH THIS INSTRUCTION
BOOK
FIRST. IT CONTAINS IMPORTANT INSTRUCTIONSAND WARNINGS CONCERNING THE ASSEMBLY AND USEOFTHIS MODEL.
Entire Contents -Copyright
1997 30051
40
BON9P03
TABLE
OF
CONTENTS
INTRODUCTION
................................................
3
PRECAUTIONS
..................................................
4
DECISIONS YOU MUST MAKE
.........................
4
Tail configuration
............................................
4
Engine selection
.............................................
4
Exhaust system
..............................................
4
Retractable landing gear
................................
4
Flaps
...............................................................
4
TOP FLITE SCALE ACCESSORIES
.................
5
Operational lighting
.........................................
5
Scale cockpit interior
......................................
5
NOTES FOR COMPETITION MINDED MODELERS
........................................................
5
DOCUMENTATION
............................................
5
OTHER ITEMS REQUIRED
...............................
5
Accessories
....................................................
5
Building supplies
.............................................
6
IMPORTANT BUILDING NOTES
.......................
6
COMMON ABBREVIATIONS
............................
7
TYPES OF WOOD
..............................................
7
METRIC CONVERSIONS
...................................
7
NOTES FROM THE DESIGNER
........................
7
DIE-CUT PATTERNS
..................................
8
&
9
GET READY TO BUILD
...................................
10
BUILD THE TAIL SURFACES
.........................
10
Make the skins for the tail surfaces
..............
10
Build the stab and elevators (straight
-
tail)
....
11
Build the fin and rudder (straight
-
tail)
...........
15
Build the stab and ruddervators (V
-
tail)
........
17
Make the stab tips
........................................
20
BUILD THE WING
............................................
21
Make the wing skins
.....................................
21
Preparations
.................................................
21
Build the outer wing panels
..........................
22
Sheet the top of the wing panels
..................
23
Finish the outer wing panels
.........................
24
Build the center section
................................
27
Sheet the top of the center section
...............
28
Prepare the bottom of the wing for sheeting.28
Sheet the bottom of the wing panels
............
30
Cut out the wheel wells
.................................
31
Build the wing tips
.........................................
31
Build the flaps
...............................................
32
Build the ailerons
..........................................
34
Mount the flap and aileron servos
................
34
Join the wing panels
.....................................
35
BUILD THE FUSELAGE
..................................
36
Preparation
...........................
:
.......................
36
Build the bottom of the fuselage
...................
37
Mount the servos
..........................................
38
Finish framing the fuse
.................................
38
Sheet the fuselage sides
..............................
39
Glue the tail cone together
...........................
40
Build the turtle deck (V
-
tail)
..........................
42
Hook up the ruddervators
.............................
43
Fit the tail cone
.............................................
44
Center the stab
.............................................
45
Align the stab horizontally
.............................
46
Mount the fin
.................................................
47
Build the turtle deck (straight
-
tail)
.................
47
Hook
up the rudder and elevator
..................
49
Build the dorsal fin
........................................
49
Fit the tail cone
.............................................
50
MOUNT THE ENGINE
......................................
50
MOUNT THE NOSE LANDING GEAR
.............
52
Fixed gear
.....................................................
52
Retractable gear
...........................................
53
FINISH CONSTRUCTION
................................
55
Hook
up the throttle
......................................
55
Sheet the forward deck and bottom
..............
56
Fit the cabin top
............................................
57
Mount the cabin top
......................................
58
Fit the windows
.............................................
59
Mount the wing to the fuse
...........................
55
MOUNT THE V-TAIL STAB
.............................
40
MOUNT THE STRAIGHT-TAIL STAB AND FI N
.....
45
Sheet the bottom of the wing center section 60 Make the belly pan
.......................................
60
Build and fit the cowl to the fuselage
............
61
FINISHING
........................................................
63
Fuel proofing
.................................................
63
Cabin details
.................................................
63
Scale details
.................................................
63
Final sanding
................................................
63
Cover Top Flite MonoKotefilm
.....................
64
Painting
.........................................................
64
Join the control surfaces
...............................
65
Glue in the windows
.....................................
65
Make door and hatch outlines
......................
66
Apply the decals
...........................................
66
GET YOUR MODEL READY TO FLY
..............
66
Balance your model
......................................
66
Balance the airplane laterally
.......................
67
Install your receiver and battery pack
...........
67
Control surface throws
.........................
68&69
PREFLIGHT
......................................................
69
Charge your batteries
...................................
69
Balance your propellers
................................
69
Find a safe place to fly
..................................
69
Ground check your model
............................
69
Range check your radio
................................
69
Engine safety precautions
............................
69
FLYING
.............................................................
70
Fuel mixture adjustment
...............................
70
Takeoff
..........................................................
70
Flying
............................................................
70
Landing
.........................................................
71
TWO-VIEW DRAWING
.....................
Back Cover
Flaps
.............................................................
71
-2-
PROTECT YOUR MODEL,
THIS IMPORTANT SAFETY
PRECAUTION
YOURSELF
&
OTHERS-FOLLOW
Your Beechcraft Bonanza is not a toy, but a sophisticated working model that functions very much like an actual airplane.
Because of its realistic performance,
if
you do
not assemble and operate your Bonanza correctly, you could possibly injure yourself or spectators and damage property.
To
make your
R/C
modeling experience totally enjoyable, get assistance with assembly and your first flights from an experienced,
knowledgeable modeler.
You’ll learn faster and
avoid risking your model before you’re truly ready
to
solo.
Your local hobby shop has information
about flying clubs in your area whose membership
includes qualified instructors.
You can also contact the Academy of Model Aeronautics (AMA), which has more than 2,300 chartered clubs across the United States. We recommend you join the AMA which will insure you at AMA club sites and events. AMA Membership is required at chartered club fields where qualified flight instructors are available.
Contact the AMA at the address or toll
-
free
phone number below:
SINCE
1936
AcademyofModel Aeronautics
51 51 East Memorial Drive
Muncie,
IN
47302
Fax (765) 741
-
0057
(800)
435-9262
Your Top Flite Gold Edition Beechcraft Bonanza is intended for scale and general sport flying including
mild
aerobatics such as loops, stall turns, rolls, etc. Its structure is designed to withstand such stresses.
If
you intend to use your Bonanza for more abusive types of flying such as racing, aggressive aerobatics, or flying from rough fields, it is your responsibility to reinforce areas of the model that will be subjected to the resulting unusually high stresses.
I
NTRODU
CTl
ON
Thank you for purchasing the
Top Flite Gold
Edition Beechcraft Bonanza.
From this kit you can build either the V35B
V-tail (1 970, 1971
)
or the F33A straight tail (1970,
1971).
If
you like the looks of the V-tail best, don’t
be intimidated. Actually, the V
-
tail is a little easier
to build than the straight tail because it has fewer
parts! See page 7 for more comments on the differences between the V
-
tail and the straight tail.
Since this is a scale model with lots of detail, you’ll find it takes a little longer to complete than the sport models you’ve built before. But since this is a Top Flite Gold Edition kit, it isn’t more difficult to build than those sport models. The Top Flite
Bonanza uses the same materials and standard construction techniques you’ve already become accustomed to. You won’t have to learn anything new to end up with a first class scale model! Not only that, nearly all of the trim schemes you’ll find on full size Bonanzas are quite simple and should be easy to duplicate with Top Flite
MonoKote film!
The Top Flite Beechcraft Bonanza is an excellent
Sportsman or Expert Scale subject. Its large size and accurate scale outline afford you the opportunity to go a ll out with as many extra details
as you like. And with the abundance of Bonanzas
at airports around the country, finding a full scale
plane to model shouldn’t be a problem. The option
of building either a V
-
tail or conventional tail opens
up the possibilities even more!
-3-
Anyone who has mastered a low wing sport model should be able to fly the Bonanza without difficulty. It handles very much like a full size Bonanza
-
smoothandpredictable.
Because of its 81” wingspan, the Top Flite Beechcraft Bonanza is eligible for IMAA* events. In order to be IMAA legal some of the control components and hardware may need to be replaced to conform to Giant Scale rules even though this model does not require heavy duty hookups.
Several scale accessories specially designed for the Top Flite Bonanza are available separately including a full cabin interior, in
-
cowl exhaust system, and a complete lighting kit. See the Scale Accessories section on page
5
for more
information.
*IMAA (International Miniature Aircraft Association)
is an organization that promotes non
-
competitive
flying of giant scale models.
IMAA
International Miniature Aircraft Association
205
S.
Hilldale Road
Salina, KS 67401
Please inspect all parts carefully before
starting to build!
If
any parts are missing, broken or defective, or if you have any questions about building or flying this model,
please call us at (217) 398
-
8970 and we’ll be
glad to help.
If
you are calling for replacement
parts, please look up the part numbers and the
kit
identification number (stamped on the end of the carton) and have them ready when calling.
PRECAUTIONS
You must build the plane
according to the
plans and instructions.
Do
not alter or modify the
model, as doing
so
may result in an unsafe or
unflyable model.
In a few cases the plans and instructions may differ slightly from the photos. In those instances you should assume the plans and written instructions are correct.
2.
You must take time to
build straight, true
and
strong.
3.
You must use a proper RIC
radio
that is in first
class condition, the correct sized
engine
and
correct
components
(fuel tank, wheels, etc.)
throughout your building process.
4.
You must properly
install
all R/C and other
components
so
that the model operates properly
on the ground and in the air.
5.
You must
test
the operation of the model before
every flight
to
insure that all equipment is operating, and you must make certain that the model has remained structurally sound. Be sure to check external nylon clevises often and replace
them
if
they show signs of wear.
6.
If
you are not already an experienced
R/C
pilot
you must
fly
the model
only with the help
of a
competent, experienced
R/C
pilot.
NOTE:
We, as the kit manufacturer, can provide you with a top quality kit and great instructions, but ultimately the quality and flyability of your finished model depends on how
you
build
it; therefore, we cannot in any way guarantee the performance of your completed model, and no representations are expressed or implied as to the performance or safety
of
your
completed model.
Remember: Take your time and follow
directions to end up with a well
-
built model that
is straight and true.
DECISIONS YOU MUST MAKE
TAIL CONFIGURATION
You
may build your Bonanza as a
straight
tail
or a
V-tail.
Complete instructions are provided for both. The main differences in construction are building the tail surfaces themselves, the way they mount to the fuse, and the turtle deck sheeting.
If
you wish to utilize the elevators as
ruddewators
(elevators and rudder) on the V-tail,
you will need a computer radio with V
-
tail mixing
or a servo mixer such as the Ace MixMaster
(ACEM2510). However, the Bonanza will fly just
fine with elevators only and no rudder input.
Do
not be intimidated by the V-Tail configuration. It
flies beautifully and is as easy
to
handle as the
straight tail.
ENGINE SELECTION
Recommended engine size:
.60
to
.91
cu.
in.
2-stroke
-or-
.90to,120 cu.
in.
4-stroke
The Bonanza will fly
well
with any of the
recommended engines. The 4
-
stroke engines
and most
.75
2-stroke engines will turn a larger prop at lower RPM’s. This is often desirable for scale realism. Many
.60
2-stroke engines produce about as much horsepower as the popular
.75
or .90 2-stroke engines and will fly
the Bonanza well.
If
you use a
.60
2-stroke,
a
ball bearing, Schnuerle-ported engine is highly recommended. Our prototype Bonanza weighed 13 pounds with all of the options, including flaps, scale cockpit interior and operational lighting, and was flown with a SuperTigre
G-75.
It turned
a Top Flite Power Point 12x8 prop at 9,600 RPM.
This engine provided excellent performance and more than enough power, even in gusty winds.
Although larger engines can be used to
power this model, the extra horsepower is
not
needed.
The included adjustable engine mount will
hold a range of engines from
.60
2-stroke
through 1.20 4
-
stroke.
EXHAUST SYSTEM
A Top Flite header and muffler are available that will fit inside your cowl. They are designed for 2
-
stroke engines mounted horizontally, as
used on the model and shown in the instructions.
For part numbers see the accessory list on page 6.
RETRACTABLE LANDING GEAR
You may build the Bonanza either with fixed or retractable landing gear. Of course, fixed gear will be much easier to install than retracts; but we provide detailed instructions on retract installation
so
you should have no trouble. We chose the Robart #BZA80 retracts because they are specially designed for this model. This
landing gear is a special adaptation of the Robart
#640
mains and the #631 nose gear. Other
systems may work as well but it is up to you to
make modificationsto fit them into the model.
This model was designed to incorporate scale
flaps; however,flaps are optional are not
necessary
for an excellent flying experience.
Without flaps, the takeoff roll is longer and the
landing speed is faster.
The flaps are not difficult to build, but they do
require good craftsmanship to
fit
well. Flaps add
nicely
to
the model’s flight characteristics and scale appearance while causing no bad effects. Only slight trim correction is needed when they are used with the recommended throws. They are a highly recommended
fun
option
for those who wish to install them. More information on the use of the flaps may be found in the “Flying” section.
For part numbers see the accessory list on page
5.
-4-
FLAPS
Operational lighting
ROTATING BEACON
ING
\
NAVIGATION
LIGHTS
STROBE LIGHT
(GREEN
-
RIGHT, RED-LEFT)
An operational lighting system (TOPQ7912) has been developed specially for the Top Flite Bonanza and was installed in our prototypes. Guidelines are provided in this manual for building the wiring into the wing and building brackets to hold the wing tip and tail navigation lights. You can install the lights in the fuse at any time. The instructions included with the lighting kit provide information on how to hook everything up. The lighting kit includes one rotating beacon for the top
of
the fuselage, one landing light for the front of the cowl, and three navigation or
position
lights for the wing tips and tail cone (green in the right wing tip, red in the left wing tip, and white in the tail cone).
If you would like toadd the strobe lights in the wing tips, order RAM #RAM01 (RAMQ2301) and purchase additional clear lenses directly from RAM.
Scale cockpit interior
Your model won't be complete without the Top Flite Beechcraft Bonanza Scale Cabin Interior (TOPQ8402). It includes the floor, side panels, full instrument panel and six seats! You can install the Cabin Interior at any time because the cabin top is removable but it's easiest
to
build the cockpit into the model while it's under construction. The servos and
pushrods are located
so
the Cabin Interior can
be installed without any modification.
NOTES
FOR
COMPETITION
MINDED MODELERS
We designed our model from Beechcraft's own
1969 3
-
view drawings and from measurements taken from a V35B at a local airport. The model scale is 1 5 .
If
you plan to enter your Bonanza in scale competition (it's lots of fun, and the runways are almost always paved!), this kit qualifies for
Fun
Scale
and the
Sportsman
and
Expert
classes in
Sport Scale.
Fun Scale and Sport Scale have the same flight requirements where you must perform ten maneuvers of which five are mandatory.
If
you have never competed in a scale contest, you could start out in Fun Scale. In Fun Scale, the only documentation you need for static judging is any proof that a full size aircraft of this type, in the
painffmarkings scheme on your model, did exist.
A
single photo, kit box cover, even a painting is sufficient proof!
If
you're interested, contact the AMA for a rule book which will tell you everything you need
to
know. Look in the back of the AMA
magazine
Model Aviation
for a schedule of events.
The trim scheme of the Bonanza on your kit box
was
inspired
by several trim schemes and is not
taken from one particular plane.
If
you are not too concerned with an exact scale trim scheme you can duplicate the one on the kit box, make a
variation of the one on the box, or design your own trim scheme.
If
you are goingtocompete in scale competition use the photos in your documentation package as a guide for your trim scheme.
DOCUMENTATION
three view drawings and photo packs of full size Beechcraft Bonanzas are available from:
Scale Model Research,
31 14 Yukon Ave, Costa Mesa, CA 92626
(714) 979
-
8058
OTHER ITEMS REQUIRED
Accessories
These are additional items you will need to
complete your Bonanza that are
not included
with
your kit. Order numbers are in parentheses
(GPMQ4130). Our exclusive brand is listed
where possible:
TOP
is the Top Flite brand,
GPM
is the Great Planes brand, and HCA is the Hobbico brand.
4-to 6-channel radio with 6to 9 servos (2) 24"extension for ailerons (2) 12"extension for elevator and rudder servo (1)"Y
Harness for ailerons
3-1/2" Main Wheels (ROBQI51
6)
2-3" Nose Wheel (ROBQI513)
(6)
3/16 Wheel Collars (GPMQ4309)
14 oz. Fuel Tank (GPMQ4106) 2-3/4" White Spinner (GPMQ4525) 36"Medium Silicone Fuel Tubing (GPMQ4131)
1 / 2 R/C Foam Rubber Padding (HCAQ1050)
1/5 Scale Pilot Figures (WBRQ2485)
Fuel Filler Valve (GPMQ4160)
Exhaust Deflector (HCAP2175)
3-4 rolls Top Flite Super MonoKote covering,
see
Finishing
on page 64
Paint, see
Finishing
on page 64
Propellers,
see
the engine instructions
Items for V-tail with elevator only:
(1)"Y
Harness for elevator servos
(if
building
V
-
tail with elevator only)
For Flaps, the following additional items will be
required:
(1)
"YHarness
OR
(2) 9"Servo Extensions (1) Dual Servo Extension
Robart #309 Super Hinge Points (ROBQ2509)
Two standard servos
-5-
For an In Cowl Muffler setup, the following items will be required:
O.S
.61SF&FX Top Flite Header (TOPQ7920) SuperTigre .61-.90KTop Flite Header (TOPQ7925) SuperTigre .75-.9OG Top Flite Header (TOPQ7926)
.61-.75
Bonanza In CowlMuffler (TOPQ7917)
BUILDING
SUPPLIES
Here's a checklist of supplies you should have on hand while you're building.
We recommend Great
Planes Pro
CA
and
Epoxy.
Glue/Filler
4 oz. Thin CA (GPMR6003) 4 oz. Medium CA+ (GPMR6009) 2 oz. Thick CA-(GPMR6015) CA Accelerator (GPMR6035) CA Debonder (GMPR6039) CA Applicator Tips (HCAR3780) 30
-
minute epoxy (GPMR6047)
6
-
minute epoxy (GPMR6045)
Pro Wood Glue (GPMR6161)
J
&
Z
Products
Z
RC/56
canopy glue (JOZR5007) Microballoons (TOPR1090) Milled Fiberglass (GPMR6165) Lightweight Hobby Filler (Balsa Color, HCAR3401)
Auto body filler (Bondo@or similar) 3M #75 Spray Adhesive (MMMR1900)
Denatured or lsopropyl Alcohol
Tools
#11 Blades (HCAR0311, 100 qty.)
Single Edge Razor Blades (HCARO312, 100 qty.) Razor Plane (MASRl510) X-Acto@Building Square (XACR7726) X-Act0 Building Triangle (XACR7725) T
-
Pins (HCAR5100-small, HCAR5150
-
medium, HCAR5200-large)
3/32
"
9/32
"
1/8 5/16
"
5/32
"
9/64" or #29
Q 3/16" u11/64"or#10
1 / 4 13/64
"
or #7
Drill Bits:
1/16
"
17/64
"
Tools
(Cont.)
1/4-20 Tap and drill set (GPMR8105)
8-32 Tap and drill set (GPMR8103)
Kyosho"
LexarP
Curved Scissors (KYORl 01
0)
Long handle 9/64 ball driver (GPMR8004) Long handle 3/32
"
ball driver (GPMR8002) Silver Solder (GPMR8070w/flux) Masking Tape Wax Paper Easy-Touch'"Bar Sanders* Heat Gun (TOPR2000) Trim Seal
Tool
(TOPR2200) Hot Sock (TOPR2175) Sealing Iron (TOPR2100)
EASY-TOUCH
TM
HAND SANDER
*A flat, durable, easytohandle sanding
tool
is a necessity for building a well finished model. Great Planes makes a complete range of
Easy-Touch Bar
Sanders
(patent pending) and replaceable
Easy-Touch adhesive-backed sandpaper.
While building the Bonanza we used two 5-1/2" Bar Sanders and two
11"
Bar Sanders equipped with
80
-
grit and 150-grit adhesive-backed sandpaper.
Here's the complete list
of
Easy-Touch Bar Sanders
and adhesive backed sandpaper:
5
-
1/ 2 Bar Sander (GPMR6169)
11
"
Bar
Sander (GPMR6170)
22" Bar Sander (GPMR6172)
80
-
grit (GPMR6180)
150
-
grit (GPMR6183)
220
-
grit (GPMR6185)
12' roll of Adhesive
-
backed sandpaper
Assortment pack
of
5-1/ 2 strips (GPMR6189)
We also use 3M 320
-
grit or 400-grit wet-or-dry
sandpaper
for
finish sanding.
IMPORTANT BUILDING NOTES
There are
two
types of screws used i\n this kit:
number and a length.
Sheet metal screws are designated by a
For example #4 x 5/8":
Machine screws are designated by a number,
threads per inch, and a length.
For example 4
-
40 x 3/4":
When you see the term
test fit
in the instructions, it means that you should first position the part on the assembly without using any glue, then slightly modify or
custom fit
the part as
necessary for the best fit.
.
Whenever the term
glue
is used this means you should rely upon your experience to decide what type of glue to use. When a specific type of adhesive works best for that step we will tell you what type of glue to use.
Whenever
just
epoxy
is specified you may use
either30-
minute epoxyor6-minute epoxy. When
30
-
minute epoxy is specified it is highly
recommended that you use only 30
-
minute epoxy because you will need the working time and/or the additional strength.
-
Occasionally we refer to the
toporbottom
of the
model or
up
or
down.
To avoid confusion, the
top
or
bottom
of the model is as it would be when the
airplane is right side up and will be referred
to
as
the top even
if
the model is upside down during
that step,
i.e.
the top main spar is always the top main spar even if the wing is upside down when you are working on it. Similarly,
move the former
up
means move the former toward the top of the
fuselage even
if
the fuselageisupside down when
you are working on it.
Incidence and Thrust Angles: The incidence
angles and down thrust angles shown on the fuselage side view are in reference to the stepped main fuselage stringer (the
1/4"
x
3/8"x36
"
stepped stringer), which is set at
0".
The right thrust shown on the bottom view is in reference to the centerline of the fuselage. Remember, this is
-6-
the
bottom view
so
right thrust is viewed as an
offset to the left from the bottom.
When you get to each step, read that step
completely through to the
end
before you begin. Frequently there is important information or a note at the end of the step that you need to know before you start.
Photos
and
sketches
are placed
ahead
of the
step they refer to. Frequently
you
can study photos in following steps to get another view of the same parts.
COMMON ABBREVIATIONS USED IN
THIS
BOOK
AND ON THE PLANS:
Deg=Degrees
Fuse
=
Fuselage
LE
=
Leading Edge (front)
LG
=
Landing Gear
Lt
=
Left
Rt
=
Right
Stab
=
Stabilizer
TE
=
Trailing Edge (rear)
"
=
Inches
Elev
=
Elevator
Ply
=
Plywood
TYPES
OF
WOOD:
.,......_....
...
.
Balsa Basswood
Plywood
Inch Scale
0
"
1
"
2
"
3
"
INCHES
X
25.4
=
MM
(CONVERSION FACTOR)
1/64
"=.4 mm 3/4"=19.0 mm
1/32
"=.8 mm
1"
=
25.4 mm
1/16
=
1.6rnm
2"
=
50.8 mm
3/32
"=2.4
mm
3
"=76.2 mm
118"
=
3.2
rnrn
6=152.4 mm
5/32
"=4.0
rnrn
12
"=304.8 mm
3/16
=
4.8
mrn
18=457.2 mm
114"=6.4
mrn 21"=533.4 mm
3/8
=
9.5rnm
24
"
=
609.6 mm
1/2"
=
12.7rnrn 30"=762.0 mm
5/8
=
15.9
rnrn 36"
= 914.4 mm
NOTES
FROM
THE
DESIGNER
Scale Accuracy:
The Bonanza was designed using three
view drawings from Beechcraft dated 1969. In addition,
measurements of all aircraft components were taken from a V35B Bonanza at a local airport.
Wing Design:
The TF Bonanza was designed with an
"1­Beam"type of wing spar rather than the more traditional "D­Tube
"
type construction. Actually, the design could be
called an
"I-
Tube". This simplifies construction and is
approximately
50%
stronger than D-Tube designs. The wing was designed with an absolute minimum number of seams that must be sanded on the finished wing. The result is a very smooth wing.
Flaps:
Flaps on the full scale aircraft allow steeper approaches and slower landing speeds. They do exactly the same on this model. The improvement in performance is well worth the effort.
Landing Gear:
If you are installing fixed gear you will note
that the strut extends
out
from the center of the groved rail
instead of the end. This allows landing stresses
to
be distributed across three ply reinforced ribs, rather than being concentrated at the end of the rail.
If
you plan
to
install retractable landing gear,Ihighly recommend the Robart units especially designed for the Bonanza. They are
very robust and include shock absorbing struts. One of our
prototype models was built with Robart
#606HD
mains and a #607 nose unit. Though adequate, they required a lot of maintenance and occasional repair. Gear doors would look great on this model but you will have
to
do some
modifications
if
you want to install then. The mounting rails
4
"
5
"
6"
0
10
20
30
40 50
60
70
80
90
100
110
120
130
140
150
160
Metric Scale
-7-
are designedtominimize damage in the event of hard landings or contact with obstacles.
Fuselage Design:
The fuselage design is fairly
conventional. The cabin top is a LARGE ABS piece and
it
drove many of the other design elements -such as how
to
get it into the box! But itdoes simplify construction and
looks great.
It
is designedtobe removable but ifyou are not
concerned with access
to
the fuel tank and cabin interior it
can be permanently glued in place, allowing the seams
to
be filled in. We found that ifyou choose your trim design carefully, the seams are pretty well hidden.
The cabin area is reinforced with
1/8
lite ply. While it is
more than strong enough,
I
would recommend that you
reinforce the area with some basswood rails along the
bottom of formers F2, F4 and F6 across the width
of
the
fuselage. We have included ample extra 1/4" x 3/8"
basswood material for this purpose.
V-Tailvsstraight tail:
I
personally feel that a Bonanza is
not a Bonanza if it isn't a V
-
Tail.Ifyou are intimidated by
rumors about V
-
Tails being hard tobuild or difficulttofly,
you shouldn't be. The V
-
Tail is easier to build and
just
as
easy
to
fly.
I,
on
the other hand, was intimidated by the
V-Tail!
Just
kidding.Itwas designing the model tobe either
aV
-
Tail or straight tail, using the same basic mounting
structure and pushrods and showing
it
all on the plans that
I
found intimidating.
Do
You Need a Computer Radio?
NO!!
A computer radio
will simplify radio installation and allow full utilization of the
ruddervators but it is in no way required. Simply connect the ruddervator servos together with a Y
-
cable and use them as
elevators. Or use one of the many mixers available
to
obtain V-Tail mixing. Incidentally, this model duplicates virtually all of the flight characteristics of the full size aircraft. The rudders are somewhat ineffective and it has the
characteristic Bonanza tail wiggle. The
full
size aircraft has
differential throw when rudder is applied
-
the ruddervator having more up throw than down. This compensates for a nose down tendency otherwise. Try
to
duplicate this ifyou use a computer radio. We used a Futaba radio and did get the required compensation as you will note in the recommended control throws section.
Will It Really FlyOna
.60
Size Engine?
YES!! And very scale like as well. Our test flying was done with a new Super Tigre .75 with a TF in
-
cowl muffler.Itwas during
winter and it was cold so we weren't able
to
dial in the
engine very well.
It
was turningaTF 12-8 Power Point prop
at 9,600 RPM and we never felt a need for more power.
It
flew in a very scale like manner.
Good luck and good flying.
I
hope you enjoy building and
flying your Bonanza as much as
I
did designing it.
GET
READY
TO
BUILD
1. Unroll the plan sheets, then roll them inside
out
so
they lie flat.
2.
Remove all the parts from the box. Use a
ballpoint pen (not a felt
-
tip pen) to lightly write the
name or size on each piece
so
you can identify it
later. Use the
die-cut patterns
on pages
8
&
9
to
identify and mark the die
-
cut parts before you
remove them from their die
-
cut sheets. Many of the parts already have numbers stamped on them, but in some cases the number is located alongside the parts. You may remove all the die
-
cut parts from their die sheets now or wait until you need them. If a part is difficult to remove, don't force it out but cut around it with a
#I1
blade. After you remove the parts from their die sheets, lightly sand the edges to remove slivers or die
-
cutting irregularities. Save
some of the larger scraps of wood.
DO NOT PUNCH OUT THE
ROUND LIGHTENING HOLE
W4, W5,
W6
Note: If you are going to install retracts, don't
punch out the round
lightening hole
in the die-cut
3/32
"
balsa wing ribs W4, W5 and W6. Instead,
apply thin CA around the lightening hole to glue it
in place.
3.
Separate the parts into groups such as stab,
fin, wing
and fuse.
Store smaller parts in zipper-top food storage bags.
BUILD THE TAIL SURFACES
Make the skins
for
the tail surfaces
1. See the Hot Tip that follows and use six
1/16
"
x
3
"
x
30"balsa sheets to make two
1/16"x
9
"
x
30
"
stab skin
planks.
If you're building
the straight
-
tail, make a third
plank
for the
finlrudder skin from three more 1/16
"
x
3
"
x
30
"
balsa sheets.
Hey, if you're building the V-tail it
looks as if you are going to have three sheets
of
1/16
"
balsa leftover!
HOW TO MAKE THE SKINS
A. Use a straightedge and a sharp
#I1
blade to true the joining edges of the sheets. When you trim them, do not cut all the way through the first time but make
several passes so
you
slice
the
wood instead of splitting it.
B.
Tightly tape the sheets together with masking
tape placed about every
4
"
along the seams. The sheets will not lay flat because they are tightly taped together.
C. Place wax paper on your workbench. Flip the sheets over and apply a bead of aliphatic resin
(wood workers glue
such as Great Planes Pro"")
between the seams. Immediately proceed
to the
next steD.
-10-
D. Use a credit card or thin peice of plywood to squeegee the excess glue from the seam. Wipe the glue off your squeegee with a paper towel or a
stick of wood. Immediately proceed to the next step.
INCORRECT: SHEETS NOT FLAT AND EVEN
....
y
CORRECT SHEETS ARE
FLAT AND EVEN
.
.
....
E. Press the joining edges of the sheets down with your fingers
so
they are flat and even. Place
weights on top of the sheets to hold them flat.
F. Squeegee the glue, press the seams flat, and place weights along the other glue joint. Let the glue dry.
G.
Use the same procedure to make the wing
skins when you build the wing.
2.
After the glue is dry, peel off the masking tape and decide which side of the planks will be the outside. Use a bar sander or a large, flat sanding block and 150
-
grit sandpaper to sand the planks
so
they are flat, even and smooth. The idea is to do the sanding
before
you glue the skins to the
structure.
3.
Cut the
9
"
x
30
"
sheets in half, making four (or
six for the straight tail)
9
"
x
planks.
LE Grain
Stab
TE
!
-
Elevator (Ruddervater)
Elevator (Ruddervater)
4.
Cut the
stab and elevator skin templates
from the plan. Use a straightedge and a ballpoint
pen to mark their outline onto the
9
"
x
planks
(do not use a felt
-
tip pen). The templates are
slightly oversize to allow for slight variances in
construction. Note the
grain direction.
Cut the
stab and elevator skins
from the planks.Ifyou're building the straight tail do the same for the fin and rudder skin.
Note:
The template shown on the plans for the elevator (ruddervator) is larger than needed. You will need to trim this to the correct size when you fit the skin into place.
Beech Fact:
Let's get it straight. All Bonanza 35's (that's A through V including the very first Bonanza
-
the35are V-tails. Models 33 through 33C
are
Debonairs
(more on the
Debonair
in a later
Beech
Fact).
Models 33E throughGare straight tail Bonanzas, as well as the very last Bonanzas produced: the 36 and A36. But
it's
not that simple. The
designations didn't necessarily proceed from A,
to
B, to C, etc. There were variations of some of the models such as the V35, V35TC. V35A, V35A-TC and
so
on.
Or, the F33, F33A and F33C. But, th e
number
designation rule
still applies. Now you can really
impress your friends!
-
11
-
I
I
If
you're buildingthe V-tail, skip to"Build the
stabilizer and ruddervators
" on page
17.
BUILD THE STABILIZER AND ELEVATORS
Build the right and left stab halves simultaneously. The left half of the stab plan shows the straight tail stab with dashed lines indicating the V
-
tail stab.
The right half of the stab plan shows the V
-
tail stab
with dotted lines indicating the straight tail stab.
STI. Position the plansothe stab is over your flat building board (or cut the stab from the wing plan) and tape it down and cover it with wax paper.
s1s
ph
ST2.
Glue
both die-cut
118"
balsa
straight tail
LE braces
together and both die-cut
3/32
"
balsa
S1S
ribs
together.
ST3.
Test fit the die-cut
3/32
"
balsa
stab ribs
S2S
through
S7S
in the notches of both die-cut
1/8"
balsa
stabTEspars
Place both assemblies over the plan and add the LE brace. See the photo at step ST4.
-
ST4.
Use a small square to align the stab
TE
spar at rib
S2S
over the plan. Pin rib
S2S
over its
location on the plan with a T
-
pin about in front
of
the TE spar.
ST5.
Use the same method to align theTEspar and pin the rest of the ribs on both sides of the stab to your building board over the plan.
ST6.
Pin the fronts of the ribs to your building
board over the plan.
ST7
Add
botn
de-cut
1
8
"
balsa
elevator
LE
spars
(S8)
to
the assembly.
ST8.
Make sure all the jig tabsofall the ribs are contacting your building board. Glue the stab TE spar and elevator LE spar to the ribs with medium CA. Don't use large amounts of CA or build up fillets of glue. Later we will instruct you to reinforce glue joints that don't
look
strong.
ST10.
Glue the die-cut
1/16
plywood
straight
tail
TE doubler
to
the front
of theTEbrace (it's
the one with straight edges).
STI1.Add the center rib
S1Sand glue it into
position.
ST12.
Sand the fronts of the ribs to match the aft
sweep of the leading edge. Cut two shaped
5/16"x
15"balsa
stab/fin leading edges
to a length of
13-314"
and bevel the joining ends to match the
plan. Glue them to the ribs and the LE joiner
so
the
topiseven
with the
top
of the ribs. The bottom will
extend below the ribs but will be sanded flush later.
-12-
ST13.
Cut a
1/16
notch in center rib
S1S
behind
the LE brace. Test fit the die
-
cut
1/16"plywood
straight tail LEdoubler
in the notch. Deepen the
notch as necessary
so
the top of the doubler is
even with the top of rib
SIS.
Glue the doubler
to
the LE brace and glue rib
S1
S
to
the doubler.
ST14.
Cut the end
off
both
SlAS
ribs at the
embossed line and set those little pieces aside.
They will b e used later to glue the aft end
of
S1
AS into position. Fit the to the elevator LE spars, pin them
to
the plan, and then glue them to
the elevator LE spars.
ST15. Sand the top of the leading edges, stab
and elevator spars, and the TE brace
so
they
match the contour of the ribs.
Do
not change the
shape of the airfoil by sanding too much.
ST16.
THIS STEPISVERY
IMPORTANT!
Arrange the T-pins so
every other rib
is held down
with one pin near the front and one pin near the
rear and make sure all the pins go into the jig tabs
at the same angle.
This will allow you to
finagle
the stab off your building board by lifting it up and to one side after the top sheeting is glued in place
(the T
-
pins are concealed).
ST17. Use your favorite method to glue the stab
skin to the stab. We recommend using aliphatic
resin to glue the skin to the ribs and TE spar, and CA for only the leading edge. Apply glue to the stab structure. Working quickly, position the stab skin
and hold the leading edge down until the CA
hardens. When the CA is hardened, wet the front of the skin with a
50/50
mix of alcohol and water and press it to the rest of the frame, holding it down with weights until the glue dries.
Note:
If
you choose to use CA for the entire job, be aware that residual accelerator you may have used earlier can make the CA you use for this step cure quickly. You'll have to work rapidly.
ST I8. Glue the elevator skin to the elevator. You can use CA for this step since the skin is small and easy to position. Make sure the trailing edge contacts the
stoppers
on the top of the jig tabs on
ribs S7S and S2S.
ST19. After the glue has thoroughly dried,
remove all the T
-
pins you can reach.
Carefully
lift the stab (with the elevators) from your building board. Trim the jig tabs from the ribs and take out the rest
of
the T-pins.
ST20. Use a razor plane or a#I1
blade to trim
the
bottom
of the LEsoit is the same size as the
front of the ribs and matches the airfoil shape.
ST21. Sand the bottoms of the ribs, leading
edges, stab spars, elevator spars and the TE brace
so
they smoothly blend.
L
ST22. Glue the little tips you cut
off
the end of
the
S1ASribs to the sheeting andS1AS.
BEVEL THE TE TO MATCH THE RIBS
TOP
SHEETING'ON
ELEVATOR
,
THE BOTTOM SKIN WILL FIT LIKE THIS
TOP SHEETING
'
ST23. Use a bar sander and 150-grit sandpaper
to bevel the trailing edge of the top elevator skin
S
O
it will accommodate the bottom skin. While you sand, apply pressure only to the sheeting and use the ribs to set your sander at the correct angle.
Do
not bevel the trailing edge to a
sharp edge
but
leave about 1/32
"
squared off.
Hint:
Support the TE with the edge of your workbench or a platform while you sand.
ST24. Glue four die
-
cut
1/8"
balsa
elevator
torque rod blocks
between both sets of ribsSlAS
and S2AS.
ST25. Cut twelve 1-7/8" long
hinge blocks
from
the
1/4
x
3/8" x 3 6 balsa stick. Glue them evenly spaced to the stab TE spar and the elevator LE spar where shown on the plan. Glue the die
-
cut
1/8" balsa
stab gusset
to the hinge block and rib
S7S as shown on the plan. Position the gusset
so
it
is even with the bottom of the hinge block
so
you do not break it when you cut the hinge slot. Align the grain as shown on the plan.
-13-
ST26. Trim the elevator torque rod blocks and
any protruding hinge blocks
so
they are even with
the bottoms of the ribs.
ST27. Reinforce any glue joints that do not
look strong.
ST28. Glue the elevator skins to the bottom of
the elevators
so
the trailing edges align.
ST29. Glue the stab skins
to
the bottom ofthe
stab.
If
you have not used any accelerator on the stab you may glue the skins on with thick or medium CA. Otherwise, use aliphatic resin. Work over a flat work surface and be careful not to add any twist into the stab as you press the skins to the stab frame.
Optional:
Use the die-cut
1/8"
balsa
straight tail stab cradles
S2T
and
S7T
to hold the stab flat on your workbench while you glue the bottom skins on. Use the stab cradles the same as
the wing cradles shown in steps
1-5
on page 30.
ST30. After the glue dries, use a bar sander with
150
-
grit sandpaper to sand the sheeting even with
the ends of the stab and elevators.
ST31.
Cut the ribs and separate the elevator from the stab. Sand the excess sheeting and rib stubs from the TE of the stab and the LE of the elevator. Sand the elevator sheeting even with rib SIAS.
ST32. Glue a die-cut 1/8" balsa
stab
TE
(S10)
to
the TE
of
both stab halves. Glue a die-cut
1/8"
balsa
elevatorLE(also
S10)
to theLEof both
elevators.
ST33. Sand the stab TE's and the elevator LE's
so
they are even with the ends of the stab and
elevators. Sand the stab TE and elevator
LE's
so
they blend with the tips and skins.
ST34. Use
two
T-pins, placed in the
center
of the leading edge of one of the elevators near the ends, to align a straightedge and draw a centerline with a ballpoint pen.
ST35. Mark the other elevator and the TE of the
stab the same way.
ST36. Cut the hinge slots on the centerlines of the elevators and the stab where shown on the plan.
'3/4'
ST37. Cut six
hinges
from the 2
"x9
"
CA
hinge
strip
as shown in the sketch. Snip the corners off
the hinges
so
they go into the slots easier. Temporarily join both elevators to the stab with the hinges.
If
necessary, adjust the hinge slots sothe
elevators and stab align.
ST39. Skip ahead to
Make the stab tips
on
page
20
to make the tip blocks (the straight tail and
V
-
tail tips are shaped the same way). When you're
done, return to step ST40.
ST40. Using the plan, accurately mark the
location of the
1/8"
elevator joiner
wire
and horn
(from now on referred to as just the
elevator
joiner)
on the elevators.
ST38. Locate the 3/4" shaped balsa
stab tip
ST41.
Drill
a 9/64"hole and cut a groove in the
center of both
LE's
for the joiner. Test fit the
elevator joiner in the elevators.
Hint:
Use a
1/8"
brass tube sharpened at one end
to cut the grooves.
blocks.
The tip blocks match the
V-tail
stab tips,
so
use the plan to reshape them to fit your straight
tail stab.
-14-
Cut a small groove in the TE of the stab
so
the
horn
on the elevator joiner will not bind
against the stab when the elevator deflects downward. Test fit the elevators to the stab, with the elevator joiner in place, and make adjustments
if
necessary.
Beech Fact:
remarkable airplane and held many world records. In
1949
it
light
planes flying 4,957
from
Honolulu
Odon.In1958itheld
miles
Pendleton, Oregon
The
Bonanza was (and
held
the
world record non-stop distance
miles
to
New Jersey piloted by Capt.
in45hours,
the
43 minutes from Manila
flown
by Capt.
in
same
36 hours,
record
Pat
Boling.
still
2
flying
is)
for
all
minutes
Bill
7090
to
a
BUILD THE FIN AND RUDDER
ST1. Place the fin plan over your building board
and cover it with wax paper.
BEVEL THE NOTCHES IN THE
RIBS
FIN
THE ANGLE ON THE PLANS
ST2. Test fit the die-cut 3/32"balsa
through
R6
finTEspar
the assembly over the plan. the notches of the fin spar, remove the ribs and bevel the notches in the spars and the ribs as shown in the sketch.
AND SPARS TO MATCH
ORIGINAL NOTCHES
fin ribs
in the notches of the die-cut 1/8" balsa
(R7)
and
rudderLEspar
If
the ribs fit tightly into
TE
spar and the rudder LE
(R8).
R2
Place
ST3. Use a small square to position the fin TE
sparover the plan near rib R2. Align rib R2 over
the
plan and pin it to your building board. Use one
-
pin near the front of the jig tab and one T
pin
!ar the rear of the jig tab.
ST4. Use the same method to align the fin TE spar over the plan at each rib. Pin the rib to your building board. Glue the ribs to the spars with medium CA. Use small drops of CA and do not buildup fillets. Later, we will remind you to reinforce the glue joints.
Refertothis photo for the next three steps
ST5. Cut rib R1 apart between the spar notches.
R1
Add fin rib
to
them
and rudder rib
the plan and glue them in position.
R1A
to the spars. Pin
ST6. Sand the fronts of the ribs to match the aft
sweep of the leading edge. Cut a shaped 5/16
"
x15"balsa
of
12-1/2". Glue it to the frontofthe ribssothe
of
the LE is
bottom of the
stab/fin leading edge
even
with the
LE
will extend below the bottom of
top
of the ribs. The
to a length
top
th e ribs but will be sanded flush later.
-15-
ST7.
leading edge and the sub spars
Sand the upward facing edges of the
Do
contour of the ribs. airfoil by sanding
not change the shape of the
too
much.
so
they match the
ST8. Arrange the T-pinssothey all go into the
jig tabs at the same angle. This will allow you to
finagle the fin and rudder off your building board by
lifting it up and to one side after the top sheeting is
-
glued in place (the T
ST9.
Glue
pins are concealed).
the fin and rudder skin to the
structure. The bottom of the fin skin should extend
so
below rib R1 by approximately 1/4"-1/2" trim it later. Make sure the trailing edge
you can
of
the
rudder meets the stoppers on the top of the jig tabs
R1
A.
Note:
on ribs R6 and
The rudder skin was cut
wider than needed, to allow enough material to trim
to
size now.
it
ST10. After the glue has thoroughly dried,
remove all the T
-
pins you can reach. Carefully lift the fin (with the rudder) from your building board. Trim the jig tabs from the ribs and take out the rest
-
of the T
pins.
ST11. Use a razor plane or a #11 blade to trim
the right side of the
LE
so
it is the same size as the
front of the ribs and matches the airfoil shape.
ST12. Sand the bottoms ofthe ribs, leading edges, fin spar, rudder spar and trailing edges so that they blend.
ST13. Bevel the trailing edge of the left rudder skin the same way you did the stab.
ST14. Glue the four die-cut1/8"balsa rudder
torque rod blocks betweenR1Aand
R2
in
the rudder.
ST15.Cut six 1-718" long hinge blocks from the
1/4" x 3 / 8
x
36" balsa stick. Test fit, then glue the
hinge blocks, evenly spaced,
to
the fin TE spar and
the rudder LE spar where shown on the plan.
ST16. Glue the die-cut 1/8" balsa fin gusset to the hinge block and rib R6. The gusset should be raised
so
it is even with the left side of the fin TE
and rib R6
(so
it does not interfere with the
hinge slot).
ST17. Trim the elevator torque rod blocks and
any hinge blocks
so
they are even with the ribs.
BEVEL
FIN
POST
FRONT
SIDE
ST18. Cut a5"
long fin
post
froma114
"x318
"
x
36
"
basswood stick. Bevel one endsoit matches
the plan. Bevel the sides
to accommodate the
sheeting. Set the fin post aside for now.
ST19. Reinforce glue joints that don't
look strong.
ST20. Glue the other rudder and fin skin to the
right side of the rudder and fin.
Optional: Use the
die
-
cut 1/8" balsa finlstab cradles
RlC
and
R6C
to
hold the fin and rudder flat on your workbench
while you glue the right skins on.
ST21. Sand the tip of the fin and rudder sheeting
flush with rib R6.
ST22. Cut the ribs and separate the rudder from
the fin. Sand the excess sheeting and rib
stubs
from the TE ofthe fin and the LE of the rudder. Sand the bottom of the rudder even with rib
A.
ST23. Glue a die-cut 118" balsa fin trailing edge
(R9)
to the fin TE spar and a die-cut 1/8" balsa
rudder leading edge
(R9)tothe rudder LE spar.
Sand the fin TE and rudder LE
so
they blend with
the tips and skins.
ST24. Use the
straightedge and pin
technique to draw a centerline on the LE of the rudder and the TE of the fin.
ST25. Cut the hinge slots on the centerline of
the fin and rudder where shown on the plan.
ST26. Cut three more hinges from the hinge strip and temporarily join the rudder to the fin. If necessary, adjust the hinge slots
so
the fin and
rudder align.
ST27. Securely tape the rudder to the fin with masking tape on both sides. Sand the ends of the
fin and rudder
so
they are even.
ST28. Draw a centerline on the top and bottom
of t he 518" x 718"
x
6-1/4" balsa fin tip block. Cut
the block into two pieces as shown on the plan.
Sand the edges you just cut
so
they are smooth
and match the angle on the plan.
-16-
ST29. Use thick or medium CA to glue the
rudder tip block
only to the rudder. Use the
centerline on the rudder tip block as a guide to make sure it is centered on the rudder and fin.
ST30. Glue the fin tip to the fin, making sure there is a 1/16" gap between the fin tip and the rudder tip.
ST31. Use a razor plane or a hobby carving knife followed by sanding to carefully shape the fin and rudder tip blocks. Inspect your progress frequently and use the centerlines as a guide.
Hint: Stick a T
-
pin through the top of the rudder tip into the fin. This will hold the rudder tip while you shape it.
ST32. Shape the LE of the fin as you did with
the stab.
ST33. Separate the rudder from the fin.
ST34. Shape the leading edge of the rudder to a
"V"
as you did with the elevators. Use the centerline on the leading edge as a guide. Make sure the angle of the
"V"
will allow the throws
indicated in the back of this manual.
ST35. Rejoin the rudder to the fin with the
hinges. Shift the rudder upward
so
there is approximately a 1/32" gap between the rudder tip and the fin.
ST36. Sand the topofthe rudder tipsoit matches the fin tip (since you raised the rudder slightly).
What a ni9pie
P
f
workmanship! Put the stab
and fin in a safe place, clean
off
your workbench,
vacuum the floor, read the following
Beech Fact,
then skip to page21and build the wing.
Beech
Fact:
At first, the
Bonanza
model existed only
in the V
-
tail configuration. The original straight tail
Beech, introduced in 1959, was named the
Debonair.
It was intended to be a less expensive,
bare essentials
model in the Beechcraft lineup to compete with Piper's Comanche and Cessna's soon
-to-be-
released 21
0. However, after many upgrades and changes, the Debonair evolved into what was basically a straight tail Bonanza.
So
in 1968 Beech decided to drop the
Debonair name and called both the
33
and the
35,
the
Bonanza. Neat-O!
BUILD
THE
STABILIZER AND
RUDDERVATORS
The right half of the stab plan shows the V-tail stab
with a dashed line indicating the straight tail stab.
The left half of the stab plan shows the straight tail
stab with dashed lines indicating the V
-
tail stab.
Build the
right
side of the stab firstsoyour
progress matches the photos.
V1. Position the plan so the stab is over your flat building board (or cut the stab from the wing plan) and tape it down and cover it with wax paper.
V2. Test fit.the die-cut 3/32"balsa
stab ribs
S2V
through
S7V
in the notches of the die-cut
1/8"
balsa
stab
TE
spar
(S9)
and the
ruddervator LE
spar
(S8).
Place the assembly over the plan.
V3. Use a small square to help align the
ruddervator LE spar S8 over the plan at rib S2V.
-
17-
Pin the rear of the jig tab on S2V to the plan. Use
the same procedure to pin the rear of the jig tabs
on the rest of the ribs to the plan.
V4. One atatime, align the fronts of the ribs
over the plan and pin the jig tabs down
to
your
building board.
V5. Still without using glue, join
rib
SIV
to
the
assembly and pin it to your building board.
....
V6. Glue two die-cut 1/8'' balsaV-
tail
LE
braces
together. Place them in the notches of ribs
S1Vand S2V as shown on the plan.
V7. Make sure all the jig tabs of all the ribs are contacting your building board, then glue the stab
TE
spar, ruddervator LE spar and the V-tail
LE
bracetothe ribs with medium CA. Don't use large
amounts of CA or build up fillets of glue. Later we will instruct you to reinforce glue joints that don't
look
strong.
V8. Bevel the fronts of the ribs to match the aft
sweep of the leading edge. Cut a shaped
5/16
"x15"
balsa
stab/fin leading edge toa length of
Glue it to the fronts of the ribs
so
the
top
is
even
with
the
top
of the ribs. The bottom of theLEwill extend
below the ribs but will be sanded flush later.
V9. Check the fit of the
-
cut notches of the ribs SIV, S2V and S3V.
die
sub spar (S11)
in the
Make any adjustments needed.
VIO. Test fit, then glue the sub spar in
position. Use a 90" triangle to insure that the sub
spar is vertical.
V14. Use your favorite method toglue the stab skin to the stab. We recommend using aliphatic resin
to
glue the skin to the ribs and
TE spar, and CA for only the leading edge. Apply the glue. Working quickly, position the stab skin and hold the leading edge down until the CA cures. When the CA is cured, wet the front of the skin with
50/50
a
mix of alcohol and water and press it to the rest of the frame, holding it down with weights until the glue dries.
Note:
If
you choose to use CA for the entire job, be aware that residual accelerator you may have used earlier can make the CA you use for this step cure
to
quickly. You'll have
work rapidly.
V19. Glue the little tip you cut
rib SlAV to the sheeting and SIAV.
For
clarity
we've drawn a /ine indlcating
BEVEL THE TETOMATCH THE RIBS
TOP
SHEETING
'
ON
ELEVATOR
THE BOTTOM SKIN WILL FIT LIKE THIS
off
the end of
the bevel
.
V11. Cut the end off rib SlAV at the embossed line and set that little piece aside. Glue SlAV to the ruddervator
LE
spar over its location
on the plan.
V12. Sand the top of the leading edge, sub
LE
spar, elevator TE spar and the ruddervator
so
they match the contour of the ribs. Don't change
spar
the shape of the airfoil by sanding too much.
V13.
THIS
STEP
IS
VERY
Arrange the T
-
pins
so
every other rib
IMPORTANT!
is held down with one pin near the front and one pin near the rear and make sure all the pins go into the jig tabs
at the same angle.
This will allow you to
finagle
the stab off your building board by lifting it up and to one side after the top sheeting is glued in place
-
pins are concealed).
(the T
V15. Glue the ruddervator skin to the ruddervator. You can use CA for this step since the skin is small and easy to posidon. Make sure the
trailing edge contacts the
stoppers
on the top of the
jig tabs on ribs S7V and S2V.
V16. After all the glue has dried, remove all
-
pins you can reach. Carefully lift the stab
the T (with the ruddervator) from your building board.
-
Trim the jig tabs from the ribs and take out
-
pins.
of the T
the rest
V17. Use a razor plane or a#I1 blade totrim
the
bottom
of the
LE
so
it is the same size as the
front of the ribs and matches the airfoil shape.
V18. Sand the bottoms of the ribs, leading
edges, stab, ruddervator spars and trailing edges
so
they blend together.
-18-
TOP SHEETING
'
V20. Use a bar sander and 150-grit
to
sandpaper ruddervator skin
bevel the trailing edge ofthe top
so
it will accommodate the bottom skin. While you sand, apply pressure only to the sheeting and use the ribs to set your sander at the correct angle. Do not bevel the trailing edge to a
sharp edge
Hint:
but leave about 1/64
squared off.
Support theTEwith the edge of your
workbench or a platform while you sand.
V21. Glue four die-cut 1/8" balsa
torque rod blocks
between ribs SlAV and
ruddervator
SS2AV You can see the torque rod blocks in the following photo.
V22.
Remove a small section of rib
S2v
between the LEbrace and the sub spar. Now you should have a slot in rib
S2V
like the one in the
photo below.
DO
NOT
cut the slot shown in rib S1
V
until instructed to dosolater.
I
V23.
Cut six
2-118"
long hinge blocks from
the
1/4"x3/8"x36"balsa stick. Glue the hinge blocks evenly spaced to the stab TE spar and the ruddervator
LE
spar where shown on the plan.
Glue the die
-
cut 1/8" balsa stab gusset to the
hinge block and rib
S7V
as shown on the plan.
Position the gusset
so
it is not on the centerline of
the hinge
so
you do not break it when you cut the
hinge slot. Align the grain as shown on the plan.
V24.
Trim the ruddervator torque rod block
and any protruding hinge blocks
so
they are even
with the bottoms
of
the ribs.
V25.
Reinforce glue joints that don't look
strong.
V26.
Glue the bottom stab and ruddervator skins to the bottom of the stab and ruddervator. Work over a flat surface and be careful not to add any twist into the stab as you press the skins onto the stab frame. Make sure the
TE
of the
ruddervator skins align. Optional: Use the die
-
cut
1/8" balsa V
-
tail stab cradles S2V and S7V to hold the stab flat on your workbench while you glue the bottom skins on. Use the stab saddles the same as the wing saddles shown in stepsl
-
5on
pages
30.
V27.
Use a bar sander with 80-grit sandpaper
to sand the sheeting even with rib
S7V.
V28.
Cut the ribs and separate the
ruddervator from the stab. Sand the excess
sheeting and rib
stubs
from the TEof the stab and
the
LE
of the ruddervator. Sand the root of the
ruddervator sheeting flush with rib SIAV.
V29.
Cut
4-3/8"
off the
small
end
of
the die-
cut
1/8"
balsa stab
TE
(S10).
Glue the stab TEto
the stab
so
the root end aligns with the inner edge
of rib
S3V
as shown on the plan.
V30.
Shape the stab
TEsoit blends with the
stab and tip.
-19-
V31.
Glue a ruddervatorLE(also
S10)
to the
LE of the ruddervator and sand it
so
it blends with
the skins and tips.
V32.
Use
two large T-
pins,
placed in the center of the leading edge of the ruddervator near the ends, to align a straightedge and draw a centerline with a ballpoint pen.
V33.
Mark the trailing edge of the stab the
same way.
V34.
Cut the hinge slots on the centerline
of
the ruddervator and the stab where shown on the plan.
Do
not cut the hinge slot in the stab nearest
the root until instructed to do
so.
V35.
Cut three hinges as shown in the sketch
from the
2
"
x
9
"
CA
hinge
strip.
Snip the corners
off the hinges
so
they go into the slots easier.
V36.
Temporarily join the ruddervator to the
stab with
two
hinges.Ifnecessary, adjust the hinge
slots
so
the ruddervator and stab align.
MAKE THE STAB
TIPS
1. Securely tape the ruddervator (or elevator
if
you're building the straight tail) to the stab with masking tape on both sides. Sand the ends of the stab and ruddervator
so
they are even.
2.
Draw a centerline all the way around a
3/4"
shaped balsa
stab tip block.
3.
Place the stab tip block over its location on the plan. Mark where the ruddervator tip meets the stab tip on both sides of the block.
4. Cut the stab tip from the ruddervator tip.
True the edges you just cut with a bar sander.
RUDDERVATOR
L
-_I
5.
Glue the
stab tip
to
the stab. The sharp
pointofthe stab tip should align with the TE of the
stab. Glue the
ruddervator tip
to the ruddervator
so
it is 1/8" aftofthe LE and aligns with the stab tip
(as shown in the sketch).
'.*'
-
6.
Use a razor plane or a hobby carving knife,
followed by sanding to
carefully
shape the ruddervator and stab tip. Inspect your progress frequently. Use the centerlines as a guide and the plan as a reference
so
you know what the curve of
the tip should look like.
Hint:
Stick a T-pin through the ruddervator tip into the stab. This will hold the ruddervator tip while you shape it.
Note:
When you shape the left stab tip, in addition to the plan, use the finished tip on the right stab as a guide to shape the left stab tip. This way you can make sure both of the stab tips are identical.
7.
Shape the stab LE as shown on the plan.
8.
Separate the ruddervator from the stab.
9.
Shape the leading edge of the ruddervator
to a
"V"
as shown on the plan. Use the centerline on the leading edge as a guide. Make sure that the angle of the
"V"
will allow the throws indicated in
the back of the manual.
Straight tail builders, make the other stab tip the same way; then, return to step
ST40
on
page
14.
V10. Starting at rib S1V,remove a 1 -3/8" strip
of
top
sheeting between the V-tail LE brace and
the sub spar. Remove a 1-1/4" strip of
bottom
sheeting between the V-tail LE brace and the sub spar. See the following photo.
s1
v
Vll.
Remove the small section of rib S1V between the LE brace and the sub spar. Now you should have a slot in the stab like the one in the photo.
What a nice piece of workmanship! Put the right stab in a safe place. Clean off your workbench, vacuum the floor, and build the
left
stab the same way.
-
20
-
BUILD
THE
WING
MAKE THE WING SKINS
AFT
WING
SKIN CUT-OFF
1. Glue
three
3/32"x3
"x36"balsa sheets
together to make an
aft
wing skin.
Trim a wedge from the aft wing skin. Glue it back onto the skin as shown in the sketch.
2. Glue
two
3/32
"x3
"x30
"
(not
36")
balsa
sheets together to make the
forward outer wing
skin.
Note:
You will need a total of four
aft wing skins
and five
forward wing skins
(one of the forward wing skins will be cut into four pieces to make the forward
inner
skins). You can make all the wing skins now in an assembly line fashion or make them as needed.
3. After the glue dries, remove the masking tape and mark the best side of each skin as the top. Sand the bottoms of both wing skins
so
they are
flat (or almost flat). Sand the tops of the skins
so
they are flat andsmooth.
PREPARATIONS
1.
Unroll the wing plan.
Roll
it inside out soit will
lie flat. Cut the
right
wing panel with the center
section from the wing plan. Position it on your
flat
building board and cover the plan with wax paper.
Perform steps 2through6if
you
are installing
retractable landing gear.
Have you purchased your retracts yet? Ifyou have (or as soon as you do), take the neoprene air lines out of the package and hang them from a hook somewhere in your shop letting them dangle under their own weight. This will get all the kinks out and make them easier to work with when it's time to install them.
D
2.
Prepare a set of
right
wing ribs by using
30
-
minute epoxytoglue the die-cut 1/16
"
plywood
retract landing gear rib doublers
W4R, W5R
and
W6R
to the die-cut 3/32"balsa
ribs
W4, W5
andW6exactly
as shown in the
photo. Make sure the doublers are on the side of the ribs as shown in the photo and on the right wing plan.
3. Prepare a set of
left
wing ribs the same way
but
use the photo above
to make sure you glue
the doublers to the correct side of the ribs.
-
21
-
14. Remove the shaded area of balsa shown in e previous two photos after the epoxv is fullv ured.
,
SLOT
FOR
SERVO CORDS
\
3/16
"
HOLES
FOR
WING TIP LIGHTS
S
FOR
LINES
5.
Drill 5/32"holes and cut slots at the locations suggested in the sketch in both sets of ribs W2, W3 and W4 for the retract air lines and
servo cords. Make the slots large enough
so
the
connectors on the ends of your servo cords will
pass through.
If
you will be installing lights in the
wing, drill 3/16
"
holes through wing ribs W3 through W14 in the approximate location shown in the sketch.
Hint:
An appropriate size brass
tube sharpened at one end cuts very clean holes.
Extend lines
well cutout
I
-
D
6. Use a ballpoint pen to extend the die-cut wheel well cutout in both W3 ribs. Cut partway through the rib along the line
so
the cutout will be
easier to remove later.
Beech Fact:
In 1946 Walter H. Beech
announced his all new, revolutionary, single
engine entry in the postwar market. He named
it
the Bonanza, descriptive of an extra value
offered in the way of economy, performance and pleasure to the owner.
Perform steps7through9only if you are installing fixed landing gear,
4.
Test fit the die-cut
1/8"
balsa
aft inner spar
7.
Prepare a set of
right
wing ribs by using
30-
minute epoxy to glue the die-cut
1/8"
plywood
fixed landing gear rib doublers
W4G, W5G
and
W6G
to the die-cut
3/32
"
balsa
ribs
W4, W5
andW6exactly
as shown in the photo. Make sure the doublers are on the side of the ribs as shown in the photo.
8.
Prepare a set of
left
wing ribs the same way
but
use the photo above
to make sure you glue
the doublers to the correct side of the ribs.
Remove the shaded area of balsa shown
ir
the previous two photos after the epoxy
is
fully cured.
Note:
Details for fixed landing gear are shown or
the
left
wing plan.
10.
If
you will be installing lights in the wing, drill
3/16
"
holes through wing ribs W3through
W14
in the approximate location shown in the sketch on step
5
page
21.
3.
Fit the ribs and spar web to the bottom spar
so
the ribs accurately align with the plan.
11.
Use
I
straightedge and a ballpoint pen to
mark a vertical line
1/16
"
from the front and back of
the spar notches in both
W2
ribs.
Use a sharp
hobby knife to
lightly
cut halfway through the balsa along the lines. You will remove this section of balsa to accommodate the spar joiners when it is time to join the wing.
BUILD THE OUTER WING PANELS
For clarity, some of the photos show the wing off
the building board without the plan, but of course you should build your wing over the plan the same as we do.
Build the
right
wing panel first soyour progress
matches the photos.
1.
Do
not use any glue until step
8.
Pin a
1/4"x3/8"x36
"
balsa
bottom spar
over its
location on the plan
so
the root end extends past
the dashed line by about
1/8".
Stick the pins
through the spar at an angle
so
they will not
interfere with the spar web when you position it in the next step.
2.
Test
fit
ribsW2through
W14
to the die-cut
1/8"
balsa
spar web
(W15).
If
necessary, deepen
the notches
(in
the ribs or in the spar web)sothe
ribs fit all the way into the spar web.
-22-
BEVEL THE NOTCHES IN THE RIBS AND SPARS TO MATCH THE ANGLE ON THE PLANS
ORIGINAL NOTCHES
5.
Test fit the die-cut
118"
balsa
aft outer spar
(W16)
and the die-cut
1/8"
balsa
aileron spar
(W17)
into the notches of ribs through
W14.
If necessary, bevel the notches in the spars and ribs the same way you did in the previous step.
6. Temporarily remove rib W2from the
assembly.
7.
One at a time, accurately align the jig tabs
of all the ribs with the plan and pin them
to
your
building board. In addition to T
-
pins, place weights
on top of the ribs and the aft spars to insure that
all
the jig tabs are contacting your building board.
Inspect all joints and make sure everything aligns with the plan. The spar web must fully contact the bottom spar. A die
-
cut 1/8" plywood
90
degree
gauge
is supplied in the kit to help you keep the
ribs vertical as you glue them.
8. Use medium or thin CAtoglue all the joints. Use the CA sparingly at this stage of construction and do not build up fillets. This will allow you
to
realign parts ifnecessary and keep
you from gluing the jig tabs to the ribs.
We
will
remind you to reinforce all glue joints later.
9.
Place ribW2back onto the assembly. Align
W2
with the dashed line depicting where it contacts
the plan. Use the die
-
cut 1/8" plywood
dihedral
gauge
to setW2at the correct angle. Glue it to the
bottom spar and the spar web. Glue
W2
to the aft inner spar using the dihedral gauge to set it at the correct angle.
10.
Test fit a
1/4"x3/8"x36"balsa upper
spar in the notches of the ribs
so
the end of the
spar aligns with rib
W2.
Glue the spar to the ribs
and the spar web with thick or medium CA.
Remember, don't use too much glue.
ALIGN THE LE W TH THE TOP
OF
EACH
RIB
11.
Cut a
1/4"x36"shaped balsa
leading
edge
to a length of
29-1/2".
Glue the LE to ribs
W4
through
W14sothe top aligns with the tops of the
ribs (the same as on the stab).
-
12.
Bevel the endofthe remaining piece of
6-1/2" leading edge
so
it matches the LE on the
wing when you position it on ribs
W4,3and2.Glue
it in position. Glue
rib
W4A
to
the side of rib
W4.
Hint:
Glue the LE to ribW2lastsoyou can use
the dihedral gauge to make sure
W2
is at the
correct angle.
NOTE:
Use a long straightedge along the length of
W2
to insure that it is flat along it's length (from the
LE to the TE).
-23-
Beech Fact:
Among other famous Beechcraft models,
some include variations of the stagger
-
wing biplane;
several versions of the 18A which is a twin engine, low
wing mono
-
plane (distinguishable by its twin rudders); a light, single engine model named the Musketeer; a sort
of
bare-bones
straight tail Bonanza called the
Debonaic
the
T-34
(which is a
US.
Navy trainer); and
of course, several versions of the ever
-
popular twin
engine
Baron.
SHEET THE TOPOFTHE WlNGPANELS
1.
Use a large sanding block or a bar sander
with 150
-
grit sandpaper to sand the tops of the top
spar, aft spars, LE and ribs
so
they all smoothly blend together. Make sure the tops of the aft spars match the tapering angle of the ribs but sand the ribs lightly
so
you maintain the designed
airfoil shape.
2.
Remove the T-pins from the bottom spar
and replace them
so
they are all sticking in from the front. This way you will be able to remove them when the aft top sheet is in position. Remove the T
-
pins from the aft jig tabs and replace them in
every other jig tab
so
they all go into the building
board at the same angle
(you
know
the
drill).
Remove the weights from the top of the wing
(if
you
used them).
Note:
If
you observe that the wing panel remains flat and all the jig tabs are contacting your building board when you remove the T
-
pins, you may leave
the T
-
pins out of the jig tabs. In this case the
weights that will be used to hold the sheeting to the
ribs will be enough to hold the wing flat to your building board.
FORWARD INNER SKIN
I
FORWARD OUTER SKIN
-\AFT
SKIN
NOTE GRAIN DIRECTION
Use this photo and the sketch
for
the next few steps
This photo shows a few weights on top of the wing, but in actuality we used enough weights to fully cover the skins.
You
can use magazines for
weights too. T
-
pins in the front ensure that the
skins are securely bonded to the top spar.
3.
Trim the aft wing skinsoit fits the wing.
The
TE should be straight and true and contact the
stopper
portion of the jig tabs on ribs W14 and W3.
The
front
of the sheet should
end
in the center of
the top spar. The ends should extend past W2 and
W14 equally.
4. Use your favorite method toglue the
aft
wing skin to the wing. We recommend using aliphatic resin because it gives you plenty of time to align the skin and position your weights or T
-
pins. Hold the wing skin in position with magazines or weights made from plastic bags filled with lead shot or
BBs.
If you choose touse T-pins to hold the skin
to the wing,
lightly
mark lines on the top of the wing skin indicating the location of the ribs underneath.
Do
not disturb the wing until the
glue fully cures.
5.
Remove the T-pins from the bottom spar. The weights on the aft sheeting will hold your wing flat.
6.
Trim the forward
outer
wing skinsoit fits
the wing. The
aft
edge of the skin should contact
the aft skin (in the center of the spar) and the
front
edge of the skin should extend past the leading
edge of the wing by approximately 1/4". The
root
end of the sheet should accurately align with the
glue joint between W4 and W4
-
A and the
tip
of the
sheet should extend past W14 by about 1/16.
Note:
The grain direction of the forward outer skin
runs
parallel to the leading edge
of the wing.
7. Wet the top of the forward outer skin with a
50/50
mix of alcohol and watersoit will bend
easier. Glue it to the wing using weights or T
-
pins
to
hold it down.
8. If you haven't already done
so,
glue
two
more 3/32
x3x
30" balsa sheets together for the
forward inner skin.
From that sheet, cut a piece that fits between ribs W2 and W4 and glue on a third piece cut from leftover 3/32" balsa to
fill
up the rest of the space. Note that the grain direction is parallel to the leading edge between ribs W2 and W4. Trim the sheet to fit the wing. Glue it in position.
9. After the glue on all the sheeting is dry,
remove the T
-
pins you can reach and lift the wing
off your building board.
-24-
10.
Clean the glue blobs and wood chips
off
your workbenchsothey won't leave dents in your beautiful wing sheeting. Turn the wing over and
carefully cut the jig tabs off the ribs.
11.
Reinforce all glue joints that don't look strong. It is particularly important that the joint between the spar web and both spars are securely glued.
12. Position the
left wing plan
on your building board and cover it with wax paper. Return to step 1 on page 22, and repeat the steps to build the left wing panel.
FINISH THE OUTER
WING
PANELS
Start with the
right
wing panelsoyour progress
matches the photos.
1.
Glue a die-cut 3/32" balsa sub-rib
W2A
to
ribW2where shown on the plan. The
sub
rib provides additional gluing area when the sheeting is installled. Use the W2A that does not have a notch cut in it for the flap spar.
Glue the die-cut 3/32" balsa
flap ribs
W2A
and
W8A
and
aileron ribs
W9A
and
W14A
to the wing where shown on the plan. Note that W8A and W9A are perpendicular
to
the aileron spar W17.
Hint:
Temporarily place a
shim
made from 1/16
" leftover plywood between the ribs for perfect alignment.
3. Stick a pin through the wing sheeting in a few places along the space between W8A and W9A, along the space between W2A and W2A, and along the space between W14A and W14. These pin points will indicate where to cut the sheeting to separate the ends of the flap and aileron from each other and the wing.
3/32
"
3-3/16
"
11/32
"
4. Cut a shaped 18" balsa
flap spar
to fit between flap ribs W2A and W8A. Test fit, then glue the flap spar in the notches of the flap ribs.
5.
Starting with 80-grit sandpaper on a large
sanding block or your bar sander, sand the
remainder of the jig tabs from the ribs and blend the bottoms of the aft spars and the aileron spar to the contour of the ribs.
APPROXIMATELY
1/32
"
BEVEL
6. Use a bar sander and 150-grit sandpaper
to bevel the trailing edge of the top wing skin
so
it will accommodate the bottom skin. While you sand, apply pressure only to the sheeting and use the ribs
to
set your sander at the correct angle. Donot
bevel the trailing edge to a
sharp edge
but leave
about 1/32
"
squared off.
Hint:
Support the TEwith the edge of your workbench or a platform while you sand.
Perform steps
7-13
if
you
are installing
retractable landing gear.
rail brace
7.
Cut the 1/2"x3/4"x6-3/4" grooved
basswood
aft landing gear rail
to a length of 6
-
1/8". Test fit and glue the rail in position with 30
-
minute epoxy
(with the groove facing the top
sheeting).
Test fit, then glue the 1/4"x1/2" x 9
"
plywood
forward landing gear rail
in position
with 30
-
minute epoxy. Immediately proceed to
the next step before the epoxy cures.
8. From a 1/4"x3/8"x24"basswood stick,
cut a piece that is 1-1/2" long. Glue this
landing
gear rail brace
to rib doubler W5R and the
bottom of the forward landing gear rail with 30
-
minute epoxy.
9.
Test fit your retract unit with only the strut
but not the wheel.
If
necessary, enlarge the
clearance holes in the ribs and doublers
so
the air
cylinder and the strut do not interfere with the ribs.
10. Cut along the line you started earlier on
rib W3 for the wheel cutout and
remove the
section of balsa for the wheel.
11.
Mount a wheel to your landing gear
strut. Place your retract unit on the landing gear
rails in the location shown on the plan (by the
way, the
oleo scissors
face
forward).
Retract the
wheel by hand to check the operation and make
sure your retract is mounted in the correct location.
Now is the time toplan your installation and make sure everything fits. It will be more difficult
to
make corrections after the bottom
sheeting is in place.
-
25
-
J
12.
Drill holes in the rails and mount your landing gear. Use the screws included with your landing gear.
Hint:
Countersink the holes in the
landing gear for
#6x1/2"
flat head screws.
13.
Now isaconvenient time to plan your
air line routing.
If
you haven't already done
so,
drill or cut holesinthe ribs to guide the air lines.
A
5/32"brass tube sharpened at one end makes
a
great drillto cut holes through the ribs.
Perform
steps
14-16
if
you
are installing fixed
landing gear.
I
14.
Use 30-minute epoxy toglue the
1/2"
x
314"x6-3/4"
grooved hardwood
landing gear rail
in the notches of the ribs and rib doublers with the groove visible, as shown in the photo. At the same time, glue the
3/4"x3/4"x1"maple
torque block
to rib doubler W4G and the top of the landing gear
rail. The fixed landing gear rail and rib doublers
are shown on the
left
wing plan.
15.
Cut the
1/4x1/2"
x
9
"
plywood
flap
servo hatch forward rail
to a length of3-
1/16".
Glue it into the notches of ribsW6and
W7.
16.
After the epoxy on the landing gear has
fully cured, drill a
31/6"hole through the landing gear rail and the torque block. The center of the hole should be
3/32"from the plywood rib doubler W4G. Make sure you hold the drill perpendicular to the bottom of the landing gear rail.
17.
Optional:
From the right side of the plan cut off the two paper tube strips along the dashed lines. Roll
these strips and cut them tothe lengths needed. They are used to allow easy routing of the servo wires and their extensions. For fixed gear the tubes go from R2toR9.
For retracts they go fromR7to
R9.
For retract installation, the wires can easily be fished through the small holes in
R4, R5
and
R6.
-
26
-
18.
Cut three 3-
1/16"long
servo hatch cover
rails
from the
1/4"x3/8"x24"basswood stick (the same stick you used for the landing gear rail support if you are building retracts). Glue the rails in the notches of the ribs where shown on the plan.
U
19.
Cut three
1-1/2"
long
flap hinge blocks
from the shaped
5/8"
x
9
"
balsa stock. Bevel the
ends of the hinge blocks
so
they fit the ribs, then
glue them in the location shown on the plan.
See
the cross section
on the wing plan to be sure you
know the position of the blocks.
20.
Cut five 1"
long
aileron hinge blocks
froma1/2"x1/2"
x
6
"
balsa stick. Cut one
2-7/8"
long hinge block from the
5/8"x1/2"x6"balsa
stick. The long hinge block is the one closest to the
root end of the aileron and is the
base
for the
aileron control horn.
21.
Bevel the ends ofall the aileron hinge
blocks
so
they fit against the ribs as shown on the
plan. Bevel the
tops
of the hinge blocks that fit in
the aileron
so
they match the angle of the ribs.
Glue the hinge blocks in the wing and aileron.
22.
Use a bar sander and 80-grit sandpaper
to sand the sheeting, spars and
LE
so they are
flush with root rib
W2
and tip rib
W14.
23.
Mark the locations of the aileron hinge
slots on the outer wing TE and the aileron
LE,
so you will know where to cut the hinge slots after the wing and aileron are sheeted. Mark the location of the flap hinge blocks the same way.
24.
Return to step1on page24and finish the
left wing panel.
BUILD
THE CENTER SECTION
1.
Position the center section wing plan (which is
attached
to
the right wing plan) over your building
board and cover the plan with wax paper.
2.
Use thick or mediumCAto glue two die-cut
118"
plywood
dowel rib doublers
W1D
and one
bolt plate rib doubler
W1
P
to the sides of the die-
cut
118"
balsa ribs W1as shown on the plan. Pay careful attention to which sides of the ribs the doublers are glued.
3.
Glue two sets of
1/8"
die-cut plywood
wing
bolt plates
together to make two
114"
plates.
4.
Glue the
1/8"
die-cut plywood
leading edge
doubler
(W21)
to the die-cut
1/8"
plywood
center
leading edge
(W21A)
so
the
bottoms
of the
notches
align.
W21A
is narrower than
W21
so the
top and bottom edges will be offset
1/16".
5.
Test fit the wing bolt plate in the notches of
the ribs where shown on the plans. Adjust the
notches
if
necessary so the bolt plates fit.
6.
Remove the balsa from bothW1ribs between
the notches of the dowel doublers.
7.
With a straightedge and a ballpoint pen mark
two vertical lines
1/16
"
ahead of and behind the
spar notches on the
outside
of both of theW1ribs,
that have only the
W1P
doublers glued to them. Use a sharp hobby knife to cut halfway through the balsa along the lines. This section of balsa will be removed to accommodate the spar joiners when it is time to join the wing.
8.
Cut
one
11"
long piece for the
bottom center
spar
and one
9-1/4"
long piece for the
top center
-27-
spar
from a
1/4x3/8"x24
"
basswood stick. Pin
only the ends
of the
11
"
bottom center spar to
your building board over its location on the plan.
Do
not stick the T-pins through the basswood spar but insert them in a crossed fashion over the spar to
hold it to your building board.
Now
for
the
fun
part.
. .
9.
Fit the ribs onto the die-cut
1/8"
plywood
center spar web
W19.
Make sure the ribs go all
the way down in the center spar web. Deepen the
notches (in the ribs or the spar web)
if
necessary.
Fit the assembly onto the bottom spar.
10.
Join the die-cut
1/8"
plywood
aft center spar
W20,
the center leading edge assembly
(W21
and
W21A),
the
9
"
top spar, and the wing bolt plates to
the ribs. Make sure the ribs align with the plan.
11.
Pin small blocks of leftover balsa to the plan
next to the
W1
ribs, aligning them over the plan, and place weights on top of the ribs and spars to hold the jig tabs to the building board. Use a small square to make sure the
W1
ribs are vertical.
12.
Use medium or thinCAto glue all joints
excepting the top spar.
Do not use large amounts
of
CA
and do not build up large fillets. This
will make it easier
to
join other parts to the
assembly. You will be reminded
to
reinforce all glue
joints later.
13.
Remove the top spar. Glue it back in place.
SHEET THE TOP CENTER SECTION
1.
Sand the top of the leading edge, spars and
ribs
so
they blend together. You may remove the
center section from your building board
if
necessary, but pin it back down after you're done sanding.
2.
Make sure the center section accurately
aligns with the plan.
If
necessary, pin two more balsa blocks to the building board near the fronts of the ribs.
3.
Use
two
3/32
"x3
"x30
"
balsa sheets to make
one
7"
x
9
"
forward top center section wing skin
and one
11"
x
9
"
aft top center section wing skin.
4.
Sand the sheetssothey are flat and smooth.
Trim the forward skin
so
the aft edge aligns with the center of the top spar and the front extends past the
LE
by approximately
1/8".
If
you find it necessary, wet the top of the forward top skin first, before gluing it to the center section of the wing.
You're an expert at sheeting now,
so
this should
be
easy.
5.
Trim the aft skin sothe front edge joins the forward skin and the aft edge extends past the ends of the ribs
1/2".
Trim the ends of the aft top
skin
so
it extends past the
W1
ribs by
approximately
1/16
"
to allow for sanding later.
Glue the aft skin tothe center section.
7.
After the glue dries, remove the center section
from the plan. Trim, then sand the bottom spar and
the top sheeting flush with the end ribs.
Do
not
sand off the tabs on the ends of the aft spar
W20.
They will key into ribsW2and align the outer
panels with the center section.
8.
Remove the jig tabs and sand the bottoms of
the ribs and spars
so
they all blend together. Bevel
the trailing edge of the top sheeting the same way
you did for the outer panels.
1/8"
W21
A
1/4"
HOLES
9.
Drill
1/4"
holes through the LEof the center
section
(W21A)
where shown on the sketch.
Slightly round one end of both
1/4"x2-1/2"
wing
dowels.
Test fit, then glue the wing dowels into the
center section with 30
-
minute epoxy.
10.
Reinforce all glue joints that don't look
strong.
Do
not build up any glue fillets where the
dihedral braces will be fitted.
Beech Fact:
The T-34 evolved from the Beech
designated Model
45
which began as a converted A35 Bonanza. Although Walter Beech did experiment with the V
-
tail for military purposes, he thought that the conservative military would prefer the conventional straight tail which
is
what emerged for the final design.
It
is
named the
Mentor.
PREPARE THE
BOTTOM
OF
THE
WING FOR SHEETING
1.
If
you are installing retracts, build a partition
on both wing panels from leftover
3/32
"
balsa
to
seal the wing aft of the wheel well compartment. Fuelproof the nooks and crannies of the wheel well inside the wing that you will not be able to reach after the bottom sheeting is in place. You can see the partitions in the following photo.
Remember where you cut
partway
through
ribs
W2
on both wing panels
1/16
"
ahead of and
behind the spar notches? Use a hobby knife or a
fine razor saw
to
cut the rest of the way through rib
W2
on the right wing panel and remove the balsa
within the area you cut.
3.
Cut away the portion of balsa on rib
W1
between the spars on the right side of the
center
section
the same way.
4.
Test fit the die-cut
1/16
"
plywood
dihedral
braces
W23
and the die-cut
1/8"
plywood
dihedral
braces
W22
in the outer wing panel. Ifnecessary chamfer the corners of the braces to accommodate small glue fillets in the wing.
Note:
Make certain you fit the braces right side up the same as the dihedral of wing.
-28-
5.
Temporarily join the center section to the right wing panel with the dihedral braces to make sure everything fits. Make adjustments where needed
so
the center section fully contacts the right panel. Separate the wing sections and remove the dihedral braces.
Read the following five steps before you actually use any glue
so
you understand the procedure and
can gather the items
you
will need.
6.
Mix a batch of
45-
or 30-minute epoxy.
Spread a film
of
epoxy in the outer wing panel everywhere it contacts the dihedral braces. Spread a film of epoxy on the
1/8"
and
1/16
"
ply dihedral
braces
except where they will contact the center
section
wing panel. Fit the dihedral braces into the
right wing panel.
Make certain you fit the braces
rjght side
up.
7.
Remove excess epoxy from the parts of the
dihedral braces that will contact the
center
section.
8.
Set the dihedral braces by
temporarily
joining the center section to the right wing panel. Clamp the dihedral braces
to the right wing panel
only.
Carefully remove the center section and wipe
away excess epoxy with a paper towel.
9.
Insert two approximately
2"x2"
pieces of wax paper between the dihedral braces where they protrude from the right panel, then insert a piece of
1/8"
balsa between the two pieces of wax paper.
Clamp the outer
1/16
"
ply dihedral braces to the
inner
1/8
ply dihedral braces.
10.
Use small balsa sticks and small pieces of
paper towel to wipe away all excess epoxy
so
it will
not interfere with the center section when it is time
to join it to the right wing panel.
11.
After the epoxy cures, glue
W2
to
the
1/16
"
dihedral braces.
12.
Returntostep2and glue the dihedral
braces in the left wing panel.
13.
If
you're installing retracts, glue leftover
3/16
"
or
1/4"
balsa to the front of the forward landing gear rail and between the rails to support the sheeting. Use a ballpoint pen or a pencil (not a felt
­tip pen) to trace the outline of the landing gear onto the rails
so
you know where
not
to
apply glue when you glue on the bottom sheeting. Later, the sheeting over this area will be removed
to
accommodate the landing gear mounts.
-29-
14.
Cut holes and slots in the
Wl's
on the ends
of the center section
to
match the holes for the
servo cords and retract air lines in the
W2's
of the outer panels. Cut the holes slightly oversize just in case they don't align perfectly.
We've temporarily joined the wing panels and installed the air lines and servo cords in the right wing panel to mock
-
up the installation to give
you
an idea of how to route them later. If you wish, you could test your installation now to make sure your setup will work.
15.
Glue a piece of leftover
3/32
"
balsa to the center section sheeting aft of the spar (note the grain direction). Cut a
3/4"
hole through the sheeting at this location for the servo cords and air lines
to
exit the wing into the fuse.
16.Ifyou will be adding the optional lighting kit, route the wiring through the holes you drilled in the ribs. The red
light
cover
goes in the left tip, and the
green
light
cover
goes in the right tip.Ifyou have
purchased the strobe lights in addition to the Top
Flite Lighting Kit, route those wires too. Cut a hole in the center section sheeting ahead of the main
spar for the wires and connectors
to
exit the wing.
17. Separate the wing panels and remove the
servo cords and air lines but leave the tip light
wires in both outer wing panels.
18. Sand the bottom of the outer wing panels
with a bar sander and 150
-
grit sandpaper sothe spars, landing gear and servo rails blend to the shape of the ribs.
Sheet the bottomofthe
wing
panels
1.Ifyou have not already done
so,
make the forward and aft bottom wing skins the same way you made the top wing skins on page 21.
2. Use a ballpoint pen to mark the top
sheeting over ribs
W14,
W9
andW4at the leading
and trailing edges.
3. Test fit the die-cut 1/8" balsa
wing cradles
W14C, W9C and W4C
on the top of the wing, aligning them with the marks you made. Sand away any slivers or slight die
-
cutting irregularities
until the cradles match the contour of the wing.
4.
Glue the die-cut 1/8" balsa
feet
to the cradles. Apply one drop of thick or medium CA near the front and rear of each cradle and tack glue them
to
the top wing sheeting in their proper
locations. You only need enough glue to hold the
cradles to the wing
so
they won't fall off when you
turn it upside down.
I
5.
Place the wing on your workbench
so
it
is
resting on the cradles. Trim the
stoppers
on the
cradles
so
the trailing edge of the bottom sheeting
aligns with the trailing edge of the top sheeting and
the front edge of the sheeting
ends
at the center of
the spar (the same way as the top sheeting).
6. Glue the aft bottom skin to the wing. Use
T
-
pins or weights to hold the skin in place until the
glue dries.
Caution:
Do
not add too much weight
because this may bow the wing.
7. Test fit, trim, then glue the forward
outer
skin to the wing panel. Just the same as the top forward outer skin, the wood grain should be parallel to the
leading edge
of the wing panel.
8. Use the remainder of the 3/32
"
x
6
"
x 30
"
balsa sheet you used for the forward
inner
top skin
to make a forward inner bottom skin. Test fit, then
glue the skin to the wing panel.
9.
After the glue dries remove any T-pins you may have used and take the weights off the wing panel. Trim all the sheeting
so
it is even with the tip and root ribs and the leading and trailing edges of the wing.
10.Ifyou are installing fixed landing gear, use the plans as a guide to poke holes through the wing skin with a pin until you locate the groove in the landing gear rail. Remove a strip of balsa from the groove just long enough to accept the landing gear wire. Use the
nylon straps
as a template to
mark holes in the sheeting for the #2
x
3/8" screws.
Drill 1/16
"
holes at the marks and Test fit the landing gear to the wing with the straps and screws as shown on the plan. Remove the landing gear.
Note:
The nylon straps should be inset into the
balsa skin
so
that they are secured to the
basswood landing rail.
11. Set the right wing panel aside and sheet the
bottom
of
the left wing panel the same way.
Beech
Fact:
Beech also manufactures jet aircraft
including the 400A/400T Beechjet (their
only
production turbo fan, purchased from Mitsubishi in
1986
and fitted with a new Beech interior and larger
fuel capacity); and a few turboprops including the
Model
1300
Airliner, Model
1900D
and the Model
1900C; and of course, the Model 2000/2000A
Starship
featuring a canard front wing, pusher turboprop engines and composite construction.
-
30
Perform these steps only if you are installing retracts.
CUT
OUT
THE WHEEL WELLS
Start by cutting and removing just enough sheeting to mount the landing gear to the rails.
2. Retract the gear to the wing and draw a
rough outline of the wheel onto the sheeting. Cut
the sheeting within the outline. Retract the wheel
again and draw a more accurate outline. Cut the sheeting until the wheel fully retracts into the
wheel well, leaving at least
clearance
between the wheel and the sheeting (in case you
tweak
your landing gear on oneofthose
bumpy landings).
BUILD THE WING TIPS
Cut the molded clear plastic
right wing tip
lens
along the cutlines. If you are installing the
optional lighting kit, drill holes in the die
-
cut
balsa
tip lens rib
for the lighting wires to
pass through.
2.
Align with
so
the edges of the
lens are flush with the wing sheeting. Glue
to
W14 in this position.
Top of wing
3.
Glue the die-cut 1/8 balsa
aft lens rib
WT1 to the aft edge of WT14 Position the 1 1/2"
x
21/8x
6
"
balsa wing tip block on the wing tip and
trace the outline of the wing onto the block.
-
31
4. Read the note below and roughly carve the wing tip block to fit the wing tip. Glue it to the wing tip and sand it to the final shape. When you near the final shape
of
the tip block, tape the tip lens to
the wing tip and shape the tip block to match the
lens. To avoid scratching the lens with your sandpaper, cover it with masking tape.
Bottom
\
curved
\
Note:
The
trailing edge
of the tip block isthe same width as the trailing edge of the wing and does not taper. This means that the shape
of
the
tip block
changes
from the TE where it is
flat
to
where it is
curved.
This gives the wing tip a
concave appearance.
Proceed slowly
and inspect
your work frequently as you
zero-in
on the
final shape.
5.
Shape the leading edgeofthe wing as shown on the cross section on the wing plan and blend it to the wing tip lens.
Perform this step only if
tip lighting.
you are installing wing
6.
Use the templates
make the
reflector bracket
balsa. Drill a small hole th braces that hold the lenses they
snap
in. Do not fit the paint the pieces. Glue the as shown on the plan. Paini wing tip lens to match the color chosen. On our prototype we white. Tape the wing tip lens the lights while you work on t
on the wing plan to
from leftover 1/16
rough the part
of
the
in your lighting kit
so
lenses until after you
brackets
to
the wing tip
t
everything inside the
scheme you have
painted the insides
to the wing to protect
he rest of the wing.
7.
Returntostep1on page 31and build the
wing tip on the left wing panel plan.
BUILD
THE
FLAPS
Skip this section if you are not building flaps.
1. Use a fine razor saw to cut only the
ends
of
the flap from the wing along the holes you poked
in the top sheeting.
I
I
REMOVE
A
2.
Useaballpoint pen tolightly mark the flap
on the bottom of the wing as shown in the sketch.
Remove the 3/8 strip of sheeting from the bottom.
This will expose the ribs
so
you know where to cut
them to separate the flap from the wing.
32
I
CUT THE TOP SHEETING
IN THIS AREA
Use a razor saw to cut through the ribs and
top sheeting as shown in the sketch.
\
FLAP SPAR
BOTTOM SHEETING
TOP
SHEETING
D4.
Trim the TE of the wing in the flap area and
the
LE
of the flap as shown in the sketch.
A
dowel wrapped with 150-grit sandpaper can be used to round
out
the rib stubs.
L
5.
Cut a hole in the inner wingTEfor the flap horn at the location shown on the plan. The hole should be
biased
toward the top of the wing.
6. Place the flap over the plan and mark the
location of the die
-
cut 1/16"ply
flap horn.
Fit but
do not glue the flap horn into the flap.
Note:
Each
flap has a different location for the flap horn
so
make sure you use the correct wing plan for the flap you are working on.
7.
Cut the 5/8"x1-318"
x
18"
balsa
flap
LE
into two pieces that fit on both sides of the flap horn. Cut a 1/16
"
notch in the longer LE to
accommodate the flap horn. Glue the LE to the flap
so
the top edge is flush with the top of the flap.
8.
Remove the flap horn.
Temporarily tack
glue
the short flap LEtothe flap with
a few drops
of thick or medium CA. Sand the ends of the flap
LE
so
they are even with the ends of the flap. Sand the top and bottom of the flap LE flush with the top and bottom of the flap.
9.
Cut the flap
root and tip end templates
from the plan. Glue them to the ends of the flap with rubber cement or spray adhesive. Use the templates as a guide
to
shape the flap LE with a razor plane or a hobby carving knife followed by a bar sander.
10. Drill a 1/16"hole through the punch mark in the front of the flap horn for the clevis. Add a few drops of thin CA to the hole. After the CA hardens redrill the hole. Remove the flap LE you tack glued on. Insert the flap horn into the flap and securely glue it in place. Permanently glue the flap LE to the flap.
-33-
11.
Assemble the die-cut 1/8" plywood
flap
hinge drill guides
by gluing the pieces together as
shown.
Optional:
Glue a piece of 7/32"brass
tubing (3/16"
I.D.)
to the hinge drill guides to guide
your drill even better.
---
12. Position the
wing
flap hinge drill guide on the wing over each hinge block (you marked them before you sheeted the bottom of the wing) and drill 3/16
"
holes for the Hinge Points.
Hint:
Instead of
using a drill bit, use a piece of 3/16
"
brass tube sharpened at one end to drill holes with clean edges.
13. Insert three #309 Robart Super Hinge
Points into the holes in the wing but do not glue
them in. Fit the flap to the wing and mark the
locations of the hinge points on the flap.
14. Use the
flap
hinge drill guide to drill holes
in the flap the same way you did for the wing.
\
15.
Cut 1/4" off the end of the outermost hinge point that fits into the flap. Test fit the flaps to the wing with the hinge points. Adjust the position (depth) of the hinges until the flap aligns with the
wing the same way it was before you cut it loose.
Make adjustments until the flap fits the wing and freely moves about its range of motion. Strive for a good fit where the top of the flap meets the top of the wing.
16. Return to step 1 page 32 and mount the
other flap to the wing the same way.
BUILD THE AILERONS
1. If you have built flaps remove them from the right wing panel. Use a razor saw to separate the aileron from the wing by cutting between the LE
of the aileron and the TE of the wing. Refer to the plans to find the location of this gap and poke a pin through the sheeting to verify you have found the gap. Use the razor saw to cut the ends of the
aileron from the wing along the holes you poked in
the top sheeting.
2. Sand the sheeting and the rib stubs on the
wing even with the
TE.
Glue a piece of leftover 3/32" balsa to the wing tip rib. Sand it to the shape of the wing.
3. Sand the sheeting and the rib stubs on the
aileron even with the LE and the tips. Glue the die
-
cut
1/8"
balsa
aileron leading edge
(W17A)
to the front of the aileron. Sand the leading edge flush with the ends and top and bottom of the aileron sheeting.
4. Use the Straightedge and T
-
pin technique
to mark a centerline on the wing TE and the aileron
LE. Cut the hinge slots where shown on the plan. Test fit the aileron to the wing with the hinges. Adjust any hinge slots
if
necessarysothe aileron
and wing align. Sand the tip of the aileron
so
there is about a 1 /16" gap between the end of the aileron and the wing tip.
5.
Bevel the leading edge of the aileron to a "Vusing the centerline as a guide. The bevel must permit the full amount of aileron throw as specified on page 68, plus a bit extra to prevent servo binding.
34
-
6. Replace the flap onto the wing. Adjust the
root of the aileron and the tip of the flap
so
there is
approximately a 3/32" gap between them.
7.
Return to the first step and build the aileron
on the left wing panel the same way.
MOUNT THE FLAP AND AILERON
SERVOS
1. Cut the openings in the bottom of the wing
sheeting for the die
-
cut
1/16
"
plywood
aileron and
flap servo hatch covers
(if
you're building flaps). Start by cutting a smaller opening at the location indicated on the plan. Carefully enlarge the hatch openings using a fresh #11 blade and a straightedge until the hatch covers fit.
Hint:
As
you
zero-in on the final shape of the hatch openings,
use the hatch covers themselves as a template to cut the openings.
2. Drill 1/16" holes through the punch marks in the servo hatch covers. Place the hatch covers on the rails in the hatches and drill 1/16" holes through the hatch covers into the rails.
3.
Enlarge the holes i n the hatch covers
only with a
3/32
"
drill bit. Countersink the holes for
the
#2
x 3 / 8 flat head screws with a countersink or other pointed tool. Test fit the hatch covers to the rails with the screws.
If
necessary, remove the hatch covers and sand the sides of the hatch covers
so
they align with the edges of the hatch.
Note: Though the hatch covers are
1/16
thick and
the wing sheeting is 3/32
"
thick, by the time you sand the wing sheeting smooth it will be the same height as the hatch covers.
If
not, you can raise the
hatch covers by placing thin shims made from
1/64plywood or thin cardstock on top of the rails.
4. Use 30-minute epoxy to glue the 5/16
"
x
3/4"x7/8" servo mount blocks to the servo hatch covers as shown on the plan.
Note: You can increase the strength of this joint by drilling a few shallow 1/16
"
holes into the servo
mount blocks. This will create epoxy pins that
extend into the blocks.
5.
Mount
your
servos to the blocks with
'k,,u
screws included with your servos. Test fit the servo
hatches in the wing and screw them down with the hatch cover screws.
6. Returntothe first step and mount the flap and
aileron servos in the other wing panel.
7. Glue leftover 1/16"balsa sheeting to the
inside of the bottom sheeting around the wheel well cutout with the grain direction opposite that of the wing sheeting. This will reinforce the sheeting
around the wheel well cutout.
8. Brush another coat of fuelproof paint inside the wheel wells while they are still easy to reach with a paint brush.
JOIN THE WING PANELS
1.
Remove the flaps. Test fit both outer panels to
the center section. Make small adjustments
if
necessary to minimize any gaps you see. Test
fit
your clamps to make sure you have enough of them and to make sure you know where you are going to place the clamps when you actually glue the wing together.
A
I
4
4
3-9/16
"
BALSA
STICKS
2. Optional: The dihedral braces and the preset angle of the root ribs on the outer panels will determine the dihedral in the wing. But
if
you wish to check the dihedral before you permanently glue the wings together, clamp the wing together, raise
the center section off your workbench with balsa sticks of equal size
(so
the wing is not resting on the clamps) and measure the height of both wing tips. The height of
both
tips (measured under the
bottom of the spar at tip rib W14) should be 3
-
9/16
" (not including the balsa sticks).Ifthe measured dihedral of both wing tips is within a range of 3-3/8" to 3-3/4", the dihedral is okay.
3. Mix a batch of 45 or 30-minute epoxytojoin the wing panels to the center section. Apply epoxy to all the mating surfaces of the end ribs, spars and dihedral braces.
If
you have installed the wires for the wing tip lighting, pull the wires through the root ribs
so
you can route them into the center section. Join the outer panels to the center section and position your clamps. Wipe away excess epoxy with a paper towel before it cures and do not disturb the wing until the epoxy cures.
MAKE THE FLAP AND AILERON
PUSHRODS
1.
Cut a 1/8" deep notch in the aileron for the
die
-
cut 1/8" plywood aileron
horn
mounting
plate where shown on the plan. Glue the horn mounting plate to the aileron and sand it to match the leading edge.
-
35
El
2. Make the aileron pushrods from a
.074" x
4
threaded end rod
with a
nylon clevis
and
a
solder clevis.
We recommend silver solder
for the solder clevis. Drill 1/16
"
holes in the aileron horn mounting plate and add a few drops of thin CA to the holes and allow to harden. Mount a
control horn
to the aileron with two #2x3/8"
screws and hook up the servo with the pushrod.
U
3. Thread another nylon clevis onto the end of
another
.074
x
4"threaded end rod. Bend and cut the wire to the length shown on the wing plan for the
right
flap pushrod. Enlarge the holes in your
flap servo arms with a hobby knife (or a #48 drill for
perfection) and connect the flap pushrod to the servo arm using a nylon
FasLink".
Rotate the flap
servo arm to the
down
position and set the flap hatch cover (with the flap servo and pushrod connected) over the flap hatch and guide the pushrod out of the hole in the TE.
4. Temporarily connect the clevis to the flap
horn to see
if
the pushrod is approximately the
correct length.
5. Connect the other aileron and flap pushrod the same way. Make final adjustments to the lengths of the pushrods when you set up your radio.
This is as far as we cangowith the wing until it is fitted to the fuse. But first, we need a fuse,
so..
.
build the
fuse!
BUILD
THE
FUSELAGE
PREPARATION
Note:
The die-cut 1/8" plywood formers are
stamped with only the necessaly portion of their
name. For example,
F-2B
is stamped
28.
All
die
-
cut parts are 1/8" plywood unless they are
otherwise noted.
1. Position the bottom view of the fuselage plan
over your flat building board. Cover it with wax paper. You may cut the bottom view from the rest of the plan.
2.
Use 30-minute epoxy to glue two die-cut 1/8"
plywood
FlB's
together and
F1T
to the front of
F1DT
(there are two F1
DT's
included in the kit but
only one is used). Clamp the assemblies
to
a flat
table or board or lay weights on them with wax
paper underneath. Inspect the parts closely before the epoxy cures to make sure they remain aligned. Wipe away excess epoxy before it cures. From
now on the F1B assembly will be referred to as the
firewall.
-
36
-
3. Drill 1/16"holes through the punch marks in
F2D
andF2that are closest to the bottom of the formers. Glue F2D to the front of F2 with the holes aligned. After the glue dries, drill 5/16
"
holes
through the punch marks.
If
you do not have a
5/16
"
drill bit you can start with a 1/4" hole and
enlarge it to approximately 5/16
"
with a hobby knife
or a round wood file. These holes do not have to be
exactly
5/16"or perfectly round.
4.Ifyou're installing retracts, drill 1/8" holes
through the punch marks in the bottom of
F6
for the
air tank dowels and through the punch marks in F2
for the pull/pull nose steering cable guide tubes.
5. Drill 3/16"holes through the punch marks in
the die
-
cut 1/8" plywood formers F6through
Fll.
When you drill the holes press down on each former to prevent the wood from splitting when the drill bit goes through.
TYPICAL HOLES AND SLOTS
FOR
AIR TUBES AND WIRES
SLOT
FOR
SERVO WIRES
1/8"
AIR
TUBE HOLE
6.Ifyou plan to install the Top Flite Beechcraft Bonanza Scale Interior Kit drill holes and cut slots in the formers for routing the air lines and servo wires between the fuse sides and the cockpit interior in formers F3, F4 and F5.
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