GREAT PLANES Easy Sport 40 Instruction Manual

WARRANTY

Great Planes Model Manufacturing Co. guarantees this kit to be free from defects in both material and
workmanship at the date of purchase. This warranty does not cover any component parts damaged by use or
modification. In no case shall Great Planes' liability exceed the original cost of the purchased kit. Further, Great
Planes reserves the right to change or modify this warranty without notice.

In that Great Planes 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 buyers are not prepared to accept the liability associated with the use of this product, they are
advised to return this kit immediately in new and unused condition to the place of purchase.

READ THROUGH THIS INSTRUCTION MANUAL
FIRST. IT CONTAINS IMPORTANT INSTRUCTIONS
AND WARNINGS CONCERNING THE ASSEMBLY
AND USE OF THIS MODEL.

ES03 V1.0 Entire Contents © Copyright 1996

P.O. Box 788 Urbana, IL 61801 [phone]

INSTRUCTION MANUAL

TM

ADE IN

SA

INTRODUCTION ...............................................................2

PRECAUTIONS.................................................................3

DECISIONS YOU MUST MAKE........................................3

Engine Selection............................................................3

PREPARATIONS...............................................................3

Required Accessories ...................................................3

Building Supplies and Tools...........................................3

Optional Supplies and Tools .........................................4

Common Abbreviations..................................................4

Get Ready to Build.........................................................4

PARTS LIST......................................................................5

WING ASSEMBL Y.............................................................6

Assemble the Wing Joiners ...........................................6

Prepare the Wing Roots.................................................6

Join the Wing Panels.....................................................6

Install the Aileron Servo Tray.........................................7

Install the Wing Bolt Plate..............................................7

INSTALL FUSELAGE COMPONENTS.............................7

Install the Engine Mount ................................................7

Install the Servo Tray .....................................................8

Install the Pushrod Tubes ..............................................8

Assemble the Fuel Tank.................................................9

Completing the Engine & Fuel Tank Installation...........10

MOUNT THE WING TO THE FUSELAGE......................10

Installing the Wing Hold-Down Plate............................10

INSTALL THE TAIL COMPONENTS ..............................12

Join the Elevator Halves..............................................12

Align & Install the Stabilizer..........................................12

Install the Vertical Fin...................................................14

Install the Elevator Halves ...........................................14

INSTALL THE LANDING GEAR.....................................15

Mount the Main Landing Gear .....................................15

Mount the Nose Gear...................................................15

RADIO INSTALLATION ..................................................16

Install the Radio Components......................................16

Install the Pushrods & Control Horns...........................17

FINAL ASSEMBLY..........................................................19

Balance the Propeller...................................................19

Install the Wheels.........................................................19

Install the Canopy........................................................19

Control Surface Throws...............................................20

Balance Your Model.....................................................20

PREFLIGHT.....................................................................21

Charge the Batteries....................................................21

Find a Safe Place to fly................................................21

Ground Check the Model.............................................21

Range Check the Radio...............................................21

Engine Safety Precautions...........................................21

FLYING ............................................................................22

Takeoff..........................................................................22

Flight............................................................................22

Landing........................................................................22

AMA Safety Code...........................................................23

FLIGHT LOG ...................................................Back Cover

Your Easy Sport 40 is not a toy, but rather a sophisticated,
working model that functions very much like an actual
airplane. Because of its realistic performance, the Easy Sport,
if not assembled and operated correctly, could possibly cause
injury to yourself or spectators and damage property.

If this is your first sport model we recommend that you
get help from an experienced, knowledgeable modeler
with your first flights. 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 may also contact the national Academy of Model
Aeronautics (AMA), which has more than 2,300 chartered
clubs across the country.

Academy of Model Aeronautics

5151 East Memorial Drive

Muncie, IN 47302-9252

Tele. [phone]

Fax [phone]

Congratulations and thank you for purchasing the Great
Planes Easy Sport 40 ARF! This model has many features
that are usually found only in kit-type aircraft. These
features include: rod-in-tube pushrods, an adjustable glass­filled nylon engine mount, multiple color covering and high
quality Great Planes hardware. The construction technique
that is used for this aircraft results in a model that is lighter
and stronger than conventional, built-up balsa airplanes.
The Easy Sport 40 ARF will provide an excellent second
aircraft to help build confidence and assist in perfecting
your aerobatic skills.

The Great Planes Easy Sport 40 ARF is similar to the
original Easy Sport 40 kit. The Almost-Ready-to-Fly version
is stable enough to be a great second airplane, yet has
aerobatic capabilities which allows rapid advancement of
your aerobatic skills. This Easy Sport has the same good
looks and excellent stability at low speeds that can be
found on the kit version and reflects the design expertise
and high quality standards of Great Planes kits.

INTRODUCTION

PROTECT YOUR MODEL,YOURSELF

& OTHERS...FOLLOW THIS

IMPORTANT SAFETY PRECAUTION

TABLE OF CONTENTS

2

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
airplane, please call us at [phone]. If you are
calling for replacement parts, please reference the part
numbers and the kit identification number (stamped on
the end of the carton) and have them ready when calling.

1. Build the model according to the instructions. Do not
alter or modify the model, as doing so may result in an
unsafe or unflyable model. In a few cases the instructions
may differ slightly from the photos. In those instances the
written instructions should be considered correct.

2. Take time to build straight, true and strong.

3. Use a radio control system that is in first-class condition
and correctly-sized engine and components throughout
your building process.

4. You must properly install all components so that the
model operates properly on the ground and in the air.

5. You must check the operation of the model before every
flight to ensure that all equipment is operating, and that the
model has remained structurally sound. Be sure to check
nylon clevises or other connectors often and replace them if
they show signs of wear or fatigue.

6. If you are not already an experienced R/C pilot, you
should fly the model only with the help of a competent, well
experienced R/C pilot.

Remember: Take your time and follow directions to end
up with a well-built model that is straight and true.

Items in parentheses (OSMG2691) are suggested part
numbers recognized by distributors and hobby shops and
are listed for your ordering convenience. GPM is the Great
Planes brand, TOP is the Top Flite®brand, and HCA is the
Hobbico®brand.

❏ 4 Channel Radio with 4 Servos
❏ Engine - See Engine Selection above
❏ Propellers (see engine instructions for sizes)
❏ 18" Silicone fuel tubing (Great Planes #GPMQ4131)
❏ 1/4" Latex foam rubber for receiver & battery

(Hobbico #HCAQ1000)

Note: Larger wheels than those included may be required
for operation on rough grass fields.

These are the building tools, glue, etc. that we recommend
and mention in the manual. We recommended Great

Planes Pro™CA and Epoxy

❏ 1 oz. CA thin (Great Planes #GPMR6002)
❏ 1 oz. CA+ Medium (Great Planes #GPMR6008)
❏ 6-Minute Epoxy (Great Planes #GPMR6045)
❏ 30-Minute Epoxy (Great Planes #GPMR6047)
❏ Hand or electric drill
❏ Hobby saw (razor saw)
❏ Hobby knife, #11 Blades
❏ Common pliers
❏ Screwdrivers (phillips and flat blade)
❏ T-Pins
❏ String
❏ Straightedge with scale
❏ Masking tape (required for construction)
❏ Sandpaper (medium grit)
❏ T-Bar sander (or similar)
❏ Isopropyl rubbing alcohol (70%)
❏ Round file
❏ Felt-tip pen
❏ Mixing sticks
❏ Drill Bits: 1/16", 3/32", 5/64", 5/32", 7/64"

Building Supplies and Tools

Required Accessories

PREPARATIONS

Engine Selection

The recommended engine size range is as follows:

.40 to .51 cu. in. 2-stroke
.52 to .70 cu. in. 4-stroke

The Easy Sport 40 will fly well with any of the recommended
engine sizes. For “Hot Dogging” and speedy performance,
we suggest either an O.S.®.46 FX or a SuperTigre™GS-45,
both 2-stroke engines. An O.S. FS-70 Surpass is a good
choice for those who prefer 4-stroke engines.

DECISIONS YOU MUST MAKE

NOTE: We, as the kit manufacturer, can provide you
with a top quality kit and great instructions, but ultimately
the quality 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.

PRECAUTIONS

3

❏ Dremel

®

MultiPro™or similar

❏ 1 oz. Thick CA- (GPMR6014)
❏ 6-Minute Pro Epoxy (GPMR6045)
❏ CA Applicator Tips (HCAR3780)
❏ Epoxy Brushes (GPMR8060)
❏ CA Debonder (GPMR6039)
❏ Trim Seal Tool (TOPR2200)
❏ Heat Gun (TOPR2000)
❏ Straightedge (Fourmost Non Slip, FORR2149)
❏Kyosho Curved Scissors for trimming canopy (KYOR1010)

Elev = Elevator Fuse = Fuselage
LE = Leading Edge (front) LG = Landing Gear
Lt = Left Ply = Plywood
Rt = Right Stab = Stabilizer
TE = Trailing Edge (rear) " = Inches

1. Remove all parts from the box. As you do, identify each
part by comparing it with the parts list on page 5. Using a
felt-tip or ballpoint pen, lightly write the part name on each
piece to avoid confusion later. Use your bar sander or
sanding block to lightly sand the edges to remove any
irregularities or slivers.

2. As you identify and mark the parts, separate them into
groups, such as fuse (fuselage), wing, fin, stab (stabilizer)
and hardware.

Get Ready to Build

Common Abbreviations

Optional Supplies and Tools

4

Futaba®4NBF Conquest 4-channel Radio

Flexibility and convenience make the Futaba
Conquest FM radio systems a good choice
for experienced fliers. FUTJ39**

Great Planes Pro™Thin, Instant Set CA

Instant-setting Pro CA is ideal for fast
assembly, with a curing time of 1-3 seconds.
All Pro CAs are dated for freshness.

GPMR6002

O.S.®.70 Surpass 4-stroke Engine

Lower noise, higher torque, increased fuel
economy and longer engine life make the
O.S. .70 Surpass engine an excellent choice
for your model. OSMG0870

Great Planes Pro Medium CA

Thick CA+ is an excellent gap filler that cures
in 10-15 seconds. All Pro CAs “wick” better
into balsa wood for the strongest possible
bond. GPMR6008

Great Planes Pro 6-minute Epoxy

Pure, powerful Pro 6-minute Epoxy cures
very quickly while also providing incredible
strength. Two-bottle set includes 4.5 oz.
bottles of epoxy and hardener. GPMR6045

Great Planes Pro 30-minute Epoxy

Pro 30-minute Epoxy provides modelers with
longer curing time to reposition parts and
provides greater strength for high-stress
areas. GPMR6047

5

1 S tabilizer/Elevator Assembly
2 Rudder/Fin Assembly
3 Wheels
4 Main Landing Gear Wire
5 Pushrods
6 Right Wing Panel
7 Servo Tray
8 Wing Joiner
9 Plywood Wing Hold-Down Plates
10 Aft Root Ribs
11 Forward Root Ribs
12 Aileron Servo Tray
13 Stabilizer Mounting Base
14 Wing Bolt Plate
15 Wing Tape
16 6-32 x 1" Screws
17 Wheel Collars

18 6-32 x 3/4" Sheet Metal Screws
19 Nylon Landing Gear Straps
20 #6 Flat Washers
21 Silicone Clevis Retainers
22 Nylon Steering Arm
23 Nylon Control Horns
24 Nylon Clevis
25 Swivel Clevis
26 Nose Gear Wire
27 Engine Mount R & L
28 Spinner
29 Fuel Tank Assembly
30 Left Wing Panel
31 Canopy
32 Wing Fairing
33 Fuselage
34 Hatch

29

34

16

17

18

20

22

19

21

23

24

25

30

3

4

31

32

33

2

3

4

5

6

7

8

9

10

11

12

13

14

15

3

26

27

28

1

PARTS LIST

6

Note: As epoxy is used for most of this kit’s assembly, it’s a

good idea to keep rubbing alcohol and paper towels handy
for cleanup. Before the epoxy has had time to cure, moisten
a paper towel with alcohol and clean off any excess epoxy.

❏ 1. Lightly sand the edges of the three plywood wing

joiners to remove any rough edges. Use 30-minute epoxy
to glue the three pieces together. Be sure that the slight
dihedral angle is on the same edge of all three pieces.

Clamp the wing joiners together or weigh them down on a
flat surface while the epoxy cures.

❏ 2. Measure and mark the location of the aileron servo

tray opening. Using a sharp hobby knife, carefully cut the
opening for the aileron servo tray in both wing panels on
the bottom of each wing panel.

Note: The opening begins directly behind the wing spar.

❏ 3. Sand the inside of both wing roots for a nice flush fit.

Use 30-minute epoxy to glue the die-cut ply forward and
aft root ribs to both wing roots. Be sure that they are

aligned with the top and bottom of the wing. When
installing the forward root rib, it should be noted that the
tab is placed toward the top of the wing. Use strips of
masking tape to hold the parts in position until the epoxy
has cured.

❏ 1. Draw a centerline on the wing joiner as shown in the

photo. Test fit the wing joiner into each wing panel. You
must be certain that the joiner fits all the way into the wing
panels. The joiner should fit snugly into each wing panel.
Sand the joiner if it does not fit snugly or does not fit
completely into the wing panels.

❏ 2. Test fit the panels together with the wing joiner in

place. The angled edge of the joiner points towards the
bottom of the wing. Check the alignment of the leading
and trailing edges. They should line up nicely with the roots
fitting together without any gaps. Sand the root ribs if any
imperfections are keeping the wing halves from fitting
together properly.

Join the Wing Panels

Prepare the Wing Roots

Assemble the Wing Joiners

WING ASSEMBL Y

7

Carefully read and practice the following step
completely before mixing any epoxy. The entire step
must be completed before the epoxy begins to set.

❏3. When you are satisfied with the fit, pull the panels apart

and mix up a large batch (about 1.5 oz.) of 30-minute
epoxy. Using an epoxy mixing stick, liberally spread epoxy
inside both of the joiner slots and on one half of the joiner

itself. Next, quickly install the glued end of the joiner into one
of the slots. Spread more epoxy onto the root ribs and the
protruding end of the wing joiner. Slide the two wing panels
together. The epoxy should squeeze out around the edges.
This is a good sign that there is enough epoxy to securely
join the two wing halves. Double check the alignment and
wipe off any excess glue with a paper towel and rubbing
alcohol. Hold the two wing halves together using masking
tape. Continually check the alignment of the wing halves
while the epoxy cures.

❏4. Once the glue has cured, check the joint for any small

gaps and fill them with epoxy. Wipe off any excess epoxy
using a paper towel and rubbing alcohol. The paper towel
can also be used to remove any fingerprints or epoxy
residue that may have been left behind.

❏ 1. Glue the aileron servo tray and uprights into the wing

using 6-minute epoxy.

❏ 1. Lay the wing bolt plate on a table with the punch

marks facing upwards. Draw a centerline across the wing
bolt plate. Using a hobby knife, gently score the wing bolt
plate along this centerline. This score line is to allow the
wing bolt plate to be easily bent to the contour of the wing
and should not be cut completely through the plate.

❏ 2. Position the wing bolt plate on the trailing edge of

the top of the wing. Use the centerline on the wing bolt
plate to center it between the aft root ribs. Draw a line
around the plate on the covering using a felt-tip pen.
Carefully remove the covering with a hobby knife. Be

careful not to cut into the wood.

❏ 3. Using 6-minute epoxy, glue the wing bolt plate in

place with the punch marks facing up. Clamp it in position
while the epoxy cures.

Note: The following steps depict the installation of a 2-stroke
engine. The steps are similar if you are using a 4-stroke
engine, although some changes to the throttle pushrod
routings will need to be made.

Install the Engine Mount

INSTALL FUSELAGE COMPONENTS

Install the Wing Bolt Plate

Install the Aileron Servo Tray

❏ 1. Remove the center spreader from the engine mount

halves. Trim any excess flashing with a hobby knife or file.

❏ 2. This is a good time to fuelproof the tank and engine

compartments. Lightly brush a mixture of 30-minute epoxy
thinned with isopropyl alcohol into both compartments. Be
careful not to get any of the epoxy into the blind nuts that
are located in the firewall.

❏ 3. Fit the two halves of the engine mount together. Use

four #6 flat washers and four 6-32 x 1" phillips head
screws to attach the engine mount to the firewall. Blind

nuts have already been installed in the firewall for this
purpose. Don’t tighten the screws completely yet, as the
mount will need to be adjusted to fit the engine.

❏ 4. Test fit the engine to the mount. Adjust the width of

the mounting rails to accommodate the engine without
being too tight or too loose. Tighten the mount screws so
that you can mark the engine screw holes without allowing
the rails to move.

❏ 5. Position the engine so that the drive washer is

4-15/16" from the firewall. Using one of the 17-1/2" push
rods, sharpen the non-threaded end using a file or
sandpaper. Use this sharpened wire to scribe the four
mounting holes onto the rails. Use a 7/64" drill bit to drill
pilot holes through the rails for the #6 sheet metal screws.

❏ 6. Attach the engine to the rails using four #6 x 3/4"

sheet metal screws.

❏1. Separate the two die-cut 1/8" (3.2mm) ply parts of the

servo tray assembly, then lightly sand off any rough spots
from the edges. Save the excess plywood for use in

later steps.

❏ 2. Test fit the servo tray assembly by first placing the

front brace behind the landing gear mounts. The servo tray
is then installed by “locking” it into the cut-out of former #4
and the front brace. When satisfied with the fit of these
components, glue them in place using medium CA. Be sure
to make a fillet along the joint between the servo tray and
the fuselage side.

❏ 1. Measure and cut a 21" length from each of the two

outer pushrod tubes supplied. The 21" pieces will be
used for the rudder and elevator. Save the pieces that were
cut off for the nose gear and throttle pushrods.

❏ 2. Locate the pushrod exit slot under the covering on

the tail section of the fuselage by lightly pressing with your
fingers. The slot should be located 3-3/4" from the rear the
fuselage and 7/8" from the bottom of the fuselage. Trim the
covering to provide access to the pushrod exit. Check the

Install the Pushrod Tubes

Install the Servo Tray

#6 x 5/8" Sheet Metal Screw (4)

8