GREAT PLANES Giant Super Sportster 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-assemb led 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 use of this product, the buyer is advised to return this
kit immediately in new and unused condition to the place of purchase.

To make a warranty claim send the defective part or item to Hobby Services at the address below:

Hobby Services

3002 N. Apollo Dr. Suite 1

Champaign IL 61822 USA

Include a letter stating your name, return shipping address, as much contact information as possible (daytime telephone number, fax
number, e-mail address), a detailed description of the problem and a photocopy of the purchase receipt. Upon receipt of the package
the problem will be evaluated as quickly as possible.

READ THROUGH THIS MANUAL BEFORE STARTING
CONSTRUCTION. IT CONTAINS IMPORTANT WARNINGS
AND INSTRUCTIONS CONCERNING THE ASSEMBLY
AND USE OF THIS MODEL.

GPMZ0189 for GPMA1044 V1.0© Copyright 2006

Champaign, Illinois

[phone], Ext 5

[e-mail]

INSTRUCTION MANUAL

Wingspan: 82 in [2085 mm]
Wing Area: 1293 sq in [83.4 dm2]
Weight: 13-14.5 lb [5850-6575 g]
Wing Loading: 23-25 oz/sq ft [70-79 g/dm2]
Length: 72 in [1820 mm]
Radio: 4-5 channel transmitter, 6-7 servos
Engine: 1.60-2.00 cu in [26-33 cc] 2-stroke,

1.20-2.00 cu in [20-33 cc] 4-stroke,
2 cu in [32 cc] gas

™

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

SAFETY PRECAUTIONS..................................................3

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

Radio Equipment .........................................................3

Engine Recommendations..........................................3

Fuel Tank Setup...........................................................4

ADDITIONAL ITEMS REQUIRED.....................................4

Required Hardware and Accessories..........................4

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

IMPORTANT BUILDING NOTES......................................5

ORDERING REPLACEMENT PARTS ..............................5

KIT CONTENTS ................................................................6

PREPARATIONS ...............................................................7

ASSEMBLE THE WINGS..................................................8

Hinge the Ailerons.......................................................8

Mount the Servos and Hook Up the Ailerons..............9

Mount the Wings .......................................................10

ASSEMBLE THE FUSELAGE.........................................11

Join the Stabilizer and Fin.........................................11

Mount the Servos and Hook Up the Controls...........13

Mount the Tail Gear...................................................13

Mount the Engine and Hook Up the Throttle.............14

Glow Engine

........................................................14

Gas Engine (Fuji-Imvac™BT-32)

.........................15

Mount the Kill Switch (Gas Engines)

..................16

Assemble the Fuel Tank ............................................17

Glow Engines

......................................................17

Gas Engines

.......................................................17

Install the Fuel Tank ..................................................18

Mount the Cowl .........................................................19

FINAL ASSEMBLY..........................................................21

Mount the Main Landing Gear ..................................21

Finish Radio Installation............................................22

Finish the Cockpit and Mount the Canopy................23

Apply the Decals .......................................................24

GET THE MODEL READY TO FLY .................................24

Check the Control Directions ....................................24

Set the Control Throws..............................................24

Balance the Model (C.G.)..........................................25

Balance the Model Laterally ......................................25

PREFLIGHT.....................................................................26

Identify Your Model....................................................26

Charge the Batteries .................................................26

Balance Propellers....................................................26

Ground Check...........................................................26

Range Check.............................................................26

ENGINE SAFETY PRECAUTIONS.................................26

AMA SAFETY CODE......................................................27

IMAA SAFETY CODE.....................................................27

CHECK LIST ...................................................................29

FLYING ............................................................................29

Fuel Mixture Adjustments..........................................29

Takeoff.......................................................................29

Flight..........................................................................30

Landing......................................................................30

TEMPLATES....................................................................31

Thank you for purchasing the Great Planes Giant Super
Sportster ARF. The Super Spor tster is a classic design
that has been around for several years, yet its smooth
lines and gentle curves make it just as popular now as it
was at the start. The Super Sportster is an honest flyer
that is relaxing and enjoyable. Its rugged construction
makes it a practical plane that is easy to handle, so it
should remain in your stable for a long time. Powered by
a 1.60 two-stroke, the Super Sportster handles just like a
hot .60-size plane with the stability and presence of a
giant-scale model. Powered by a Fuji-Imvac 32, the
Sportster flies a little “softer.” The Fuji-Imvac also fits
nicely in the cowl and you can enjoy the economy and
“cleanliness” a gas engine provides. For more on engine
selection read the “Engine Recommendations” section
on the next page.

For the latest technical updates or manual corrections to
the Giant Super Sportster ARF, visit the Great Planes
web site at www.greatplanes.com. Open the “Airplanes”
link, then select the Giant Super Sportster ARF. If there
is new technical information or changes to this model, a
“tech notice” box will appear in the upper left corner of
the page.

We urge you to join the AMA (Academy of Model
Aeronautics) and a local R/C club.The AMA is the governing
body of model aviation and membership is required to fly at
AMA clubs.Though joining the AMA provides many benefits,
one of the primary reasons to join is liability protection.
Coverage is not limited to flying at contests or on the club
field. It even applies to flying at public demonstrations and
air shows. Failure to comply with the Safety Code (excerpts
printed in the back of the manual) may endanger insurance
coverage.Additionally, training prog rams and instructors are
available at AMA club sites to help you get started the right
way. There are over 2,500 AMA chartered clubs across the
country. Contact the AMA at the address or toll-free phone
number below:

Academy of Model Aeronautics

5151 East Memorial Drive

Muncie, IN 47302-9252

Tele. [phone]

Fax [phone]

Or via the Internet at:

http://www.modelaircraft.org

IMPORTANT!!!

Two of the most important things you can do to preserve the
radio controlled aircraft hobby are to avoid flying near full­scale aircraft and avoid flying near or o ver groups of people.

AMA

INTRODUCTIONTABLE OF CONTENTS

2

1.Your Giant Super Sportster ARF should not be considered
a toy, but rather a sophisticated, working model that
functions very much like a full-size airplane. Because of its
performance capabilities, the Sportster, if not assembled
and operated correctly, could possibly cause injury to
yourself or spectators and damage to property.

2. You must assemble 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
as correct.

3.You must take time to build straight, true and strong.

4. You must use an R/C radio system that is in first-class
condition, and a correctly sized engine and components
(fuel tank, wheels, etc.) throughout the building process.

5.You must correctly install all R/C and other components so
that the model operates correctly on the ground and in the air .

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

7. If you are not an experienced pilot or have not flown this
type of model before, we recommend that you get the
assistance of an experienced pilot in your R/C club for your
first flights.If you’re not a member of a club, your local hobb y
shop has information about clubs in your area whose
membership includes experienced pilots.

8.While this kit has been flight tested to exceed normal use,
if the plane will be used for extremely high stress flying, such
as racing, or if an engine larger than one in the
recommended range is used, the modeler is responsible for
taking steps to reinforce the high stress points and/or
substituting hardware more suitable for the increased stress .

9. WARNING:The cowl and wheel pants included in this kit
are made of fiberglass, the fibers of which may cause eye,
skin and respiratory tract irritation. Never blow into a part
(wheel pant, cowl) to remove fiberglass dust, as the dust will
blow back into your eyes. Always wear safety goggles, a
particle mask and rubber gloves when grinding, drilling and
sanding fiberglass parts. Vacuum the parts and the work
area thoroughly after working with fiberglass parts.

Remember:Take y our time and follow the instructions to
end up with a well-built model that is straight and true.

This is a partial list of items required to finish the Giant
Super Sportster ARF that may require planning or decision
making before starting to build.Order numbers are provided
in parentheses.

Five

medium

torque rating (minimum 50 oz-in [3.9 kg-cm]),
ball bearing servos are required for the elevator, ailerons
and rudder (Futaba®9001 recommended, FUTM0075). One
standard servo is required for the throttle and an additional,
optional standard servo may be used for a throttle-operated
engine kill switch for spark-ignition engines.

In addition to the servos, the following radio equipment will
also be required:

❏ (3) 24" [610 mm] servo extensions f or rudder and elev ator

servos (HCAM2721 for Futaba)

❏ (2) 12" [300 mm] servo extensions for aileron servos

(HCAM2711 for Futaba)

❏ (1) 6" [150 mm] servo extension from receiver for aileron

connection (HCAM2701 for Futaba)

❏ (2) dual servo extensions for aileron and elevator

servos (FUTM4130)

❏ Minimum 1,000 mAh receiver battery (NR4F 4.8V 1,500

mAh NiCd, FUTM1285, or NR4B 4.8V 1,000 mAh NiCd,
FUTM1380)

The recommended engine size range is specified on the cover
of this manual. All engines within the specified range will power
the Giant Sportster well. Never fly your Giant Super Sportster
with an engine larger than one in the specified range because it
has not been designed or tested for larger engines.Powered by
a two-stroke glow engine such as the O.S.®MAX 1.60 FX, the
Sportster performs like a hot .60-size sport plane with the added
stability and durability of any well-designed giant plane.Powered
by the Fuji-Imvac 32, the giant Sportster is a little more “relaxing”
but still plenty capable of all the standard aerobatic maneuvers.
This kit comes with engine mounting posts and the rest of the
mounting hardware for the Fuji-Imv ac 32.If using a different gas
engine, different hardware may be required.

Engine Recommendations

Radio Equipment

DECISIONS YOU MUST MAKE

We, as the kit manuf acturer, provide you with a top quality ,
thoroughly tested kit and 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.

PRO TECT YOUR MODEL,YOURSELF

& OTHERS...FOLLOW THESE

IMPORTANT SAFETY PRECAUTIONS

3

If you haven’t yet decided whether to use a gas or a glow
engine, some of the things to consider are a gas engine’s
fuel economy–not only is gasoline cheaper than glow fuel,
but gas engines typically burn less fuel as well.Gas engines
are also a little “cleaner” in that they usually put out less
exhaust residue than a glow engine.On the other hand, for
the displacement, glow engines are usually more powerful
than gas engines and are also lighter and smaller.

Here are the order numbers for O.S. MAX and
Fuji-Imvac engines:

❏ O.S.1.60 FX ringed with muffler (OSMG0660)
❏ O.S.1.60 FX ringed without muffler (OSMG0661)
❏ #5010 muffler for O.S. 1.60 FX engine (OSMG2846)
❏ Fuji-Imvac BT-32S R/C gas engine (FJIG0033)

NOTE: If installing a glow engine the following drill bits will
be required:

❏ 13/64" [5.2 mm] (or 3/16" [4.8 mm])
❏ #29 drill and 8-32 tap

OR

❏ Great Planes 8-32 tap and drill set (GPMR8103)
❏ Tap handle (GPMR8120)

If installing a gas engine, a 1/4" [6.4 mm] drill will be required.

If using an O.S.Max 1.60 FX engine, replace the jam nut that
came on the engine with the jam nut included with this kit (that
has a 3/8-24 crankshaft thread).Use the spinner back plate as­is without the collared spacer ring and use the included 5 x
35mm spinner bolt to mount the spinner cone. If using an
engine with a different crankshaft thread a spinner adapter kit
from Great Planes or TruTurn will have to be purchased
separately. If a different spinner adapter kit must be used it will
probably require a 10-32 Allen-head spinner bolt, so the
appropriate-length spinner bolt may also have to be purchased.

If using a Fuji 32, the propeller bolt that came with the engine
will have to be replaced by a propeller bolt that is threaded in
the end for a spinner bolt.The TruT urn adapter kit TRUQ4035
may be used, but a 10-32 x 2-1/4" spinner bolt will also have
to be purchased. Or, a special Fuji propeller bolt (FJIG8050)
may also be used and then the 5 x 55 mm spinner bolt
included with this kit will work. In either case, when using the
Fuji engine, the collared spacer ring that came with this kit
will also have to be used in the spinner back plate.

Note: If the appropriate adapter kit or spinner bolt is not
available, a 3-1/4" Great Planes plastic spinner with an
aluminum back plate could be used instead of the included
aluminum spinner. This setup requires no adapter kit
because the cone is mounted to the back plate with four
screws. Order numbers are GPMQ4781 for the red spinner
and GPMQ4780 for the white spinner.

The fuel tank, stopper and hardware included with this kit are
suitable for use with glow fuel. If using a gas engine, the
stopper and fuel line must be replaced with a gas-compatible
stopper and lines and measures must be taken to secure the
fuel lines inside the tank.To do the conversion, the following
items must be purchased separately:

❏ (1) Sullivan #484 Gasoline/Diesel fuel tank conv ersion kit

(SULQ2684)

❏ (2) Packages Du-Bro #813 1/8" [3.2 mm] I.D. fuel line

barbs (DUBQ0670)

❏ At least six small, nylon ties (available from home

improvement, automotive or hardware stores)

❏ Great Planes gasoline fuel tubing (3', GPMQ4135)

OR

#799 3/32" I.D.Tygon Tubing (3', DUBQ0486)

If the Sullivan conversion kit is not available, a Du-Bro #400
gas conversion stopper (DUBQ0675) and one 12" [300 mm]
piece of K+S 1/8" [3.2 mm] soft brass tubing (K+SR5128­box of 5) could also be used. Full instr uctions on how to do
the conversion are in the manual.

In addition to the items previously listed in the

“Decisions

You Must Make”

section, following is the list of hardware
and accessories required to assemble the Giant Super
Sportster ARF. Order numbers are provided in parentheses.

❏ Suitable propellers
❏ 3' [900 mm] standard silicone fuel tubing (for glow

engines, GPMQ4131)

❏ R/C foam rubber (1/4" [6 mm], HCAQ1000

OR

1/2" [13

mm], HCAQ1050)

In addition to common household tools and hobby tools,
following are the most important items required to assemble
the Sportster.

❏ 1 oz. [30g] Thin Pro

™

CA (GPMR6002)

❏ 1 oz. [30g] Medium Pro CA+ (GPMR6008)
❏ CA applicator tips (HCAR3780)

Adhesives and Building Supplies

Required Hardware and Accessories

ADDITIONAL ITEMS REQUIRED

Fuel T ank Setup

Spinner Information

Per the IMAA Safety Code, magneto spark-ignition
engines must have a coil-grounding switch to stop the
engine and prevent accidental starting. The switch must
be operated manually (without the use of the transmitter)
and be accessible by the pilot and assistant.For use with
the Fuji-Imvac engine shown, the manually operated
switch was made from a Great Planes Ignition Switch
Harness (GPMG2150) as shown in the manual during the
engine installation process.

4

❏ Pro 30-minute epoxy (GPMR6047)
❏ Threadlocker thread locking cement (GPMR6060)
❏ #1 Hobby knife (HCAR0105)
❏ #11 blades (5-pack, HCAR0211)
❏ #11 blades (100-pack, HCAR0311)
❏ Drill bits: 1/16" [1.6 mm], 3/32" [2.4 mm], 1/8" [3.2 mm],

5/32" [4 mm], 3/16" [4.8 mm]

❏ Small, flat metal file
❏ Stick-on segmented lead weights (GPMQ4485)
❏ Silver solder w/flux (GPMR8070)
❏ 21st Century

®

sealing iron (COVR2700)

❏ 21st Century iron cover (COVR2702)
❏ 21st Century trim seal iron (COVR2750)

Here is a list of optional tools mentioned in the manual that
will help you build the Giant Super Sportster ARF.

❏ 2 oz. [57g] spray CA activator (GPMR6035)
❏ Pro 6-minute epoxy (GPMR6045)
❏ R/C-56 canopy glue (JOZR5007)
❏ CA debonder (GPMR6039)
❏ 3M 75 repositionable spray adhesive (MMMR1900)
❏ Epoxy brushes (6, GPMR8060)
❏ Mixing sticks (50, GPMR8055)
❏ Mixing cups (GPMR8056)
❏ Medium T-pins (100, HCAR5150)
❏ Robart Super Stand II (ROBP1402)
❏ Masking tape (TOPR8018)
❏ Wax paper
❏ Denatured alcohol (for epoxy clean up)
❏ Switch & Charge Jack Mounting Set (GPMM1000)

❏ Panel Line Pen (TOPQ2510)
❏ Rotary tool such as Dremel
❏ Rotary tool reinforced cut-off wheel (GPMR8200)
❏ Hobby Heat

™

micro torch (HCAR0750)

❏ Dead Center

™

Engine Mount Hole Locator (GPMR8130)

❏ AccuThrow

™

Deflection Gauge (GPMR2405)

❏ CG Machine

™

(GPMR2400)

❏ Laser incidence meter (GPMR4020)
❏ Precision Magnetic Prop Balancer (TOPQ5700)
❏ Aluminum Fuel Line Plug (GPMQ4166)

• The Giant Super Sportster ARF is factory-covered with Top

Flite®MonoKote®film. The following colors were used and
are available in six foot [1.8m] rolls.If only a small piece of
MonoKote is needed, maybe a modeling friend might have
some in his work shop. Some hobby shops also sell
MonoKote by the foot.

White (TOPQ0204)
Black (TOPQ0208)
True Red (TOPQ0227)

• The stabilizer and wing incidences and engine thrust

angles have been factory-built into this model. However,
some technically minded modelers may wish to check
these measurements anyway.To view this information visit
the web site at www.greatplanes.com and click on
“Technical Data.” Due to manufacturing tolerances which
will have little or no effect on the way your model will fly,
please expect slight deviations between your model and
the published values.

IMPORTANT BUILDING NOTES

Optional Supplies and Tools

5

ORDERING REPLACEMENT PARTS

Replacement parts for the Great Planes Giant Super Sportster
ARF are available using the order numbers in the Replacement
Parts List that follows.The fastest, most economical service can
be provided by your hobby dealer or mail-order company.

To locate a hobby dealer, visit the Hobbico

®

web site at
www.hobbico.com.Choose “Where to Buy”at the bottom of the menu
on the left side of the page.Follow the instructions provided on the page
to locate a U.S., Canadian or International dealer .If a hobby shop is not
available , replacement parts may also be ordered from Tower Hobbies

®

at www.towerhobbies.com, or by calling toll free [phone].
Parts may also be ordered directly from Hobby Services by calling

[phone], or via facsimile at [phone], but full retail prices
and shipping and handling charges will apply. Illinois and Nevada
residents will also be charged sales tax. If ordering via fax, include a
Visa®or MasterCard®number and expiration date for payment. Mai l
parts orders and payments by personal check to Hobby Services
at the address on the front cover of this manual.

Be certain to specify the order number exactly as listed in the
Replacement Parts List. Payment by credit card or personal check
only; no C.O.D.

If additional assistance is required for any reason contact Product
Support by e-mail at:

[e-mail]

[phone]

Replacement Parts List

Or

der #

Description How to Purchase

Missing pieces Contact Product Support
Instruction manual Contact Product Support
Full-size plans Not available

Contact your hobby supplier to purchase these items:

GPMA2900 .......Wing

GPMA2901 .......Fuselage

GPMA2902 .......Tail Surface Set

GPMA2903 .......Landing Gear

GPMA2904 .......Cowl

GPMA2905 .......Wing Joiner Tube

GPMA2906 .......Canopy

GPMA2907 .......Spinner

GPMA2908 .......Decal Sheet

6

1 Fuselage

2 Cowl
3 Canopy
4 Wing halves w/ailerons (R&L)

5 Hor izontal stabilizer w/elevators

6 Vertical stabilizer (fin) w/rudder
7 (2) wheel pants

8 (2) 3-1/2" [87 mm] main wheels

9 (2) Right and left main landing

gear wires

10 Tail gear wire
11 Aluminum wing joiner tube
12 Battery tray
13 Servo tray
14 Fuel tank w/hardware

Kit Contents (Photographed)

Wood parts:

Plywood ignition kill switch mount set
Plywood pushrod guide tube mounts (2)
10x45 mm wing dowels (2)
6x30 mm antirotation dowel
Cowl mounting blocks for gas engines (2)
Wing bolt plates (2)

Nuts, bolts, washers:

1/4-20x2" [50 mm] nylon wing bolts (2)
8-32x1-1/4" [32 mm] socket head cap screws

(SHCS) (engine mount) (4)
8-32 x 1" [25 mm] SHCS (engine) (4)
#8 flat washers (engine mount) (4)
#8 lock washers (4-engine, 4-engine mount) (8)
8-32 blind nuts (engine mount) (4)
4-40 x 3/4" [19 mm] Phillips screws (control

horns on elevators, rudder) (12)
#4x5/8" [16 mm] Phillips screws (16-main

landing gear straps, 6-cowl, 8-aileron control

horns) (30)
#4 flat washers (cowl) (6)
#4 lock washers (cowl) (6)
4-40 nuts (lock nuts for clevises on pushrods) (5)
2-56 x 3/8" [9.5 mm] Phillips screws (wheel pant

mounting) (8)

#2 x 3/8" [3/8 mm] Phillips screws (tail gear

mounting) (2)
#2 flat washers (wheel pant mount) (8)
2-56 blind nuts (wheel pant mount) (8)
2-56 ball link ball (gas engine throttle) (1)
2-56 lock nut (gas engine throttle) (1)
Brass screw-lock connector (throttle servo) (1)

4-40x1/8" [3.2 mm] SHCS for screw-lock (1)
Nylon retainer for screw-lock (1)
4-40x12" [300 mm] pushrods (2-elevators, 1-

rudder, 2-ailerons) (5)

4-40 metal clevises (2-elevators, 1-rudder, 2-

ailerons) (5)

Large solder clevises (2-elevators, 1-rudder,

2-ailerons) (5)
3/32" [2.4 mm] wheel collar (tail wheel) (1)
4-40 set screw for wheel collar (1)
1" [25 mm] tail wheel (1)
2-56 x 1" [25 mm] threaded rod (for gas throttle

pushrod) (1)

2-56 x 36" [910 mm] pushrod (glow throttle

pushrod) (1)

1/4-20 blind nuts (in fuselage) (2)

Metric fasteners for mounting
Fuji-Imvac 32 engine:

(4) 5x60 mm SHCS
(4) 5 mm lock washers
(4) 5 mm blind nuts
(4) 5 mm wheel collars
(4) 3x5 mm Phillips screw
5x12 mm flat washers (4-engine mounting,

8-wheel spacers) (12)

Hardware:

1.20–1.80 R & L engine mount halves
Aluminum Fuji-Imvac 32 engine spacers (4)
Hump straps (4-wheel pant mount, 2-spares) (6)

24" [610 mm] white, plastic pushrod (for gas

engine) (1)

24" [610 mm] gray throttle pushrod guide tube

(for gas engine) (1)
Giant control horns (5)
Giant control horn mounting plates (1)
Flat landing gear straps (main landing gear

mount) (8)
Nylon ball link (for gas throttle pushrod) (1)
Nylon clevis (for glow throttle pushrod)(1)
Clevis retainers (11)
3/8" [9.5 mm] heatshrink tubing (for servo wires) (1)
CA hinge strips (2)
Velcro

®

strips (2)
Inner, outer fueling line collar (1 glow, 1 gas) (2)
Fuel line plug (2)
Decal sheet

Tail gear assembly:

Tail gear wire
Collar with set screw
Nylon tail gear bearing
Collar w/3mm set screw
Aluminum bracket
Steering post (in rudder)

Spinner assembly:

3-1/4" [83 mm] aluminum spinner
3/8-24 jam nut
Collored spacer ring
5 x 35 mm spinner bolt
5 x 55 mm spinner bolt
5 mm nut

Kit Contents (Not Photographed)

KIT CONTENTS

Before starting to build, take an inventory of this kit to make sure it is complete, and inspect the parts to make sure they
are of acceptable quality. If any parts are missing or are not of acceptable quality , or if y ou need assistance with assemb ly,
contact Product Support. When repor ting defective or missing parts, use the part names exactly as they are written in
the Kit Contents list.

Great Planes Product Support:

3002 N Apollo Drive, Suite 1

Champaign, IL 61822

Telephone: [phone], ext. 5, Fax: [phone]

E-mail: [e-mail]

KIT INSPECTION

2

1

3

10

8

4

7

11

4

12
13

6

9

5

14

During construction there will be several occasions where
epoxy cleanup will be necessary. Instead of wasting whole
paper towels, stack three or four paper towels on top of each
other and cut them into small squares. This will conserve
paper towels and the little squares are easier to use. For
epoxy clean up, dampen the squares with denatured alcohol.

❏ 1. Examine the covering on all parts of the airframe.Where

necessary, use a covering iron with a covering sock to remove
any wrinkles. Over sheeted areas, first glide the iron over the
wrinkle until it shrinks. Then, go over the area again, pressing
hard on the iron to thoroughly bond the covering to the wood.
Note: In some areas where the sheeting is thin or unsupported,
less pressure should be used.

❏ 2.Use a straightedge and a hobby knife to cut the co vering

1/8" [3 mm] inside the openings in the bottom of both wings

for the aileron servos as shown in the sketch. Also cut the
covering from the 1/4" [6.5 mm] wing bolt holes, from the slots
for the main landing gear wires, and from the holes for the
servo wires in the top of both wings near the root ends.

❏ 3. Slit the covering up to the corners of the aileron servo

openings. Use a trim iron to iron the covering down inside
the edges of the servo openings.

Refer to the following photos for Steps 4 and 5.

❏ 4. The same as was done for the ailerons, cut and iron

down the covering from the servo openings in the fuselage.
Also cut the covering from the slots for the stabilizer and fin.

❏ 5. In the fuselage, temporarily place the servos in the servo

openings.Drill 1/16" [1.6 mm] holes for the servo screws.Screw
in all the servo mounting screws that came with the servos.
Remove the screws and servos , and then harden the “threads”
in the holes with a few drops of thin CA in each hole. Set the
servos aside until after the stabilizer has been mounted.

PREPARATIONS

7

SERVO OPENING IN WING

CUT THE COVERING 1/8" [3 mm]
FROM THE EDGES OF THE
OPENING. SLIT THE COVERING
UP TO THE CORNERS.

❏ 6. While your trim iron is out, use it to thoroughly seal

the covering around the firewall, around the air passage
cutout at the firewall under the fuselage, and around the
formers at the front and back of the wing saddle.

❏ 7. Mix up a medium-size batch (approximately 1/4 oz

[7.5cc]) of 30-minute epoxy for the following three steps.

❏ 8.Cut the covering from the holes in the leading edge of both

wing halves for the wing dowels. Chamfer one end of both 3/8"
x 1-3/4" [10 x 45 mm] hardwood wing dowels.Use epoxy to glue
in both dowels so 7/16" [10 mm] of each dowel protrudes.

❏ 9.Use epoxy to glue the 1/4" x 1-1/4" [6 x 30 mm] hardwood

alignment dowel halfway into one of the wing halves.

❏ 10. Spread a thin layer of epoxy over the edges of the

covering around the firewall–this will ensure that the co v ering is
thoroughly sealed and fuel-proofed. Use an epoxy brush to
lightly coat the formers at both ends of the wing saddle as well.

❏ 1. Cut eight 1" x 1" [25 x 25 mm] CA hinges from the

2" x 9" [50 x 230 mm] CA hinge strip. Cut the cor ners off so
the hinges go in easier.

Hinge the Ailerons

ASSEMBLE THE WING

8

1" [25 mm]

1" [25 mm]

❏ 2. Stick a T-pin through the middle of all the hinges.Insert

four hinges into the hinge slots of each wing.

❏ 3. Without using any glue, join the ailerons to the wings

and take out the T-pins. Make sure there is a small gap
between the leading edge of each aileron and the wing-just
enough to see light through or to slip a piece of paper through.

❏ 4. Apply at least eight drops of thin CA to the top and

bottom of all the hinges.Allow enough time between each drop

so the CA can soak into the hinge rather than running into the
hinge gap.Hint: CA applicator tips are highly recommended.

Do NOT use accelerator!

❏ 5. After the CA has hardened for a few minutes , pull hard

on each aileron to make sure all the hinges are secure.Add
more CA if necessary.

❏ 1. Connect a 12" [300 mm] servo extension wire to each

aileron servo. Cut one of the pieces of the supplied heat
shrink tubing in half and use each piece to secure each
servo connection.

Refer to this photo while mounting the servos

and hooking up the ailerons.

❏ 2. Use the string in the wings to pull the ser vo wires out

and place the servos in the openings.With the servos in the
wing, drill 1/16" [1.6 mm] holes for all the servo mounting
screws. Temporarily mount the servos with the screws that
came with the servos.

❏ 3. Read the Expert Tip that follows on how to solder.

Connect the aileron servos to the ailerons using the hardware
shown in the photo. The servo arms should be opposed as
shown in the sketches. When mounting the control horns,
place the front of the horn at the front of the aileron as
indicated by the arrow. Drill 3/32" [2.4 mm] holes into the
aileron for the screws.Do not cut the extra arms off the servo
arms until instructed to do so when setting up the radio later.

Note: Screw the 4-40 clevis onto the pushrod twenty full turns.

Mount the Servos & Hook Up the Ailerons

9

CONTROL HORN

HOW T O SOLDER

❏ A. Use denatured alcohol or other solvent to thoroughly

clean the pushrod. Roughen the end of the pushrod with
coarse sandpaper where it is to be soldered.

❏ B. Apply a few drops of soldering flux to the end of the

pushrod.Then use a soldering iron or a torch to heat it.“Tin”
the heated area with silver solder (GPMR8070) by applying
the solder to the end. The heat of the pushrod should melt
the solder–not the flame of the torch or soldering iron–thus
allowing the solder to flow. The end of the wire should be
coated with solder all the way around.

❏ C.Place the clevis on the end of the pushrod.Add another

drop of flux.Then, heat and add solder.The same as before,
the heat of the parts being soldered should melt the solder,
thus allowing it to flow .Allow the joint to cool naturally without
disturbing. Avoid excess blobs, but make certain the joint is
thoroughly soldered.The solder should be shiny , not rough.If
necessary, reheat the joint and allow to cool.

❏ D. Immediately after the solder has solidified, but while it

is still hot, use a cloth to quickly wipe off the flux before it
hardens. Important: After the joint cools, coat with oil to
prevent rust.Note: Do not use the acid flux that comes with
silver solder for electrical soldering.

This is what a properly soldered clevis looks like-shiny
solder with good flow, no blobs, flux removed.

❏ 4. Now that the servos and control horns have been

mounted, remove the servo mounting screws and the
control horn screws. Add a few drops of thin CA to each
screw hole to harden the “threads”in the holes. After the CA
has hardened, reinstall all the screws to securely mount the
servos and the horns.

❏ 1. Fit both wing halves together on the joiner tube.Then,

place the wing on the fuselage, keying the dowels into the
dowel holes in the former.

❏ 2.Bolt the wing to the fuselage with two 1/4-20 x 2" [50 mm]

nylon wing bolts and the plywood wing bolt plates underneath.
Use a fine-point felt-tip pen to mark the outline of the wing bolt
plates onto the wing.

❏ 3. Refer to the Expert Tip on page 12.Using care not to cut

into the balsa underneath, use the soldering iron technique or
a sharp #11 blade to cut the covering 1/16" [1.5 mm] inside the
lines you marked around the wing bolt plates.Use one of your
small paper towel squares dampened with denatured alcohol
to wipe away the ink, and then peel off the covering.

❏ 4. If any of the covering has loosened from the sheeting

around the covering you just removed, use a covering iron
with a covering sock to reseal the covering back to the wing.
Use epoxy to glue the wing bolt plates to the bottom of the
wings.This can be done by actually bolting the wings to the
fuselage, but care must be taken not to get excess epoxy
into the wing bolts or on the fuselage-otherwise it could be
difficult to remove the wing after the epoxy has hardened.
Another way to glue the wing bolt plates on is with clamps.

Mount the Wing

10