Great Planes GPMA0180 User 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 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.

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

RV44P03 for GPMA0180 V1.0 Entire Contents © Copyright 2001

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

[e-mail]

INSTRUCTION MANUAL

Printed In USA

Wingspan: 54-5/8 in. (1388mm)
Wing Area: 628.8 sq. in.(40.56dm2)
Weight: 5-3/4 lbs to 6-1/4 lbs ( 2610g - 2850g)
Length: 49-5/8 in. (1260mm)
Wing Loading: 21 oz per sq ft to 22.9 oz per sq ft (64.4 grams per dm

2

- 70.3 grams per dm2)

MADE IN

USA

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

SAFETY PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . . . 2

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

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

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

ADDITIONAL ITEMS REQUIRED . . . . . . . . . . . . . . . . . 3

Hardware and Accessories . . . . . . . . . . . . . . . . . . . 3

Adhesives and Building Supplies . . . . . . . . . . . . . . . 3

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

IMPORTANT BUILDING NOTES . . . . . . . . . . . . . . . . . . 4

Common Abbreviations . . . . . . . . . . . . . . . . . . . . . . 5

Types of Wood. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Metric Conversions . . . . . . . . . . . . . . . . . . . . . . . . . 5

DIE-CUT PATTERNS . . . . . . . . . . . . . . . . . . . . . . . . . 5, 6

BUILD THE TAIL SURFACES. . . . . . . . . . . . . . . . . . . . . 7

Build the Stabilizer and Elevator. . . . . . . . . . . . . . . . 7

Build the Fin and Rudder . . . . . . . . . . . . . . . . . . . . . 9

BUILD THE WING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Build the Wing Panels . . . . . . . . . . . . . . . . . . . . . . 10

Build the Aileron and Flaps . . . . . . . . . . . . . . . . . . 17

Aileron Installation . . . . . . . . . . . . . . . . . . . . . . . . . 19

Flap Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Join the Wing Halves. . . . . . . . . . . . . . . . . . . . . . . 20

BUILD THE FUSELAGE. . . . . . . . . . . . . . . . . . . . . . . . 22

Mount the Wing to the Fuselage. . . . . . . . . . . . . . . 30

Finish the Fuselage . . . . . . . . . . . . . . . . . . . . . . . . 31

Mount the Landing Gear . . . . . . . . . . . . . . . . . . . . 33

Mount the Engine. . . . . . . . . . . . . . . . . . . . . . . . . . 34

Install the Fuselage Components . . . . . . . . . . . . . . 36

Install the Fuel Tank. . . . . . . . . . . . . . . . . . . . . . . . 38

Finish the Radio Installation . . . . . . . . . . . . . . . . . . 39

Finish the Servo Installation . . . . . . . . . . . . . . . . . . 40

Assemble the Cowl . . . . . . . . . . . . . . . . . . . . . . . . 41

Assemble the Wheel Pants . . . . . . . . . . . . . . . . . . . 42

Install the Cowl . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Install the Wheel Pants. . . . . . . . . . . . . . . . . . . . . . 43

PREPARE THE MODEL FOR COVERING . . . . . . . . . . 44

BALANCE THE MODEL LATERALLY . . . . . . . . . . . . . 44

FINISH THE COCKPIT. . . . . . . . . . . . . . . . . . . . . . . . . 44

COVER THE MODEL WITH MONOKO TE®. . . . . . . . . . 44

Covering Sequence . . . . . . . . . . . . . . . . . . . . . . . . 44

Install the Stab and Fin . . . . . . . . . . . . . . . . . . . . . 45

PAINTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

JOIN THE CONTROL SURFACES . . . . . . . . . . . . . . . . 45

CANOPY INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 46

GET THE MODEL READY TO FLY. . . . . . . . . . . . . . . . 46

Check the Control Directions . . . . . . . . . . . . . . . . . 46

Set the Control Throws. . . . . . . . . . . . . . . . . . . . . . 47

Balance the Model (C.G.). . . . . . . . . . . . . . . . . . . . 47

PREFLIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Identify Your Model. . . . . . . . . . . . . . . . . . . . . . . . . 48

Charge the Batteries . . . . . . . . . . . . . . . . . . . . . . . 48

Balance Propellers . . . . . . . . . . . . . . . . . . . . . . . . . 48

Ground Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Range Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

ENGINE SAFETY PRECAUTIONS. . . . . . . . . . . . . . . . 49

AMA SAFETY CODE. . . . . . . . . . . . . . . . . . . . . . . . . . 49

CHECK LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

FLYING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Fuel Mixture Adjustments . . . . . . . . . . . . . . . . . . . . 50

Takeoff . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Flight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Landing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

2-VIEW DRAWING . . . . . . . . . . . . . . . . . . . . Back Cover

The RV-4 is a great flying semi-scale model that you will be
proud to take to the local flying field! This plane has great
ground handling characteristics, performs most aerobatic
maneuvers with ease and with the addition of the flap
option, crawls in very slowly on landing.Take your time and
enjoy the building process. You will be rewarded from the
very first flight!

1.Your RV-4 should not be considered as a toy, but rather a
sophisticated, working model that functions very much like a
full-size airplane.Because of its performance capabilities, the
RV-4, if not assembled and operated correctly, could possibly
cause injury to yourself or spectators and damage 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 properly install all R/C and other components so
that the model operates properly 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 already an experienced R/C pilot, you
should fly the model only with the help of a competent,
experienced R/C pilot.

PRO TECT YOUR MODEL,Y OURSELF

& OTHERS...FOLLOW THESE

IMPORTANT SAFETY PRECAUTIONS

INTRODUCTION

TABLE OF CONTENTS

2

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

Before starting to build,compare the parts in this kit with
the Parts List and note any missing parts. Also inspect
all parts to make sure they are of acceptable quality. 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], or e-mail us at
[e-mail]. If you are contacting
us for replacement parts, please be sure to provide the
full kit name RV-4 and the part numbers as listed in the
Parts List.

For the latest RV-4 updates, you can also check our web
site at www

.greatplanes.com.

If you 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 hobby shop has information
about clubs in your area whose membership includes
experienced pilots.

In addition to joining an R/C club, we strongly recommend y ou
join the AMA (Academy of Model Aeronautics). AMA
membership is required to fly at AMA sanctioned clubs.There
are over 2,500 AMA chartered clubs across the country.
Among other benefits, the AMA provides insurance to its
members who fly at sanctioned sites and events .Additionally,
training programs and instructors are available at AMA club
sites to help you get started the right way. 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

This is a list of items required to finish the RV-4 that must be
purchased separately. For some of these items there is more
than one option which will require a bit of decision making
ahead of time.Order numbers (in parentheses) are provided
for your convenience.

A quality five channel (if you do not plan on flaps you can use
a four channel radio) or greater radio system. Seven servos
with an output of at least 40 ounce-inches (five servos if you
omit the flap option).T wo - 12" servo e xtensions (HCAM2100)
for the ailerons, four - 6" servo extensions (HCAM2000) for
the flaps and receiver and two “Y”connectors (HCAM250) for
the flaps and ailerons.

There are several engines that will w ork well in the R V-4.Our
official engine size recommendation range is .40 to .52 two

-stroke or .52 to .70 four-stroke. Engines such as the O.S.

®

.40 FX (OSMG0540), O.S..46 FX (OSMG0546), O.S.FS-52
(OSMG0852), O.S. FS-70 (OSMG0870), Super Tigre

®

GS.40 (SUPG0125), GS .45 ABC (SUPG0150) and the
G-.51 (SUPG0154) are all excellent choices for the RV-4. If
you select an engine in the upper end of the size range,
remember that this is supposed to be a scale model that is
intended to fly at scale-like speeds, so prudent throttle
management should be practiced.

In addition to the items listed in the “Decisions You Must
Make” section, the following is a list of hardware and
accessories required to finish the RV-4.

❏ 2 - Wheels - 2-1/2" (GPMQ4223)
❏ 1" Tail wheel (GPMQ4241)
❏ Spinner - 2-1/4"
❏ Propellers - See engine manufacturer’s recommendation
❏ Fuel line - 3' [914mm] silicone (GPMQ4131)
❏ 10 oz. Fuel tank (GPMQ4104)

In addition to common household tools (screwdrivers, drill,
etc.), this is the “short list” of the most important items
required to build the RV-4.

We recommend Great Planes

Pro™CA and Epoxy glue.

Adhesives & Building Supplies

Hardware & Accessories

ADDITIONAL ITEMS REQUIRED

Engine Recommendations

Radio Equipment

DECISIONS YOU MUST MAKE

We, as the kit manufacturer, provide you with a top
quality 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.

3

4

❏ 1 oz.Thin Pro CA (GPMR6002)
❏ 4 oz. Medium Pro CA+ (GPMR6010)
❏ 6-Minute Epoxy (GPMR6045)
❏ 30-Minute Epoxy (GPMR6047)
❏ Hobby knife (HCAR0105)
❏ #11 blades (HCAR0211)
❏ Single-edge razor blades (HCAR0212)
❏ Small T-pins (HCAR5100)
❏ Builder's triangle (HCAR0480)
❏ Electric drill and 1/16" [1.6mm], 5/64" [2mm], 3/32"

[2.4mm], 1/8" [3mm], 9/64" [3.6mm], 5/32" [4mm],17/64"
[6.7mm] and 1/4" [6mm] drill bits

❏ Small Phillips and flat blade screwdrivers (HCAR1040)
❏ Wire cutter (HCAR0630)
❏ Great Planes Plan Protector (GPMR6167) or wax paper
❏ Sanding tools and sandpaper assortment (see Easy-

Touch™Bar Sander section)

❏ Sealing Iron (TOPR2100)
❏ Heat Gun (TOPR2000)
❏ Great Planes tap and drill set (GPMR8108)
❏ 2 - Rolls MonoKote®covering (See page 44)
❏ Trim sheets

Here is a list of optional tools and accessories mentioned in
the manual that will help you build the RV-4.

❏ Bisson Muffler (BISG4046)
❏ Pilot Figure (1/5th scale)
❏ Fuel Valv e (GPMQ4160)
❏ Great Planes CG Machine™(GPMR2400)
❏Top Flite Precision Magnetic Prop Balancer™(TOPQ5700)
❏ Top Flite Hot Sock™iron cover (TOPR2175)
❏ Straightedge with scale (HCAR0475)
❏ Cutting mat (HCAR0456)
❏ Masking Tape (TOPR8018)
❏ CA Debonder (GPMR6039)
❏ CA Applicator tips (GPMR6033)
❏ CA Accelerator (GPMR6034)
❏ R/C-56 Canopy Glue (JOZR5007)
❏ Epoxy Brushes (GPMR8060)
❏ Mixing Sticks (GPMR8055)
❏ Threadlocker (GPMR6060)
❏ Denatured Alcohol (for epoxy clean up)
❏ Felt-Tip Marker (TOPQ2510)
❏ Small metal file
❏ Rotary tool such as Dremel

®

❏ Rotary tool reinforced cut-off wheel (GPMR8200)
❏ Curved Tip Canopy Scissors for Trimming Plastic Par ts

(HCAR0667)

❏ Hook and Loop Material (GPMQ4480)
❏ Dead Center™Engine Mount Hole Locator (GPMR8130)
❏ Great Planes AccuThrow™Deflection Gauge (for

measuring control throws, GPMR2405)

❏ Great Planes Groove Tube™(GPMR8140)

A flat, durable, easy to handle sanding tool is a necessity
for building a well finished model. Great Planes makes a
complete range of Easy-Touch™Bar Sanders and
replaceable Easy-Touch Adhesive-backed Sandpaper.
While building the RV-4, 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)
33" Bar Sander (GPMR6174)
44" Bar Sander (GPMR6176)
11" Contour Multi-Sander (GPMR6190)

12' roll of Adhesive-backed 80-g rit sandpaper (GPMR6180)
150-grit (GPMR6183)
180-grit (GPMR6184)
220-grit (GPMR6185)
Assortment pack of 5-1/2" strips (GPMR6189)

We also use Top Flite®320-grit (TOPR8030, 4 sheets) and
400-grit (TOPR8032, 4 sheets) wet-or-dry sandpaper for
finish sanding.

There are two types of screws used in this kit:

Sheet metal screws are designated by a number and a
length. For example: #6 x 3/4"

This is a number six screw that is 3/4" long.

Machine screws are designated by a number, threads per
inch and a length. For example:4-40 x 3/4"

This is a number four screw that is 3/4" long

with forty threads per inch.

IMPORTANT BUILDING NOTES

Optional Supplies & Tools

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 necessar y for the best fit.

Whenever the term

glue

is written 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 the
instructions will make a recommendation.

Whenever just

epoxy

is specified you may use

either

30­minute (or 45-minute) epoxy or6-minute epoxy. When 30­minute epoxy is specified it is highlyrecommended that you
use only 30-minute (or 45-minute) epoxy, because you will
need the working time and/or the additional strength.

Photos and sketches are placed before the step they
refer to. Frequently you can study photos in following steps
to get another view of the same parts.

Not all die-cut parts have a name, or their complete name
stamped on them, so refer to the die drawings on page 5 and
6 for identification.When it's time to remove the parts from their
die sheets, if they are difficult to remov e, do not force them out.
Instead, use a sharp #11 blade to carefully cut the part from the
sheet, then lightly sand the edges to remove any slivers or
irregularities. Save some of the larger leftover pieces of wood.

Fuse = Fuselage

LE = Leading Edge (front)

TE = Trailing Edge (rear)

Stab = Stabilizer

" = Inches

Elev = Elevator

LG = Landing Gear

Ply = Plywood

Balsa Basswood Plywood

Types of Wood

Common Abbreviations

5

Metric Conversions

1/64" = .4 mm
1/32" = .8 mm
1/16" = 1.6 mm
3/32" = 2.4 mm

1/8" = 3.2 mm
5/32" = 4.0 mm
3/16" = 4.8 mm

1/4" = 6.4 mm
3/8" = 9.5 mm
1/2" = 12.7 mm
5/8" = 15.9 mm
3/4" = 19.0 mm

1" = 25.4 mm
2" = 50.8 mm
3" = 76.2 mm

6" = 152.4 mm
12" = 304.8 mm
18" = 457.2 mm
21" = 533.4 mm
24" = 609.6 mm
30" = 762.0 mm
36" = 914.4 mm

DIE-CUT PATTERNS

6

DIE-CUT PATTERNS

❏ 1. Unroll the plan sheets. Roll them inside out so they will
lie flat.

❏ 2. Position the wing plan so the stab plan is over your flat
building board. Cover the plan with Great Planes Plan
Protector or wax paper so glue will not adhere.

❏ 3. Locate the two die-cut 1/8" [3mm] balsa stab braces
(SBR) and two die-cut 1/8" [3mm] balsa stab centers (SC).

Glue the parts together to form the 1/4" [6mm] balsa stab
brace and the 1/4" [6mm] stab center.

❏ 4. Pin the balsa stab brace (SBR) over the plans.Glue the
stab center (SC) to the balsa stab brace (SBR).

❏ 5. Locate the 1/4" x 1/2" x 30" [6 x 13 x 750mm] balsa
sticks.Cut them to size as shown on the plan to form the stab

outer structure. Pin them to the building board over the
plans. Glue them together forming the stab outer structure.

❏ 6. Locate the 1/4" x 1/4" x 30" [6 x 6 x 750mm] balsa
sticks. Cut them to size as shown on the plan. Then glue
them in place to form the stab inner structure.

❏ 7. Cut the 1/4" x 1/2" x 30" [6 x 13 x 750mm] balsa sticks
to size as shown on the plan. Then glue them in place to
form the elevator outer structure.

❏ 8. Locate four die-cut 1/8" [3mm] balsa elevator roots (ER).
Glue them together to form two 1/4" [6mm] elev ator roots.Glue
one in place in each elevator half as shown on the plan.

Build the Stab & Elevator

BUILD THE T AIL SURF ACES

7

❏ 9. Cut the 1/4" x 1/4" x 30" [6 x 6 x 750mm] balsa sticks
to size as shown on the plan. Then glue them in place to
form the elevator inner structure.

❏ 10. Remove the parts from the plan. Sand the control
surfaces smooth and shape the L.E.of the stab and the T.E.
of the two elevator halves to match the cross section shown
on the plan.

Do not shape the L.E.of the two elevator halves .

❏ 11. Locate the center of the T.E. of the stab. Place a T-pin
on the center at each end of the stab. Lay a straight edge
against the pins and draw a center line on the T.E of the
stab.Repeat this procedure for each elevator half.

❏ 12. Using the plans as your reference, mark the location
for the hinges on the T.E.of the stab and the L.E. of the two
elevator halves.

❏ 13. Cut the hinge slot in the stab and elevator using a #11
blade inserted in your hobby knife .Begin by carefully cutting a
very shallow slit at the hinge location to accurately establish the
hinge slot. Make three or four more cuts, going a little deeper
each time.As you cut, slide the knife from side to side until the
slot has reached the proper depth and width for the hinge.

❏14.Drill a 3/32" [2.4mm] hole 1/2" [13mm] deep in the center
of the hinge slot. This will help the glue to better saturate the
hinge and the wood when the hinges are installed.

If you are like most modelers, cutting slots for the hinges is
time consuming and tedious. A really great time saver and
accurate tool to make this job very simple is the Great Planes
Slot Machine. This tool is available in a corded 110V AC.
(GPMR4010) as well as a cordless version (GPMR4011).
With this tool you can cut hinge slots in a matter of seconds.

1.After marking the location for the hinge, place the edge of
the cutting blade on the mark and use a little pressure to set
the teeth into the wood.

2.Squeeze the trigger on the Slot Machine and the teeth will
cut a perfectly sized width and depth for today’s CA type
hinges. Optional blades (GPMR4016) are available to cut
slots for the nylon type hinges as well.

8

DRILL A 3/32" HOLE

1/2" DEEP, IN CENTER

OF HINGE SLOT

CUT HINGE SLOT
WITH HOBBY KNIFE
AND #11 BLADE

❏ 15. Bevel the L.E.of the elevator halves as shown on the
plan cross section.

❏ 16. Trial fit the stab, hinges and elevator halves together.

Important: Do not glue the hinges in place. This will be
done after the model has been covered.

❏ 1. Locate the two die-cut 1/8" [3mm] balsa fin tops (FT).
Glue them together forming the 1/4" [6mm] balsa fin top.

❏ 2. Pin the fin top over the plan.Assemble the fin using the
1/4" x 1/2" x 30" [6 x 13 x 750mm] balsa sticks, cuttting them
to size as shown on the plan.

❏ 3. Cut the 1/4" x 1/4" x 30" [6 x 6 x 750mm] balsa sticks
to size as shown on the plan. Then glue them in place to
form the fin inner structure.

❏ 4. Locate the two die-cut 1/8" balsa rudder bases (RB).
Glue them together forming the 1/4" balsa rudder base.

❏ 5.Pin the rudder base over the plan.Construct the rudder
outer structure using the 1/4" x 1/2" x 30" [6 x 13 x 750mm]

balsa sticks. Cut them to size as shown on the plan Then
glue them in place.

❏ 6.Cut the 1/4" x 1/4" x 30" [6 x 6 x 750mm] balsa sticks to
size as shown on the plan to form the rudder inner structure.

❏ 7. Remove the parts from the plan. Sand the control
surfaces smooth and shape the L.E. of the fin and the T.E.
of the rudder to match the cross section shown on the plan.

Do not shape the L.E. of the rudder.

❏ 8. Locate a center line on the T.E. of the fin. Follow the
same procedure used for doing this on the stab and elev ator.

❏ 9. Using the plans as your reference, mark the location for
the hinges on the T.E.of the fin and the L.E. of the rudder.

❏ 10.Cut the hinge slots using the same procedure used for
the stab and elevator.

❏ 11. Bevel the L.E. of the rudder as shown on the plan
cross section.

❏ 12. Trial fit the fin, hinges and rudder halves together.

Important: Do not glue the hinges in place. This will be
done after the model has been covered.

Build the Fin & Rudder

9

❏ 13. Remove the rudder from the fin. Measure up from the
bottom of the rudder 1" [25mm] and make a mark on the
leading edge of the rudder.

❏ 14. On the mark drill a 1/8" [3mm] hole 3/4" [19mm] deep
into the leading edge of the rudder. From the bottom of the
rudder up to the hole you have drilled, cut a groove 1/8"
[3mm] wide. Hint: A perfect tool for this is the Great Planes
Groove Tube (GPMR8140).

❏ 15. Locate the tailwheel wire assembly. Trial fit it into the
hole and slot. When you are satisfied with the fit, mark the
location for the nylon bushing on the fin.Cut a slot in the fin
to accept the bushing. Trial fit the rudder with the tailwheel
wire into the fin. Do not glue the nylon bushing in place.

This will be done after the model has been covered.

❏ 1. Unroll the plan sheets. Roll them inside out so they will
lie flat.

❏ 2. Locate the left wing panel on the plan.You may find it
helpful to cut the plans in half, making them a more
manageable size to pin to your building board.

❏ 3. Position the left wing plan flat on the building board.
Cover the plan with Great Planes Plan Protector or wax
paper so glue will not adhere to it.

❏❏4. Locate the die-cut 1/8" [3mm] balsa wing shear web
(WSW), three die-cut 3/32" [2.4mm] balsa W2 ribs, five die-cut
3/32" balsa W3 ribs and one die-cut 3/32" [2.4mm] W1 rib.

Note: In the following steps it is important to pay careful

attention to assemble the parts exactly as instructed.Failure
to do so will result in a wing that is not straight.

❏❏5.Locate the die-cut 1/8" [3mm] balsa wing shear web
(WSW). Insert the end of WSW into one of the W3 ribs.

Build the Wing Panels

BUILD THE WING

10

Position the rib over the third set of notches and then twist
it into the notch.Do not

glue them to each other at this time.

❏❏6. Using your plan as your guide, install the remaining
W3 ribs into the proper notches. Do not

glue them in place

at this time.

❏❏7. Install two W2 ribs at the location shown on the plan.
Do not

glue them at this time.

❏❏8. Locate two 1/8" x 1/4" x 30" [3 x 6 x 762mm]
basswood wing spars. Cut them to a length of 26-1/4"
[667mm]. Place one of the spars at the location shown on
the plan. With all of the ribs now positioned on the wing
shear web (WSW), place WSW and the ribs onto the
basswood wing spar. Then place the top wing spar into the
notches. Do not glue the assembly together at this time.

❏❏9. Locate the die-cut 1/8" [3mm] balsa wing trailing
edge (WTE). Insert it into the notches at the trailing edge of

each of the ribs. Be sure that the tab end of WTE is at the
wingtip.Do not

glue them in place at this time.

❏❏10.Position the remaining W2 rib at the wingtip and the
W1 rib at the wing root. Note: Refer to the wing root detail
cross-section for proper orientation of the W1 rib. When you
are satisfied with the fit of all of the wing components, glue
them together with thin CA.

❏❏11. Locate the 5/8" x 1/4" x 24" [15.9 x 6 x 457mm]
balsa stick. Cut a piece to fit between the two W2 ribs.This
will be the forward balsa wing tip.Glue it in place.

❏❏12.Locate the 1/16" x 1/2" x 30" [1.6 x 13 x 762mm] balsa
sub leading edge. Use a butt joint at rib W1 and then glue it
in place on the front of each of the ribs.After gluing it in place,
lightly sand the top and bottom of the sub leading edge with a
sanding bar making sure it matches the shape of the ribs.

11

❏❏13.Locate a 3/32" x 4" x 30" [2.4 x 102 x 762mm] balsa
sheet. Cut a notch on the end of the sheet 7/8" [22.2mm]
from the L.E. and 1/8" wide.

❏❏14.Glue the 3/32" x 4" x 30" [2.4 x 102 x 762mm] balsa
sheet in place on the top of the wing. Align the sheet with
the trailing edge and on top of the wing spar when gluing it
to the wing.

❏❏15. Glue the 3/32" x 5/8" x 30" [2.4 x 15.9 x 762mm]
balsa wing trailing edge sheet in place. Now would be a
good time to add some thin CA to all joints to be sure that
everything is glued together well.

❏❏16.T urn the wing over and sheet the bottom of the wing
the same way you did the top of the wing.NOTE:You do not
need to cut the notch in the 3/32" x 4" x 30" [2.4 x 102 x
762mm] balsa sheet as you did for the top of the wing.

❏❏17.Glue the 3/32" x 5/8" x 30" [2.4 x 15.9 x 762mm] balsa
wing trailing edge sheet in place on the bottom of the wing.

❏❏18. Locate the 3/32" x 5/16" x 24" [2.4 x 7.9 x 610mm]
balsa cap strips. Cut the cap strips to fit between the
forward sheeting and the trailing edge sheeting. Use the
plan as your guide to identify the ribs that should be cap
stripped. Cap strip both the top and the bottom of the wing.

❏❏19. Sheet the bottom of the wing between the outboard
W2 ribs from leftover 3/32" x 4" x 30" [2.4 x 102 x 762mm]
balsa sheet. Extend the sheeting 3/4" [19mm] beyond the
end of the ribs.

❏❏20.After the sheeting is glued in place make a line across
the sheet, 1/2" [13mm] from the trailing edge of the W2 ribs.

❏❏21. Using a sanding bar, bevel the end of the balsa
sheeting to match the wing rib. Sand from the end of the
sheeting up to the line you drew.

12

❏❏22.Sheet the top of the wing between the outboard W2 ribs
from leftover 3/32" x 4" x 30" [2.4 x 102 x 762mm] balsa sheet.

❏❏23. Locate the 5/8" x 1-3/4" x 7" [15.9 x 44 x 178mm]
balsa block.Cut it into two 3-1/2" [89mm] long pieces.

❏❏24. Fit one of the balsa blocks between rib W1 and W2
at the trailing edge of the rib.

❏❏25. On the block make a mark 1/8" [3mm] from the
end. Draw a line from that mark to the corner as shown in
the photograph.

❏❏26. Sand the end of the block to the line you just made.

❏❏27. From the end of the block where you sanded the

taper into the block, measure forward 3/4" [19mm] from the
leading edge and draw a line across the block.

❏❏28.Locate the die-cut 1/8" plywood WBS. On each end
measure in 1/8" [3mm] and draw a line across WBS.

❏❏29. From the line out to the edge, sand the plywood to
a thickness of 3/32" [2.4mm].

13

❏❏30. Glue WBS to the balsa block between the end of the
block and the line you have made on the balsa block. Position
WBS so that it extends equally ov er each end of the balsa block.

❏❏31. Trial fit WBS and the balsa block in place between
the W2 ribs at the inboard of the wing.Using a leftover piece
of 3/32" [2.4mm] sheet, lay it in place across the W2 ribs
and the balsa block. Check to be sure the sheeting and
WBS match in thickness. If WBS is slightly high, sand a bit
more from the sheeting as indicated in step 29. Note: Make
sure you work from the bottom of the wing.

❏❏32. One you are satisfied with the fit of the balsa block
and WBS, glue it in place between the W1 and W2 r ibs.

❏❏33.When the balsa block is glued in place you will see
that the block extends well beyond the W2 r ib. Use a razor
plane to shape the block to match the shape of the W2 r ib.
If you do not have a hob by r azor plane y ou can cut this bloc k
down with a long bladed knife or a sanding block. Hint: If
you do not currently own a hobby plane it really is one of the
most worthwhile tools you can own. It is wor th a trip to the
hobby shop to purchase one.

❏❏34. Sheet the top of the wing between W1 and W2.
Sheet the area from the wing trailing edge (WTE) to 1"
[25mm] beyond the end of the ribs.

14

❏❏35. Turn the wing over on the bench so that you are
looking at the bottom of the wing. From the end of each of
the ribs measure back 1/2" [13mm] and draw a line across
the sheeting. Cut the sheeting on this line.

❏❏36. Using a sanding bar, bevel the sheeting to match
the ribs.

❏❏37. From leftover 3/32" [2.4mm] balsa sheeting, apply
balsa onto the upper wing skin from the root of the wing up
to WBS.When applying the balsa sheet it must be installed
cross grain. This will provide much more strength to the
trailing edge of the wing.

❏❏38. Sheet the area between WTE and WBS, gluing
3/32" [2.4mm] balsa sheet to the balsa block.

❏❏39. Locate the 5/8" x 1/4" x 18" [15.9 x 6 x 457mm]
balsa stick that is used for the CA hinge blocks. From the
18" stick cut six blocks 1-1/2" [38mm] long.Glue each of the
blocks in place inside the wing on the backside of the wing
trailing edge. Refer to your plan for the proper placement of
each of the blocks.

❏❏40. Locate the 1/4" x 3/4" x 30" [6 x 19 x 762mm] balsa
leading edge. On one end make a line 1/8" [3mm] from the
end, extending 3/8" [9mm] from the edge of the leading
edge. Cut this area away.

15

❏❏41. Fit the leading edge in place on the balsa sub
leading edge.The notch you just cut from the leading edge
should fit around the tab extending from W1. Once you are
satisfied with the fit, glue the leading edge to the balsa sub
leading edge on the front of the wing.

❏❏42. Trim the ends of the leading edge to be flush with
the ends of the wing.

❏❏43. Locate the left ABS plastic wing tip. Trim it on the
cut lines.When cutting the trailing edge of the wig tip there
is a cut between the top and bottom of the wingtip.

❏❏44. Locate rib W5 and insert it into the plastic wing tip.
Position the rib to be flush with the end of the wing tip then
glue it in place with thin CA.At the trailing edge of the plastic
wing tip, the top and bottom of the plastic wing tip will need
to be glued together with thin CA.

❏❏45. Place the wing tip onto the end of the wing. The
notches in W5 should fit onto the wing spars that are
extending from the wing. Important: You now need to make
a decision on how you wish to do the final installation of the
wing tip.Y ou can permanently glue the wing tip in place on the
end of the wing or you can tack glue it in place by applying a
drop of CA to a few spots on the wing tip and the wing.If you
choose to tack glue the wing tip in place it can be removed,
making it easier to apply your covering. This will also allow
you to paint the wing tip without it being attached to the wing.
After the covering is applied and the wing tip is painted, you
can permanently glue the wing tip in position. Either way will
work.The choice is left to your personal preference.

❏❏46. Sand the leading edge of the wing to shape as
shown on the wing cross section of your plan.Sand the wing
top and bottom to match the ABS wing tip.

16