Great Planes GPMA0390 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 an y 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.

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

USB4P03 for GPMA0390 V:1.0 Printed in USA Entire Contents © Copyright 2002

1610 Interstate Drive Champaign, IL 61822

[phone], Ext. 2

[e-mail]

INSTRUCTION MANUAL

Wingspan: 58-1/2 in [1485mm]
Wing Area: 595 sq in [38.4 dm2]
Weight: 5.3-5.7 lbs [2400 – 2600g]
Wing Loading: 20.5-22.3 oz/sq ft [62.5 – 67.7 g/dm

2

]

Length: 46 in [1170mm]
Radio: 4-Channel with 5 ser vos

Engine: .40 to .52 cu in [6.5 – 8.5cc] two-stroke, .52 to

.70 cu in [8.5 – 11.5cc] four-stroke

™

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

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

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

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

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

Landing Gear Configurations.................................................3

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

Hardware & Accessories.......................................................4

Adhesives & Building Supplies ..............................................4

Optional Supplies & Tools......................................................4

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

COMMON ABBREVIATIONS.......................................................6

TYPES OF WOOD........................................................................6

METRIC CONVERSIONS ............................................................6

METRIC/INCH RULER .................................................................6

DIE PATTERNS .....................................................................7 & 8

RETRACT WIRE TEMPLATE.......................................................8

BUILDING INSTRUCTIONS.........................................................9

BUILD THE T AIL SURFACES......................................................9

Build the Stab & Elevator ......................................................9

Build the Fin & Rudder........................................................11

BUILD THE WING ......................................................................13

Build the Wing Panels .........................................................13

Join the Wings.....................................................................23

BUILD THE FUSELA GE ............................................................24

RADIO AND ENGINE INSTALLATION......................................34

Radio Installation.................................................................34

Engine Installation...............................................................36

MOUNT THE WING TO THE FUSELA GE..................................38

INSTALL THE LANDING GEAR................................................41

ASSEMBLE THE CO WL............................................................45

COVER THE MODEL WITH MONOKOTE

®

................................46

Covering Sequence.............................................................47

INSTALL THE STAB & FIN........................................................47

PAINTING...................................................................................47

JOIN THE CONTROL SURFACES ............................................48

FINISHING THE MODEL ...........................................................48

Apply the Decals .................................................................48

Finish the Cockpit................................................................49

Finish the Radio Installation................................................49

GET THE MODEL READY TO FLY............................................49

Check the Control Directions...............................................49

Set the Control Throws........................................................50

Balance the Model (C.G.) ....................................................50

Balance the Model Laterally................................................51

PREFLIGHT ...............................................................................51

Identify Your Model ..............................................................51

Charge the Batteries ...........................................................51

Balance the Propellers ........................................................52

Ground Check .....................................................................52

Range Check .......................................................................52

ENGINE SAFETY PRECAUTIONS............................................52

AMA SAFETY CODE (excerpt).................................................53

CHECK LIST..............................................................................53

FLYING.......................................................................................53

Fuel Mixture Adjustments....................................................54

Takeoff.................................................................................54

Flight....................................................................................54

Landing................................................................................54

FIXED T AILDRAGGER TEMPLATE...........................................57

FIXED TRIKE TEMPLA TE..........................................................57

ENGINE MOUNT TEMPLATE....................................................57

RETRACT TEMPLA TE...............................................................59

TWO VIEW DRAWING......................................Back Cover Page

FUSE & WING PLANS..........................Center Pull-Out Section

The Great Planes Ultra Sport 40 Plus™is a kit designed to
appeal to a wide range of modelers. The starting point for
the design of this new airplane was the original Ultra Sport
kit which was legendary.The new Great Planes Ultra Sport
40 Plus can be flown low and fast or it can be used for wild
aerobatics, including 3D type flying.The Great Planes Ultra
Sport 40 Plus tracks straight no matter what flying attitude
the pilot tries to hold. This is a fly-where-you-point airplane.
The Great Planes Ultra Sport 40 Plus has an extremely
wide CG range to allow for fast and easy flying with a
forward CG or wild aerobatics with an aft CG. The new
airplane has also been designed to have no roll or pitch
coupling at an aft CG.An engine within the higher end of the
recommended engine range will provide unlimited vertical
while the 3D throws will make hovering maneuvers easy.
The Great Planes Ultra Sport 40 Plus is a great sport
airplane that will do anything the pilot asks.

For the latest technical updates or manual corrections to the
Great Planes Ultra Sport 40 Plus visit the web site listed
below and select the Great Planes Ultra Sport 40 Plus. If
there is new technical information or changes to this kit a
“tech notice” box will appear in the upper left corner of
the page.

http://www.greatplanes.com/airplanes/index.html

1. Your Great Planes Ultra Sport 40 Plus 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 Great Planes Ultra Sport 40
Plus, 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.

PRO TECT YOUR MODEL,Y OURSELF

& OTHERS...FOLLOW THESE

IMPORTANT SAFETY PRECAUTIONS

INTRODUCTIONTABLE OF CONTENTS

2

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.

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, the modeler is responsible for taking steps
to reinforce the high stress points.

Remember: Take your time and follow 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 (Great Planes Ultra Sport 40 Plus) and the
part numbers as listed in the Parts List.

You can also check our web site at

www.greatplanes.com

for the latest Great Planes Ultra Sport 40 Plus updates.

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
you 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:

The Great Planes Ultra Sport 40 Plus can use either a 4
channel radio with 5 servos (and Y harness for the ailerons)
or a computer radio. While the 4 channel non-computer
radio will provide more than enough performance to fly the
airplane, a computer radio will help the pilot to extract all
possible performance out of the airplane, and that is why it
is recommended. Five standard servos are all that is
necessary to fly the Great Planes Ultra Sport 40 Plus.

The recommended engine size range for the Great Planes
Ultra Sport 40 Plus is a .40 to .52 cu in [6.5 – 8.5cc] two­stroke, or .52 to .70 cu in [8.5 – 11.5cc] four-stroke. If an
engine in the upper end of the size range is used, throttle
management must be practiced. While all engines in the
recommended range provide good performance, a 2-stroke
engine is more suitable for high speed flying and a 4-stroke
engine is better for constant speed aerobatics. Make sure
you pick an engine adequate to your flying style.

The Ultra Sport 40 Plus has been designed around three
different landing gear configurations. Your must choose
which one you want to use before you begin construction of
the kit.These are the three options:

Fixed Tricycle: Probably the configuration that makes
ground handling easier.It is also the least aerodynamic.

Fixed Mains and Tail Wheel: This is the simplest and
lightest possible landing gear configuration. It is also more
aerodynamic than the Fixed Tricycle.Ground handling is not
as easy as with the Fixed Tricycle, especially on take off

Landing Gear Configurations

Engine Recommendations

Radio Equipment

DECISIONS YOU MUST MAKE

Academy of Model Aeronautics

5151 East Memorial Drive

Muncie, IN 47302

Tele: [phone]

Fax [phone]

Or via the Internet at:

http://www.modelaircraft.org

We, as the kit manuf acturer, 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

where the engine torque tends to steer the airplane to
the left.

Retractable Mains/Fixed Tail Wheel: This is the heaviest
and most complex of the three configurations. It is also the
most aerodynamic and the “coolest” by far.

Throughout the manual there are steps named as above
which pertain only to that landing gear configuration. Decide
which landing configuration you want to use and cross out
all steps that are for other landing gear configurations.

Following is the list of hardware and accessories required to
finish the Great Planes Ultra Sport 40 Plus. Order numbers
are provided in parentheses.

❏ Spinner – 2-1/4" (GPMQ4515)
❏ Propellers – see engine manufacturer’s

recommendation

❏ Fuel line – 3' [914mm] silicone (GPMQ4131)
❏ 10 oz. Fuel tank (GPMA4104)

If you are using a computer radio you will also need:

❏ (2) 6" Servo extensions (HCAM2700)

If you are using a non-computer radio you will also

need:

❏ (1) “Y” harness (HCAM2751)
❏ (1) 6" Servo extension (HCAM2700)

If you are building a Fixed Mains and Tail Wheel Landing
Gear Configuration you will also need:

❏ (2) 2-1/2" Main wheels (GPMQ4223)
❏ (1) 1" Tail wheel (GPMQ4241)
❏ (4) 5/32" Wheel collars (GPMQ4306)
❏ (1) 3/32" Wheel collars (GPMQ4302)

If you are building a Fixed Tricycle Landing Gear
Configuration you will also need:

❏ (2) 2-1/2" Main wheels (GPMQ4223)
❏ (1) 2-1/4" Nose wheel (GPMQ4222)
❏ (5) 5/32" Wheel collars (GPMQ4306)

If you are building a Retractable Mains/Fixed Tail Wheel
Landing Gear Configuration you will also need:

❏ (2) 2-1/2" Main wheels (GPMQ4223)
❏ (1) 1" Tail wheel (GPMQ4241)
❏ (2) Great Planes .40-size retractable landing gear

(GPMQ2905)

❏ (4) 5/32" Wheel collars (GPMQ4306)
❏ (1) 3/32" Wheel collar (GPMQ4302)
❏ (4) Screw-Lock pushrod connectors (GPMQ3870)

In addition to common household tools (screw drivers, drill,
etc.), this is the “short list” of the most important items
required to build the Great Planes Ultra Sport 40 Plus.

We

recommend Great Planes Pro™CA and Epoxy glue.

❏ 1/2 oz.Thin Pro CA (GPMR6001)
❏ 1 oz. Medium Pro CA+ (GPMR6008)
❏ 6-Minute epoxy (GPMR6045)
❏ Latex foam rubber (HCAQ1000)
❏ 30-Minute epoxy (GPMR6047)
❏ Hobby knife (HCAR0105)
❏ R/C-56 canopy glue (JOZR5007)
❏ Microballoons (TOPR1090)
❏ #11 Blades (HCAR0211)
❏ Single-edge razor blades (HCAR0212)
❏ Denatured alcohol (for epoxy clean up)
❏ Small T-pins (HCAR5100)
❏ Builder’s triangle (HCAR0480)
❏ Electric drill and 1/16" [1.6mm] [1.6mm], 5/64" [2mm],

3/32" [2.4mm] [2.4mm], 1/8" [3.2mm] [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)
❏ Pliers with wire cutter (HCAR0630)
❏ Great Planes Plan Protector

™

(GPMR6167) or waxed

paper

❏ Sanding tools and sandpaper assortment (see

“Expert

Tip-Easy-Touch™Bar Sander”

on page 5)

❏ Great Planes tap and drill set (GPMR8108)
❏ Great Planes 1/4-20 tap and drill set (GPMR8105)
❏ Great Planes Pro Threadlocker

™

(GPMR6060)

Here is a list of optional tools mentioned in the manual that
will help you build the Great Planes Ultra Sport 40 Plus.

❏ Great Planes CG Machine

™

(GPMR2400)

❏ T op 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)
❏ Milled Fiberglass (GPMR6165)
❏ Epoxy Brushes (GPMR8060)
❏ Mixing Sticks (GPMR8055)
❏ Builder’s Triangle Set (for fin alignment, HCAR0480)
❏ Felt-Tip marker (TOPQ2510)
❏ Small metal file
❏ Rotary tool such as Dremel

®

Moto-Tool

®

❏ Rotary tool reinforced cut-off wheel (GPMR8020)
❏ Sealing iron (TOPR2100)

Optional Supplies & Tools

Adhesives & Building Supplies

Hardware & Accessories

ADDITIONAL ITEMS REQUIRED

4

❏ Great Planes Slot Machine

™

(GPMR4010)

❏ Great Planes Hinge Marking Tool

™

(GPMR4005)

❏ Covering sock (TOPR2175)
❏ Curved-Tip canopy scissors for trimming plastic parts

(HCAR0667)

❏ Hook and loop material (GPMQ4480)
❏ Dead Center

™

engine mount hole locator (GPMR8130)

❏ Great Planes Accu-Throw

™

Deflection Gauge (for

measuring control throws, GPMR2405)

❏ Great Planes Groove Tube

™

(GPMR8140)

❏ Great Planes Pro Wood Glue (GPMR6160)

• 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.SHCS is just an abbreviation f or “sock et

head

cap screw” and that is a machine screw with a socket head.

For example 4-40 x 3/4".

This is a number four screw that is 3/4" long with forty
threads per inch.

• 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

30-minute (or 45-minute) epoxy or6-minute epoxy. When
30-minute epoxy is specified it is highly recommended 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 number, or their complete

name stamped on them, so refer to the die patterns on
pages 7 and 8 for identification. When it’s time to remove

There are many places in this manual where we tell you
to reinforce holes made into wood with thin CA. It is
important to do this properly to ensure the strongest
possible grip of the screw into the wood. The proper
procedure is to drill the specified pilot hole first, then run
the screw in, remove it, wick thin CA into the hole, allow
the CA to cure and reinstall the screw.

IMPORTANT BUILDING NOTES

EASY-TOUCH BAR SANDER

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 Great Planes Ultra Sport 40 Plus, two
5-1/2" [140mm] Bar Sanders and two 11" [280mm] Bar
Sanders equipped with 80-grit and 150-grit Adhesive­backed Sandpaper were used.

Here’s the complete list of Easy-Touch Bar Sanders and
Adhesive Backed Sandpaper:

5-1/2" [140mm] Bar Sander (GPMR6169)
11" [280mm] Bar Sander (GPMR6170)
22" [560mm] Bar Sander (GPMR6172)
33" [840mm] Bar Sander (GPMR6174)
44" [1120mm] Bar Sander (GPMR6176)
11" [280mm] Contour Multi-Sander (GPMR6190)

12' [3.66m] roll of Adhesive-backed 80-grit sandpaper
(GPMR6180)
150-grit (GPMR6183)
180-grit (GPMR6184)
220-grit (GPMR6185)
Assortment pack of 5-1/2" [140mm] 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.

5

the parts from their die sheets, if they are difficult to remove,
do not force them out. Instead, use a shar p #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 scraps of wood.

Fuse = Fuselage

Stab = Horizontal Stabilizer

Fin = Ver tical Fin

LE = Leading Edge

TE = Trailing Edge
LG = Landing Gear
Ply = Plywood

" = Inches

mm = Millimeters

SHCS = Socket Head Cap Screw

TYPES OF WOOD

COMMON ABBREVIATIONS

6

0" 1" 2" 3" 4" 5" 6" 7"

0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180

Inch Scale

Metric Scale

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

METRIC CONVERSIONS

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

7

DIE PATTERNS

8

DIE PATTERNS

RETRACT WIRE TEMPLATE

9

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

lie flat.

❏ 2. Position the wing so that the stab and elevator plan is

over your flat building board. Cover the plan with Great
Planes Plan Protector or waxed paper so glue will not

adhere.

❏ 3. Locate the die-cut 1/8" [3.2mm] stab center (SC). Pin

the stab center in its position over the plans.Locate one 1/8"
x 1/2" x 30" [3.2mm x 13mm x 760mm] balsa stick. Cut it to
size as shown on the plan to form the leading edge of the
stab.Glue it in place with medium CA.

❏ 4. Cut 1/8" x 1/2" x 30" [3.2mm x 13mm x 760mm] balsa

sticks to size as needed to form the stab outer structure.
Glue them in place with medium CA.

❏5. Locate the 1/8" x 1/4" x 30" [3.2mm x 6.4mm x 760mm]

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

glue them in place with medium CA to form the stab inner
structure.

❏6. Locate the 1/8" x 1/8" x 30" [3.2mm x 3.2mm x 760mm]

balsa sticks. Cut them to size as shown on the plans to
complete the stab’s inner structure.Glue them in place with
thin CA. Remove the stab from the plans and lightly sand
the top and bottom surfaces of the stab smooth.

❏ 7. Cut 1/8" x 1/2" x 30" [3.2mm x 13mm x 760mm] balsa

sticks to size to form the elevator outer structure. Use
medium CA to glue the sticks in place.

❏ 8. Locate the two die-cut elevator roots (ER). Glue one

in place in each elevator half as shown on the plan.

❏ 9. Cut the 1/8" x 1/4" x 30" [3.2mm x 6.4mm x 760mm]

balsa stick to size to form the elevator inner structure. Also,
cut the 1/8" x 1/8" x 30" [3.2mm x 3.2mm x 760mm] balsa
stick to size to complete the elevator inner structure. Use
thin CA to glue the sticks in place.

❏ 10. Remove the control surfaces from the plan and sand

them smooth. Locate four 1/16" x 3" x 36" [1.6mm x 76mm
x 914mm] balsa sheets. Mark and cut each sheet 19"
[480mm] from one end.

Build the Stab & Elevator

BUILD THE T AIL SURF A CES

BUILDING INSTRUCTIONS

❏ 11. Join two 19" [480mm] sheets together. Tape them

together with masking tape, then flip the sheets over and
glue the other side with thin CA. Let dry, remove the
masking tape and lightly sand the joint.Do this twice so that
you have one sheet for each side of the stab.

❏ 12. Sheet the top and bottom of the stab by applying

slow-curing glue such as 30-minute epoxy or wood glue to
the top and bottom of the stab structure and then placing the
structure between the 1/16" [1.6mm] sheets you just joined.
Use weights to apply pressure on the sandwich. Make sure
the stab is placed on a flat surface while the glue cures.
Sheet the top and bottom of the elevators following the
same procedure using the leftover 1/16" [1.6mm] sheets.
Again, make sure the elevators are placed on a flat surface
while the glue cures.If you wish to do so, you can round the
tip of the elevators.

❏ 13. Sand the edges of the stab and the elevators square

using a bar sander. Mate the stabilizer and elevators to
check the fit. Shape the leading edge of the stab and the
leading edge of the elevator counter balance to obtain the
shape shown in the plan’s cross section. Do not shape the
leading edge of the elevators yet.

❏ 14. Locate the center of the trailing edge 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 centerline on the
trailing edge of the stab. Repeat this procedure for the
leading edge of the two elevators. A great tool for marking
the center of the trailing edge is the Great Planes Precision
Hinge Marking Tool (GPMR4005).

❏ 15. 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.

❏ 16. Cut the hinge slots in the stab and elevators 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 of 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.

10

❏ 17. Cut six 3/4" x 1" [19mm x 25mm] hinges from the CA

hinge strip. Snip off the cor ners so they go in easier.

❏ 18. 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.

❏ 19. Bevel the L.E. of the elevator halves as shown on the

plan cross section.

❏ 20. Test 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.

❏ 21. Drill 1/16" [1.6mm] the holes for the control horns on

both elevators as indicated on the ele v ators plan.Wick some
thin CA into the holes.

❏1.Unroll the wing plan.Pin the die-cut 1/8" [3.2mm] balsa

fin base (FB) onto the plan and build the fin outer structure

Build the Fin & Rudder

To cut the hinge slot, place the blades onto the wood
where you want the slot. Lightly press the teeth into the
wood.When you are satisfied with the location, press the
button on the handle and the blades will cut easily into the
balsa wood.

We have simplified the task of cutting hinge slots with the
introduction of the Great Planes Slot Machine™. This
simple electric tool cuts a perfect width slot for use with
CA hinges.

1" [25mm]

11

3/4" [19mm]

Trim the Corners

around it using the 1/8" x 1/2" x 30" [3.2mm x 13mm x
760mm] balsa sticks.Cut them to size as shown on the plan.

❏2.Finish the inner structure of the fin using the 1/8" x 1/4"

x 30" [3.2mm x 6.4mm x 760mm] balsa sticks and the 1/8"
x 1/8" x 30" [3.2mm x 3.2mm x 760mm] balsa sticks.

❏3.Locate the die-cut 1/8" [3.2mm] rudder base (RB) and

pin it onto the plan. Construct the rudder outer structure
using the 1/8" x 1/2" x 30" [3.2mm x 13mm x760mm ] balsa
stick.Cut them to size as shown on the plan.Then glue them
in place.

❏ 4. Cut the 1/8" x 1/4" x 30" [3.2mm x 6.4mm x 760mm]

and the 1/8" x 1/8" x 30" [3.2mm x 3.2mm x 760mm] balsa
sticks to size to form the rudder inner structure. Glue them
in place with thin CA.

❏ 5. Remove the fin and rudder from the plan and sand

them smooth. Locate two 1/16" x 3" x 36" [1.6mm x 76mm
x 914mm] balsa sheets. Sheet both sides of the fin and the
rudder using the same procedure you used for the stab and
elevator.

❏ 6. Sand the edges of the fin and rudder square using a

bar sander. Mate the fin and the rudder to check the fit.
Shape the fin and the rudder to obtain the shape shown in
the plan’s cross section. Do not shape the leading edge of
the rudder yet.If you wish to do so, you can round the top of
the rudder as shown on the plan.

❏7. Locate the center of the leading edge of the rudder and

the center of the trailing edge of the fin using the same
procedure that was used on the elevator and stab.

❏ 8. Using the plan as a reference, mark the location of the

CA hinges on the fin and rudder.

12

❏ 9. Cut the hinge slots on the trailing edge of the fin and

the leading edge of the rudder following the same procedure
used on the stab and elevators.

❏ 10. Fixed Mains and Tailwheel and Retractable

Mains/Fixed Tailwheel. Drill a 7/64" [2.8mm] hole 1"

[25mm] deep in the rudder for the tail wheel assembly as
shown on the plan. Make sure it is oriented 90 degrees to
the leading edge of the rudder.Wick thin CA in the hole.Cut
a groove 1/8" [3.2mm] wide from the bottom of the rudder up
to the hole. Hint: A perfect tool for this is the Great Planes
Groove Tube™(GPMR8140).

❏11.Bevel the leading edge of the rudder as shown on the

plans cross section.

❏ 12.Test fit the CA hinges but do not glue them in place.

This will be done after the model is covered.

❏ 13. Drill 1/16" [1.6mm] holes for the control horn on the

rudder as indicated on the rudder plan. Wick some thin CA
into the holes.

❏ 1. Unroll the plan sheet. Roll it inside out so they will

lie flat.

❏ 2. Locate the right wing panel of the plan.You may find it

helpful to cut the plan in half, making them a more
manageable size to pin to your building board.

❏ 3. Position the right wing panel plan flat on the building

board. Cover the plan with Great Planes Plan Protector or
waxed paper so glue will not adhere to it.

❏❏4. Locate the die-cut 1/16" [1.6mm] balsa main shear

web (MSW), the die-cut 3/32" [2.4mm] balsa wing ribs W2
through W8 and the die-cut 1/16" [1.6mm] balsa wing
rib

W9.

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

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

❏❏5. Insert the wider end of MSW into W2. Position the

rib over the second set of notches and then twist it into the
notch.The top of MSW is marked. Push MSW forward until
it sits against W2.Do not glue them to each other at this

time.

❏❏6. Insert all other ribs in order (W3, W4, W5, ...W9)

and twist them into their notches.Because W9 is installed at
a different angle against MSW, you may need to slightly
sand MSW to be able to position W9 as sho wn on the plans.
Again, all letters in the ribs should be right-side-up. Do not
glue any of the ribs in place yet.

Build the Wing Panels

BUILD THE WING

13

❏❏7. Locate two 1/8" x 1/4" x 30" [3.2mm x 6.4mm x

760mm] hardwood wing spars. Inser t them in place in the
ribs as shown. You should now have the top and bottom
wing spars inserted on the wing ribs as shown. Do not glue
the spars in place yet.

❏❏8. Locate the die-cut 1/8" [3.2mm] wing trailing edge

(TE). Insert it into the notches at the trailing edge of each of

the ribs. Be sure that the tall end of TE is at the root of the
wing. Line up the ribs and webs with the plans. Place
weights on top of the structure to make sure it sits flat
against the building surface.Use thin CA to glue all the parts
together.

❏❏9. Locate the die-cut 3/32" [2.4mm] wing rib W1.

Place the rib in the notches in MSW at the root of the wing.
Use the die-cut dihedral gauge (DG) to set the correct
amount of dihedral for the root rib W1. Insert the trailing
edge notch on the rib in its slot in TE.Glue W1 in place with
medium CA.

❏❏10. Locate the die-cut 3/32" [2.4mm] dowel plate

doubler (DP). Inser t it as shown in the slot in W2 and the

leading edge of W1. Make sure it is inserted at 90 degrees
from the building surface.Glue it in place with medium CA.

❏❏11. Carefully cut the portion of the rib W2 that is

between the wing spars.This is done to allow the wing joiner
to later be inserted between the wing spars.

❏❏12.Locate the die-cut 1/16" [1.6mm] aft shear web

(ASW).

Insert it between ribs W1, W2 and W3, twist it and push it
against the wing spars. Glue ASW in place with thin CA.

14

❏❏13. Locate one die-cut 1/8" [3.2mm] lite-ply aileron

servo tray (AST).The tray is not symmetrical because of

the sweep of the main wing spar. Place the aileron servo
tray against the wing main shear web (MSW) and the wing
rib W4. The ser vo tray will only fit one way, so flip it if you
need to.Once you are satisfied with the fit, mark the top side
of the tray as shown.

❏❏14.Locate two die-cut 1/8" [3.2mm] servo tray

supports

(STS). Glue them to ATS as shown in the above image.

❏❏15. Fit the ser vo tray assembly to the main shear web

(MSW) and W4 as shown.You will need to slightly sand one
of the servo tray supports (STS) to make it fit as shown in
the above image.Once you are satisfied with the fit, glue the
assembly in place with medium CA.

❏❏16. Fixed Tricycle. Locate the die-cut 1/8" [3.2mm]

lite-ply ribs W3-B and W4-B. Glue them to the inner side of
the 3rd bay with epoxy as shown in the plans. Use plenty of
epoxy on this and the following steps.

❏❏17. Fixed Tricycle. Locate one of the 1/2" x 3/4" x

5-1/2" [13mm x 19mm x 140mm] hardwood landing gear
rails. Cut the rail into two pieces, one 4-1/4" [108mm] long
and another 7/8" [22mm] long.Glue them in place as shown
using epoxy.

❏❏18. Fixed Tricycle. Drill a 5/32" [4mm] hole through

the slot on the vertical piece of the landing gear rail into the
horizontal portion of the rail.This is for the landing gear wire.

15

❏❏19. Locate one 1/16" x 1/2" x 30" [1.6mm x 13mm x

760mm] balsa sub-leading edge. Glue it in place in front of
all ribs with medium CA. 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.Sand the
ends to fit the ribs.

❏❏20. Fixed and Retractable Mains/Fixed Tailwheel.

Locate the die-cut 1/8" [3.2mm] lite-ply sub-leading edge
doubler (SED) and glue it with epoxy to the sub-leading

edge between ribs W3 and W4. After the glue has cured,
lightly sand SED until it matches the shape of the ribs.

❏❏21. Fixed Mains and Tailwheel. Locate the die-cut

1/8" [3.2mm] lite-ply ribs W3-A, WL-A, and W4-A. Use
epoxy to glue them in place as shown on the wing plan.
Also, use epoxy on the cuts on the ribs. After the epoxy has
cured, sand the ribs smooth with the top and bottom
surfaces of the wing.

❏❏22. Fixed Mains and Tailwheel. Locate one of the

1/2" x 3/4" x 5-1/2" [13mm x 19mm x 140mm] hardwood
landing gear rails. Cut the rail into two pieces, one 4-1/4"
[108mm] long and another 5/8" [16mm] long. Glue them in
place as shown using epoxy. Drill a 5/32" [4mm] hole
through the slot in the vertical rail into the horizontal rail.
This is for the landing gear wire.

❏❏23. Retractable Mains/Fixed Tailwheel. Locate the

die-cut 1/8" [3.2mm] lite-ply ribs W3-A, WL-A, and W4-A.
Make straight lines between the top of the pre-cut edges
and cut the material out as shown in the above image.
Locate the 1/4" x 1/2" x 8" [6.4mm x 13mm x 203mm]
hardwood stick and cut it in four pieces 1-7/8" [48mm] long.
You will use two pieces on each retractable landing gear
mount on each wing.

❏❏24. Retractable Mains/Fixed Tailwheel. Glue W3-A,

WL-A and W4-A as shown in the above image using epoxy.

16

The strength of your landing gear depends on how well you
glue these parts in place. Make sure W3-A, WL-A and
W4-A are also glued well to the wing’s main shear web
(MSW) and to the sub-leading edge doubler (SED).

❏❏25. Retractable Mains/Fixed Tailwheel. Glue the two

1/4" x 1/2" x 1-7/8" [6.4mm x 13mm x 48mm] hardwood
retractable gear mounts between W4-A and WL-A as shown
with epoxy. Add small pieces of scrap hardwood sticks glued
with epoxy between the landing gear mounts and the lite ply
ribs to reinforce the area.

❏❏26. Locate two 1/4" x 1/2" x 30" [6.4mm x 13mm x

760mm] balsa sticks and cut them in five pieces 4-1/2"
[114.5] long, two pieces 2-1/4" [57mm] long and one piece
1-7/8" [48mm] long.Sand the edges at an angle so that they
fit between the ribs at the trailing edge of the wing and glue
them in place with medium CA.

❏❏27. Cut another piece from the leftover 1/4" x 1/2" x

30" [6.4mm x 13mm x 760mm] sticks in the above steps and
fit it between W8 and W9 at the leading edge as shown on
the plan.Glue it in place with medium CA.After the glue has
cured, lightly sand the block until it matches the shape of
the ribs.

❏❏28. Fixed and Retractable Mains/Fixed Tailwheel.

Cut a 3/32" [2.4mm] piece of scrap balsa to fit between the
main spars at the W3 rib.This piece of balsa seals the inner
end of the wing joiner pocket to prevent the epoxy from
spilling into the wing while gluing the wing joiner in place in
a future step.

❏❏29. Flip the wing over so that you can see the bottom

side and glue a small piece of scrap 1/8" [3.2mm] balsa to
the edges of the aileron servo tray. Once the glue has cured,
sand the balsa to match the shape of the ribs.

17

❏❏30. Flip the wing over again to work on the top side.

Locate a 1/16" x 3/4" x 30" [1.6mm x 19mm x 760mm] balsa
stick. Glue the stick flush with the wing trailing edge (TE)
with medium CA. Cut the ends of the stick that extend past
the wing tip and wing root.

❏❏31. Glue together two pieces of 1/16" x 3" x 30"

[1.6mm x 76mm x 760mm] soft balsa used to sheet the tail
surfaces in a previous step .Sand the joint smooth.Mark one
end of the sheet 2-3/4" [70mm] away from the long edge.
Mark the other end of the sheet 4-1/2" [114.5mm] away from
the long edge.Make a straight line through these two marks
and use a straight edge to cut along the line.One of the cut
parts of this sheet will be used to sheet the leading edge of
the wing. The other par t will be used to sheet part of the
center-section of the wing and for cap stripping the wing.

❏❏32. Sand the top of the wing smooth with a long

sanding bar.Glue the sheeting to the main wing spar and to
the ribs and sub-leading edge as shown with medium CA.
Note that the sheeting starts centered on the main wing
spar.If you prefer to use a slower curing glue, place weights
on the sheeting to keep it attached to the wing ribs as the
glue cures.

❏❏33. Once the glue has cured, flip the wing over and

add more glue if necessary to attach the sheeting to the ribs
or sub-leading edge.

❏❏34. Cut the portion of the sheet that extends past the

root and the tip.

❏❏35.Locate a 1/16" x 3" x 30" [1.6mm x 76mm x

760mm]
balsa sheet and cut four pieces 4-3/4" [121mm] long from it.
Glue one of the parts to the wing center-section. Use some
of the leftover sheeting cut in step 31 to complete the
center-section sheeting.

18

❏❏36. Cut the leftover sheeting from step 31 with the

grain into 3/8" [9.5mm] wide balsa strips.Use these strips to
make your cap strips. Cut the cap strips to fit between the
forward sheeting and the trailing edge sheeting. Use the
plans as a guide to identify the ribs that should be cap
stripped.

❏❏37.Flip the wing over and sand the bottom of the wing

smooth. Locate a 1/16" [1.6mm] x 3/4" x 30" balsa stick.
Glue the stick flush with the wing trailing edge (TE) using
medium CA. Cut the ends of the stick that extend past the
wing tip and wing root.

❏❏38. Use the sketch in step 31 to prepare the sheeting

for the bottom wing surface .Glue the sheeting in place using
the same procedure as was used for the top sheeting. Cut
the ends of the sheeting that extend out from the wing root
and tip.

❏❏39.Glue one of the 1/16" x 3" x 4-3/4" [1.6mm x 76mm

x 121mm] balsa sheets cut in step 35 to the wing center­section. Use some of the leftover sheeting cut in step 31 to
complete the center-section sheeting. Also, cut that same
leftover balsa sheet into 3/8" [9.5mm] strips and use them to
cap strip the ribs on the bottom surface of the wing.
Remember to cap strip the aileron servo tray. This is the

same

procedure as used for the top wing sheeting and cap strips.

❏❏40.Sand the tip and root of the wing smooth.Sand the

leading edge sheeting flush with the sub-leading edge.Also

19