Great Planes GPMA1295 User Manual

WARRANTY

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Model Manufacturing Co.

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INSTRUCTION

MANUAL

SPECIFICATIONS

Wingspan:

Wing Area:

72 in
[1830mm]

138 4 in
[89.2 dm2]

2

Weight:

Wing

Loading:

12.75 – 13.75 lb
[5780– 6230 g]

21– 23 oz/ft
[64–70 g/dm2]

WARRANTY

Great Planes® Model Manufacturing Co. guarantees this kit to

reat Plan

be free from defects in both material and workmanship at the

ree from defects in both material and workmanship at the

date of purchase. This warranty does not cover any component

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

guarantees this kit to

Length: 56.5 in

[1435mm]

Radio:

2

s kit immediately in new and unused condition to the

this kit immediately in new and unused condition to the

lace of purchase

place of purchase.

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

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.

Engine: .91 cu in [15cc] 2-stroke

Hobby Services

3002 N. Apollo Dr. Suite 1

Champaign IL 61822 USA

4-Channel with 7 std servos

1.20 cu in [20cc] 4-stroke
25-30cc gas

READ THROUGH THIS MANUAL BEFORE STARTING CONSTRUCTION. IT CONTAINS IMPORTANT

INSTRUCTIONS AND WARNINGS CONCERNING THE ASSEMBLY AND USE OF THIS MODEL.

© 2010 Hobbico®, Inc. GPMA1295 Mnl

Champaign, Illinois

[phone], Ext 5

[e-mail]

TABLE OF CONTENTS

INTRODUCTION

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

AMA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

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

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

Glow Engine Option & Required Parts. . . . . . . . . . . . .3

Gasoline Engine Option & Required Parts. . . . . . . . . .3

Radio System Recommendations . . . . . . . . . . . . . . . .3

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

Adhesives & Building Supplies. . . . . . . . . . . . . . . . . . .3

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

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

KIT INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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

KIT CONTENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

PREPARE FOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . .6

WING ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Aileron Servo Preparation . . . . . . . . . . . . . . . . . . . . . . 6

Bottom Wing Assembly . . . . . . . . . . . . . . . . . . . . . . . . 6

Top Wing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . .9

ASSEMBLE THE FUSELAGE . . . . . . . . . . . . . . . . . . . . .12

Main Landing Gear Installation . . . . . . . . . . . . . . . . .12

Cabane Strut Installation . . . . . . . . . . . . . . . . . . . . . .13

Horizontal Stabilizer, Tailwheel & Rudder Installation 14

Pushrod, Control Horn & Servo Installation . . . . . . . . 16

GLOW ENGINE INSTALLATION . . . . . . . . . . . . . . . . . . .18

Mount the Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . .18

Hook up the Throttle. . . . . . . . . . . . . . . . . . . . . . . . . .19

Install the Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . .21

GASOLINE ENGINE INSTALLATION . . . . . . . . . . . . . . .22

Mount the Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . .22

Hook up the Throttle. . . . . . . . . . . . . . . . . . . . . . . . . .23

Install the Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . .24

Install the Ignition Unit . . . . . . . . . . . . . . . . . . . . . . . .25

FINAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

Radio Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

Cowl and Propeller Installation. . . . . . . . . . . . . . . . . .28

Install the Wheel Pants and Fairings . . . . . . . . . . . . .31

Cockpit Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

Pilot Installation (Optional) . . . . . . . . . . . . . . . . . . . . .32

Finishing the Model . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Apply the Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

GET THE MODEL READY TO FLY . . . . . . . . . . . . . . . . .34

Check the Control Directions . . . . . . . . . . . . . . . . . . . 34

Set the Control Throws. . . . . . . . . . . . . . . . . . . . . . . .34

Balance the Model (C.G.). . . . . . . . . . . . . . . . . . . . . .35

Balance the Model Laterally. . . . . . . . . . . . . . . . . . . .35

PREFLIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

Identify Your Model. . . . . . . . . . . . . . . . . . . . . . . . . . .36

Charge the Radio Batteries . . . . . . . . . . . . . . . . . . . .36

Balance Propellers. . . . . . . . . . . . . . . . . . . . . . . . . . .36

Ground Check & Range Check . . . . . . . . . . . . . . . . .36

ENGINE SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . .36

AMA SAFETY CODE. . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

CHECK LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

FLYING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

Fuel Mixture Adjustments . . . . . . . . . . . . . . . . . . . . .38

Takeoff . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

Flight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

Landing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

Thank you for purchasing the Great Planes Waco YMF-5
ARF! We offer two options for the builder of this classic model.
Build it as a single seat mail carrier, or as a three seat civilian
open cockpit bipe. You’ll enjoy the great scale-like handling
characteristics of this big bipe and the level of detail we’ve
put into this model. This manual details the installation of
both a glow and gas engine, so please look in the Decisions
You Must Make section for the items required to complete
each type of installation before you begin building.

For the latest technical updates or manual corrections to the
Waco YMF-5 ARF visit the Great Planes web site at www.
greatplanes.com. Open the “Airplanes” link, and then select
the Waco YMF-5 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.

AMA

Academy of Model Aeronautics:If you are not already a
member of the AMA, please join! The AMA is the governing
body of model aviation and membership provides liability
insurance coverage, protects modelers’ rights and interests
and is required to fly at most R/C sites.

Academy of Model

Aeronautics

5151 East Memorial Drive

Muncie, IN 47302-9252

Tele. [phone]

Fax [phone]

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 over groups of people.

PROTECT YOUR MODEL, YOURSELF

& OTHERS… FOLLOW THESE

IMPORTANT SAFETY PRECAUTIONS

1. Your Waco YMF-5 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 Waco YMF-5, 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.

2

4. You must use an R/C radio system that is in good condition,
a correctly sized engine, and other components as specified
in this instruction manual. All components must be correctly
installed so that the model operates correctly on the ground
and in the air. You must check the operation of the model and
all components before every flight.

5. 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
hobby shop has information about clubs in your area whose
membership includes experienced pilots.

6. While this kit has been flight tested to exceed normal use,
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.

7. WARNING: The cowl, wheel pants, and some fairings are
made of fiberglass, the fibers of which may cause eye, skin
and respiratory tract irritation. Never blow into or on a part
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.

Four-Stroke Option

O.S. FS-120S-E Surpass

❏

(OSMG0930)

™

Ringed 4-Stroke engine

Gas Engine Option & Required Parts

To equip your Waco with a gasoline engine, we recommend
the DLE-30 gas engine for its power, reliability, and economy.
Regardless of the gas engine you choose, you will also
need to purchase a few other items to set up your model for
gasoline fuel.

DL Engines

❏

Sullivan Gasoline Tank Conversion Kit (SULQ2684)

❏

Dubro 1/8" Fuel Line Barbs (DUBQ0670)

❏

Dubro 1/8" ID Tygon Fuel Tubing (DUBQ0493)

❏

Fuel Line Clamps 1/8" (GPMQ4172)

❏

Ernst Charge Jack Receptacle (ERNM3001)

❏

Futaba

❏

(FUTM1380)

Futaba J-Series Switch w/ Charge Plug (FUTM4370)

❏

(4) 10-32 or M5 bolts, blind nuts, washers, & lock washers

❏

for engine mounts

(4) M4 x 20mm machine screws for cowl installation tool

❏

™

DLE-30cc Gas Engine (DLEG0031)

®

NR4RB 4.8V 1000mAh NiCd Receiver Battery

We, as the kit manufacturer, provide you with a top quality,
thoroughly tested kit and instructions, but ultimately the
quality and fl yability of your fi nished model depends
on how you build it; therefore, we cannot in any way
guarantee the performance of your completed model,
and no representations are expressed or implied as to the
performance or safety of your completed model.

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

DECISIONS YOU MUST MAKE

This is a partial list of items required to finish the Waco YMF-5
that may require planning or decision making before starting
to build. Order numbers are provided in parentheses.

Glow Engine Option & Required Parts

If you choose to equip your model with a glow engine, you
will need to purchase the items listed below. Either a two­stroke or a four-stroke engine can be used. This manual will
show the installation of an O.S. 1.20 four-stroke engine.

3' [900mm] standard silicone fuel tubing (GPMQ4131)

❏

Suitable propeller per engine manufacturer’s

❏

recommendation

®

O.S.

❏

Two-Stroke Option

❏
❏

Needle Valve Extension kit (optional) (OSMG7290)

O.S. .95 AX Ringed 2-Stroke engine (OSMG0580)
Bisson Pitts muffler (BISG4091)

Radio System Recommendations

4 Channel Radio System (computer radio with mixing

❏

preferred)

Futaba R617FS 7-Channel 2.4GHz Receiver

❏

(FUTL7627)

(1) Futaba S3004 Standard Ball Bearing Servo

❏

(FUTM0004)

6) Futaba S9001 Coreless Ball Bearing Servo

❏

(FUTM0075)

Futaba NR4RB 4.8V 1000mAh NiCd Receiver Battery

❏

(FUTM1380)

(2) 16" [405mm] servo extension (FUTM3955)

❏

(1) 12" [300mm] servo extension (HCAM2711)

❏

(1) 30" [760mm] servo extension (EMOM0129)

❏

(1) 21" [533mm] Y-harness (HCAM2500)

❏

(1x or 2x if no computer radio) 6" [152mm] Y-harness

❏

(FUTM4130)

Futaba J-Series Switch w/ Charge Plug (FUTM4370)

❏

Switch & Charge Jack Mounting Set (GPMM1000)

❏

ADDITIONAL ITEMS REQUIRED

Required Hardware and Accessories

To finish this airplane you will need the following items.

(2) 3/8" x 3" Heat Shrink Tubing (DUBM2180)

❏

R/C foam rubber 1/4" [6mm] thick (HCAQ1000)

❏

Drill bits: 1/16" [1.6mm], 5/64" [2mm], 3/32" [2.4mm],

❏

1/8" [3.2mm], 1/4" [6.4mm], 13/32 [10mm], 3/16"
[4.8mm] long drill bit

3

1 oz. [30g] Medium Pro™ CA+ (GPMR6008)

❏

1 oz. [30g] Thin Pro CA (GPMR6002)

❏

CA applicator tips (HCAR3780)

❏

CA debonder (GPMR6039)

❏

Pro 30-minute epoxy (GPMR6047)

❏

Pro 6-minute epoxy (GPMR6045)

❏

Epoxy brushes (6, GPMR8060)

❏

Mixing sticks (50, GPMR8055)

❏

Mixing cups (GPMR8056)

❏

Threadlocker™ thread-locking compound (GPMR6060)

❏

R/C-56 canopy glue 4oz (JOZR5007)

❏

Medium T-pins (100, HCAR5150)

❏

#64 rubber bands (1/4 lb [113g] box, HCAQ2020)

❏

Milled fiberglass (GPMR6165)

❏

18" flexible steel rule (HCAR0460)

❏

Builder’s Triangle Set (HCAR0480)

❏

2-56 tap and drill set (GPMR8100)

❏
❏

6-32 tap and drill set (GPMR8102)

Tap handle (GPMR8120)

❏

Pliers with wire cutter (HCAR0625)

❏

Hobbico® Heavy Duty Diagonal Cutter 7" (HCAR0627)

❏

Electric drill

❏

Household scissors

❏

Hobbico ball-end hex wrench set – metric (HCAR0521)

❏

Hobbico ball-end hex wrench set – SAE (HCAR0520)

❏

(2) 1" [25mm] C-Clamps

❏

Excel Small Clamp (EXLR5663)

❏

Easy-Touch™ Bar Sander 5.5" (GPMR6169)

❏

Sandpaper assortment

❏

Masking tape

❏

Denatured alcohol (for epoxy clean up)

❏

Paper towels

❏

Plan protector (GPMR6167) or wax paper

❏

IMPORTANT BUILDING NOTES

• 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, and then slightly modify or custom
fit the part as necessary 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 or 6-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.

• The Waco YMF-5 is factory-covered with Top Flite
MonoKote® film. Should repairs ever be required, MonoKote
can be patched with additional MonoKote purchased
separately. MonoKote is packaged in six-foot rolls, but
some hobby shops also sell it by the foot. If only a small
piece of MonoKote is needed for a minor patch, perhaps a
fellow modeler would give you some. MonoKote is applied
with a model airplane covering iron, but in an emergency a
regular iron could be used. A roll of MonoKote includes full
instructions for application. Following are the colors used on
this model and order numbers for six foot rolls.

Cub Yellow (TOPQ0220)

Black (TOPQ0208)

True Red (TOPQ0227)

®

Optional Supplies and Tools

21st Century® sealing iron (COVR2700)

❏

21st Century iron cover (COVR2702)

❏

Rotary tool such as Dremel

❏

Rotary tool reinforced cut-off wheel (GPMR8200)

❏

Dremel Drum Sander, Coarse 3/8" (DRER0968)

❏

Hobbico Retractable Fabric Tape Measure (HCAR0478)

❏

Hobbico Z-bend pliers (HCAR2000)

❏

Hobby Heat™ micro torch (HCAR0755)

❏

Panel Line Pen (TOPQ2510)

❏

Dead Center™ Engine Mount Hole Locator (GPMR8130)

❏

AccuThrow™ Deflection Gauge (GPMR2405)

❏

Precision Magnetic Prop Balancer (TOPQ5700)

❏

Great Planes 1/5th scale WWI German Pilot (brown)

❏

(GPMQ9115)

Hobbico Pin Vise 1/16" Collet w/3 Bits (HCAR0696)

❏

Great Planes E-Z Mask Tape 1/8" (GPMR1000)

❏

®

• 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.

KIT INSPECTION

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 you need assistance with assembly,
contact Product Support. When reporting 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]

4

ORDERING REPLACEMENT PARTS

Replacement parts for the Waco YMF-5 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 Great Planes web site
at www.greatplanes.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.

Parts may also be ordered directly from Hobby Services
by calling [phone], or fax 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
and expiration date for payment.

Mail parts orders and payments by personal check to:

Hobby Services

3002 N. Apollo Drive, Suite 1

Champaign, IL 61822

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.

®

or MasterCard® number

If additional assistance is required for any reason, contact
Product Support by telephone at [phone], or by
e-mail at [e-mail].

REPLACEMENT PARTS LIST

Order No. Description

GPMA4065
GPMA4066
GPMA4067
GPMA4068
GPMA4069
GPMA4070
GPMA4071
GPMA4072
GPMA4073
GPMA4074
GPMA4075
GPMA4076
GPMA4077
GPMA4078
GPMA4079

Fuselage Set
Top Wing Set
Bottom Wing Set
Cabane Set
Interplane Struts Set
Landing Gear Set
Wheel Pants
Rudder Set
Horizontal Stab Set
Tailwheel Set
Windscreens Set
Cowl Set
Decal Sheet
Bottom Wing Cover
Cowl Ring Set

Full-size plans are not available.

NOTE

You can download a copy of this
manual at www.greatplanes.com.

KIT CONTENTS

2

1

3

4

8

5

10

9

14

20

18

7

6

12

11

16

15

19

23

25

26

21

27

13

22

17

24

1. Cowl

2. Fuselage

3. Cowl Rings

4. Dummy Engine

5. Landing Gear Fairings

6. Main Landing Gear

7. Turtledeck Fairing

8. Interplane Struts

9. Engine Spacers

10. Wheel Pants

11. Wheels

12. Windscreens

13. Horizontal Tail

14. Landing Gear Center Fairing

15. Wing Fillet Fairings

16. Front Cockpit Cover

17. Horizontal Stab Tubes

18. Belly Fairing

19. Lower Wing Joiners

20. Wing Dowels

21. Cabane Struts

5

22. Rudder

23. Lower Wing

24. Upper Wing Joiners

25. Servo Mounting Blocks

26.Upper Wing

27. Tailwheel Assembly

PREPARE FOR ASSEMBLY

Before you begin assembling your model, use a covering iron
set to a medium temperature (about 250° F [121° C]) to tack
down any loose or wrinkled covering. Securely tack down the
edges of trim and where seams are present and around the
aileron servo hatch covers. We recommend using a Coverite
(COVR2700) covering iron with a sock (COVR2702).

™

2. Use a 5/64" [2mm] drill bit to drill the outermost servo

❏

arm hole on all four aileron servos.

Bottom Wing Assembly

WING ASSEMBLY

Aileron Servo Preparation

1. Locate the long servo arm that came with your servo.

❏

For Futaba standard servos this is the arm that is already
installed on the servo. For other radio systems, please use
the arm that is at least 5/8" [15.9mm] long from the center
of the shaft to the outermost hole. Center four servos using
your radio. Remove the servo arm screw and reposition the
servo arm on the splined output shaft so that the arm is 90°
(perpendicular) to the servo case side. Clip off the unused
servo arms so that your servos look like those in the photo.
Install the servo arm screw.

1. Working with the bottom left wing now, cut out three

❏ ❏

1/2" x 1" [13mm x 25mm] pieces of thin card stock (not
supplied). You may use construction paper or a manila folder
for this purpose. Lay the servo on a flat surface with the
arm hanging down over the edge of your table. Locate two
19x19x9mm hardwood blocks. Position the blocks under the
servo mounting tabs and place a piece of card stock in the
locations shown. Holding the blocks and servo in position,
use a 1/16" [1.6mm] drill to drill four holes for the servo
mounting screws.

2. Install the four servo mounting screws that came

❏ ❏

with your servo. Remove the screws and harden each of the

6

screw holes with thin CA. Let the CA cure and reinstall the
screws. Remember that you are going to set up a left side
servo and a right side servo.

3. With the hardwood blocks attached and each servo

❏ ❏

arm still centered, position your servo on the aileron servo
bay cover so that the servo arm is centered in the opening.
Glue these in place and hold the blocks to the servo bay
cover with two small clamps. The clamps shown here are
Excel 3-1/2" [89mm] plastic clamps (EXLR5663). Let the
glue cure.

6. Attach a 16" [405mm] servo lead extension to the

❏ ❏

aileron servo lead. Use a piece of 3/8" [9.5mm] diameter
heat shrink tubing (not supplied) to secure the connection or
simply tape the connectors to secure them. Route the servo
lead through each wing using the supplied guide string.

4. Mark the approximate center line of each block on

❏ ❏

both the wide side and the narrow side of each mounting
block. Using a 1/16" [1.6mm] drill bit, drill one hole into each
block by drilling through the servo bay cover and into the
block. Sighting from the back and from the side, line up the
drill with the marks you made on the blocks.

5. Install one #2 x 3/8" [9.5mm] countersunk sheet

❏ ❏

metal screw into each block. Remove the screws and harden
the holes you just tapped with a drop of thin CA.

7. Route the other end of the servo lead through the

❏ ❏

hole in the top side of the wing.

8. Note the orientation of the servo bay cover in

❏ ❏

the photo above. Position the completed servo bay cover
properly and install it to the wing using four #2 x 3/8" [9.5mm]
sheet metal screws and four #2 flat washers. Remove the
screws and servo bay covers and harden the screw holes
with a drop of thin CA.

7

9. Using a 90° builder’s square or triangle, draw a

❏ ❏

1/2" [12.7mm] long line on the aileron straight back from the
servo arm. Take note of the hardwood block that is below the
surface of the covering. You will drill into this block next.

10. Center a large nylon control horn over the line

❏ ❏

you drew so that the pushrod holes in the horn are directly
over the hinge line of the aileron. With a 1/16" [1.6mm] drill
bit, hold the horn in place and drill two 1/2" [12.7mm] deep
holes using the holes in the horn as a guide. Be careful not
to drill all the way through the aileron. Wrap a piece of
masking tape around your drill bit 1/2" [12.7mm] from the tip
to help you know how deep to drill.

11. Install the control horn using two #2 x 1/2" [12.7mm]

❏ ❏

sheet metal screws. Remove the screws and the horn and
harden the screw threads you created with a few drops of
thin CA. Reinstall the control horn.

13. Fit the clevis to the outer hole of the control horn.

❏ ❏

With the aileron servo and the aileron centered, mark the
bend line at the outer hole in the servo arm.

14. Bend the pushrod wire 90°. Clip off the excess

❏ ❏

wire so that the bent section is at least 1/4" [6.4mm] long.
Connect the wire in the outer hole of the servo arm and fit a
nylon Faslink™ to hold it in place. Make any fine adjustments
by removing the clevis from the control horn and turning it in
or out to shorten or lengthen the pushrod. Slide the silicone
retainer in place over the arms of the clevis.

15. Repeat steps 1 through 14 for the bottom right wing.

❏

16. For the next few steps, cut up some paper towels into

❏

1/4 sheets and have some denatured alcohol on hand to
clean up any epoxy.

12. Fit a nylon clevis to a 12" [305mm] one-end

❏ ❏

threaded pushrod so that the end of the threaded rod extends
1/8" [3.2mm] into the clevis barrel. Fit a silicone retainer onto
the pushrod as shown.

17. Epoxy the two 37mm x 8mm wing dowels in place

❏

so that at least 3/8" [9.5mm] of each dowel extends forward
from the leading edge.

8

18. Identify the two 208mm x 15mm bottom wing L.E.

❏

joiners. One is made out of aluminum and one is wood. Identify
the two 105mm x 12mm bottom wing T.E. joiners. Using 180­grit sandpaper, scuff the side of the aluminum joiner that will
be glued to the wood joiner. Clean the aluminum joiner with
an alcohol-dampened cloth. Mix up a batch of 30-minute
epoxy and coat the faces of each joiner. Glue the two L.E.
joiners together and the two T.E. joiners together so that you
now have one long and one short joiner. Take note of the
dihedral “V” angle in the joiners. Align the pieces and clamp
them together. Let the epoxy cure. Then, remove the clamps.

cures. Use three rubber bands on the dowels to hold the L.E.
together. Put two rubber bands on the top side of the wing
and two on the bottom side with the bolts half way through
the holes.

21. Use paper towels and some denatured alcohol to

❏

clean up any excess epoxy that is squeezed out of the joint.
Allow the epoxy to fully cure.

Top Wing Assembly

1. Prepare a left and a right servo and fit each one to its

❏

respective servo bay cover as you did for the lower wing.

18. Orient the wings so that they are both facing up. Apply

❏

some 30-minute epoxy into the L.E. and T.E. joiner slots. Apply
epoxy to both sides of each joiner. Fit the long L.E. joiner into
the L.E. slot so the “V” in the joiner is upright. Fit the short T.E.
joiner into the T.E. slot the same way. Thoroughly coat the root
rib of both wings with epoxy and fit the wings together.

20. Fit the two 1/4-20 x 2" nylon wing bolts and use some

❏

#64 rubber bands to hold the wings together while the epoxy

2. Connect a 12" [300mm] servo lead extension to the left

❏

wing servo. Because of the hole in the center wing panel, the left
wing servo will use a shorter servo lead extension. Use some
3/8" [9.5mm] heat shrink tubing or tape to secure the connector.

3. Route the servo lead through the left wing and install

❏

the servo bay cover using four #2 x 3/8" [9.5mm] sheet metal
screws and four #2 flat washers. Harden the screw holes
with thin CA.

9

pushrod wire leaving 1/4" [6.4mm] of wire and fit the pushrod
to the outer hole of the servo arm. Secure the pushrod at the
servo arm with a nylon Faslink. Adjust the pushrod length at
the clevis. Secure the clevis with the silicone retainer.

4. Connect a 30" [760mm] servo lead extension to the

❏

right wing servo. Secure the connection with heat shrink
tubing or tape. Route the servo lead through the wing and
install the servo bay cover using four #2 x 3/8" [9.5mm] sheet
metal screws and four #2 flat washers.

140°

Top wing center
section to cabane
(x4)

8. Identify the bag of four steel brackets for the top wing

❏

center section. These are the brackets that have the 140°
bend angle (or the brackets with the flattest bend).

Cabane strut to
fuselage bracket
(x4)

115°

105°

Interplane
strut bracket
(x8)

5. Line up and install the aileron control horns using the

❏

same method recommended earlier for the bottom wing. Drill
two 1/2" [12.7mm] deep holes using a 1/16" [1.6mm] drill.
Install the horns with two #2 x 1/2" [12.7mm] sheet metal
screws per horn.

6. Prepare two 12" [305mm] one-end threaded pushrods

❏

using two clevises and two silicone retainers.

7. Fit the clevis to the outer hole in the control horn. Mark

❏

and bend the rod as you did earlier. Clip off the excess

9. Use four #4 x 1/2" [12.7mm] sheet metal screws

❏

to attach the brackets to the wing center section in the
orientation shown so that they are angled inward toward the
fuselage center line. Remove the screws and brackets and
harden the screw holes with thin CA. Reinstall the brackets.

10. Attach the guide string in the wing center section to

❏

the long servo extension of the right wing aileron servo. Pull
the servo lead through the center section and route the lead
through the hole in the front left corner of the bottom of the
center section. Leave the guide string attached until after
you have glued together the wings.

10

11. Two joiners are needed to join the top left wing to the

❏

center wing section and two joiners are needed to join the
right wing to the center section. Scuff and clean the aluminum
joiner the same as was done for the bottom wing. Mix up a
batch of 30-minute epoxy and glue each 235mm x 15mm
aluminum L.E. joiner to a matching ply joiner. Be careful when
matching the dihedral angle of the joiners when you’re gluing
them together because the angle is very shallow. Clamp
these together and allow the epoxy to cure.

12. Glue a pair of 125mm x 13mm plywood T.E. wing

❏

joiners together. Then, glue the remaining pair of 125mm x
13mm ply joiners to each other. Clamp these together and
allow the epoxy to cure.

14. Do the same for the left wing, coating the joiners and

❏

ribs with epoxy. When you’re ready to slide the left wing onto
the center section, route the servo lead through the root rib
of the center section and out of the exit hole.

15. Slide the wings together tightly. Hold them together

❏

using masking tape. Stretch one long piece across the span
so the ends wrap around the wing tips. Do this for the top
and the bottom side of the wing to ensure that the tape does
not slip.

13. Apply some epoxy into the L.E. and T.E. joiner slots of

❏

both the right wing and the right side of the center section.
Coat the joiners with epoxy. Then, fit the long L.E. joiner
into the leading edge slot and the short T.E. joiner into the
trailing edge slot. Coat the root ribs of the right wing and
the right side of the center section and join the right wing to
the center section. Make sure you orient the joiners correctly
with the dihedral angle upright. Note: To protect the servo
lead contacts, wrap the connector in masking tape.

16. Clean up any excess epoxy with denatured alcohol

❏

and paper towels. Set the wing aside and let the epoxy cure.
Carefully remove the masking tape.

11

ASSEMBLE THE FUSELAGE

Main Landing Gear Installation

1. Install the main landing gear onto the fuselage using five

❏

6-32 x 3/4" [19.1mm] SHCS, five #6 split lock washers, and
five #6 flat washers. Use a drop of thread locking compound
on the screw threads.

inside. With the fairings up against the fuselage, wrap some
1/8" EZ-Mask tape (GPMR1000) or a narrow strip of regular
masking tape about 1/16" [1.6mm] above the bottom edge
of each fairing.

4. Remove one gear fairing at a time and apply a 3/16"

❏

[4.8mm] bead of R/C-56 canopy glue around the base of
the gear leg using the masking tape as a guide. Fit the gear
fairing back onto the gear leg. Repeat this for the other leg.

2. Install the main landing gear center fairing. Apply glue

❏

to the base of the fairing or the bottom of the aluminum gear
strap. Note: The center fairing is not symmetrical, so please
note the contours of the fairing and install it so that it matches
the fuselage. (If you need to remove the landing gear in the
future, trim away the covering over the access hole.)

3. Test fit the gear to fuse fairings. Note: There is a left

❏

and right fairing. The smaller radius side of each fairing faces

5. Tape the fairings up against the fuselage to hold them

❏

in place. Remove the tape after the glue dries. Gluing all
the fairings to the landing gear will allow you to remove the
landing gear easily if you have to in the future.

6. Cut 1/4" [6.4mm] off of the end of both main landing

❏

gear axles. A Dremel® rotary tool with a cutoff wheel
attachment is handy for doing this. Otherwise, use a table
vise and a hacksaw.

12