Great Planes GPMA1347 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.

GPMZ0243 for GPMA1347 V1.0 Entire Contents © Copyright 2002

1610 Interstate Drive Champaign, IL 61822

[phone], Ext. 2

[e-mail]

INSTRUCTION MANUAL

Wingspan: 79-3/4 in [2030mm]
Wing Area: 690 sq in [44.5 dm

2

]

Weight: 8.5 – 9 lb [3850 – 4080g]
Wing Loading: 28 – 30 oz/sq ft [85 – 92g/dm

2

]

Length: 52 in [1320mm]
Radio: 5-channel with 7 servos
Engine: .61 – .75 cu in [10 – 12cc] 2-stroke,

.91 cu in [15cc] 4-stroke

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

IMAA ..................................................................................2

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

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

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

Engine Recommendations...........................................4

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

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

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

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

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

COMMON ABBREVIATIONS............................................5

METRIC/INCH RULER ......................................................5

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

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

IMPORTANT INSTRUCTIONS ABOUT

WORKING WITH FIBERGLASS .......................................7

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

BUILD THE WING..............................................................7

Install the Flaps & Ailerons..........................................7

Install the Flap & Aileron Servo...................................8

Install the Flap & Aileron Hardware & Pushrods.......11

Join the Wings...........................................................12

ASSEMBLE THE FUSELAGE.........................................13

Install the Pushrod Tubes & Fuselage Formers.........13

Install the Horizontal Stab, Elevators,

Rudder & Pushrods ...................................................15

INSTALL THE ENGINE & MUFFLER..............................17

Install the Engine.......................................................17

Join the Muffler..........................................................18

Install the Nose Wheel...............................................19

Install the Main Landing Gear....................................23

Install the Fuel Tank...................................................25

INSTALL THE RADIO SYSTEM......................................25

Install the Receiver & Battery....................................28

Receiver Antenna Routing .........................................28

INST ALL THE CO WL.......................................................29

GET THE MODEL READY TO FLY..................................30

Check the Control Directions.....................................30

Set the Control Throws..............................................30

Balance the Model (C.G.)..........................................31

Balance the Model Laterally......................................32

PREFLIGHT.....................................................................32

Identify Your Model.....................................................32

Charge the Batteries ..................................................32

Balance the Propellers...............................................32

Ground Check............................................................32

Range Check.............................................................32

ENGINE SAFETY PRECAUTIONS.................................33

AMA SAFETY CODE (excerpt)......................................33

IMAA SAFETY CODE (excerpt).....................................33

CHECK LIST ....................................................................35

FLYING.............................................................................35

Fuel Mixture Adjustments..........................................35

Takeoff .......................................................................36

Flight..........................................................................36

Landing......................................................................36

ENGINE MOUNT TEMPLATE..........................................39

Of the many airplanes flying today, the Lancair (Lance-air)
is considered by many to be a “Modern Classic.” With its
sleek, clean lines, it has a very graceful appearance both on
the ground and in the air.Great Planes is proud to bring you
this wonderful classic in an easy to fly model that will
impress you by the way it flies and its good looks in the air.
We are sure you will get years of enjoyment from your
Lancair.

For the latest technical updates or manual corrections to the
Lancair, visit the web site listed below and select the Great
Planes Lancair 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.

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

For information on the full-size Lancair visit this web site:

http://www.lancair.com

The Great Planes Lancair is an excellent sport-scale model
and is eligible to fly in IMAA ev ents.The IMAA (International
Miniature Aircraft Association) is an organization that
promotes non-competitive flying of giant-scale models. If
you plan to attend an IMAA event, contact the IMAA for a
copy of the IMAA Safety Code at the address or telephone
number below.

IMAA

205 S. Hilldale Road

Salina, KS 67401

[phone]

www.fly-imaa.org/imaa/sanction.html

Scale Competition

Though the Great Planes Lancair is an ARF and may not
have the same level of detail as an “all-out” scratch-built
competition model, it is a scale model nonetheless and is
therefore eligible to compete in the

Fun Scale

class in AMA
competition (we receive many favorable reports of Great
Planes ARFs in scale competition!) In Fun Scale, the
“builder of the model”rule does not apply .To receive the five
points for scale documentation, the only proof required that
a full-size aircraft of this type in this paint/markings scheme
did exist is a single sheet such as a kit box cover from a
plastic model, a photo, or a profile painting, etc.If the photo
is in black and white, other written documentation of color
must be provided.Contact the AMA for a rule book with full
details.

IMAA

INTRODUCTIONTABLE OF CONTENTS

2

If you would like photos of the full-size Lancair for scale
documentation, or if you would like to study the photos to
add more scale details, photo packs are available from:

Bob’s Aircraft Documentation

3114 Y uk on A ve

Costa Mesa, CA 92626

Telephone: [phone]

Fax:[phone]

e-mail: www.bobsairdoc.com

1.Your Lancair 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 Lancair, if not assembled and operated correctly, could
possibly cause injury to yourself or spectators and damage
to property.

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

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

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

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

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

7. If you are not 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.

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:

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

The Lancair requires a minimum of a 5-channel radio and
receiver, plus: seven servos producing a minimum of 41oz.­in of torque, two Y-harness connectors, two 24" [610mm]
and two 12" [305mm] servo extensions.

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 manufacturer, provide you with a top
quality kit and instructions, but ultimately the quality and
flyability of your finished model depends on how y ou build
it; therefore, we cannot in any way guarantee the
performance of your completed model, and no
representations are expressed or implied as to the
performance or safety of your completed model.

PRO TECT YOUR MODEL,Y OURSELF

& OTHERS...FOLLOW THESE

IMPORTANT SAFETY PRECAUTIONS

3

The recommended engine size range for the Lancair is
.61 – .75 cu in [10 – 12cc] two-stroke, .91 cu in [15cc] four­stroke. We flew our prototype with the O.S.®.61 FX
(OSMG0561). We found this to be more than adequate
power. This coupled with the Top Flite®In-Cowl muffler
(TOPQ7917), exhaust header (TOPQ7920), and exhaust
deflector (HCAP2180) not only provided the correct power
combination but also makes for a very nice scale engine
installation. If an engine in the upper end of the size range
is used, remember that this is a scale model that is intended
to fly at scale-like speeds, so throttle management should
be practiced.

In addition to the items listed in the

“Decisions Y ou Must

Make”

section, the following is a list of hardware and
accessories required to finish the Lancair. Order numbers
are provided in parentheses.

❏ Engine and suitable propellers
❏ Exhaust deflector (HCAP2180)
❏

(2) 12" [300mm] Servo extension (HCAM2711 for Futaba®)

❏ (2) 24" [610mm] Serv o e xtension (HCAM2721 f or

Futaba)

❏ (2) Y-harness (HCAM2751 for Futaba)
❏ R/C foam rubber (1/4" [6mm] – HCAQ1000, or 1/2"

[13mm] – HCAQ1050)

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

In addition to common household tools and hobby tools, this
is the “short list” of the most important items required to
build the Lancair.

Great Planes Pro™CA and Epoxy glue

are recommended.

❏ 1/2 oz. [15g] Thin Pro CA (GPMR6001)
❏ 1 oz. [30g] Medium Pro CA+ (GPMR6008)
❏ Pro 30-minute epoxy (GPMR6047)
❏ Pro 6-minute epoxy (GPMR6045)
❏ Microballoon filler (TOPR1090)

Here is a list of optional tools mentioned in the manual that
will help you build the Lancair.

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

1/8" [3.2mm], 5/32" [4mm], 3/16" [4.8mm],
7/32" [5.6mm], 1/4" [6.4mm]

❏ #11 Blades (5-pack, HCAR0211)
❏ 3 Standard silicone tubing (GPMQ4131)
❏ 2 oz. [57g] Spray CA activator (GPMR6035)
❏ CA applicator tips (HCAR3780)
❏ CA debonder (GPMR6039)
❏ Epoxy brushes (6, GPMR8060)
❏ Mixing sticks (50, GPMR8055)
❏ Mixing cups (GPMR8056)
❏ 36" metal ruler (HCAR0475)
❏ Robar t Super Stand II (ROBP1402)
❏ Hobbico

®

Duster™can of compressed air (HCAR5500)

❏ Masking tape (TOPR8018)
❏ Threadlocker thread locking cement (GPMR6060)
❏ Rubbing alcohol (for epoxy clean up)
❏ Switch & Charge Jack Mounting Set (GPMM1000)
❏ Rotar y tool such as Dremel

®

Moto-Tool

®

❏ Rotar y tool reinforced cut-off wheel (GPMR8200)
❏ Ser vo horn drill (HCAR0698)
❏ Dead Center

™

Engine Mount Hole Locator (GPMR8130)

❏ Accu-Throw

™

Deflection Gauge (GPMR2405)

❏ CG Machine

™

(GPMR2400)

❏ Precision Magnetic Prop Balancer

™

(TOPQ5700)

❏ Sealing Iron (TOPR2100)
❏ Sandpaper–100, and 220-grit
❏ 6-32 T ap

• 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 for “socket

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.

IMPORTANT BUILDING NOTES

Optional Supplies & Tools

Adhesives & Building Supplies

Hardware & Accessories

ADDITIONAL ITEMS REQUIRED

Engine Recommendations

4

• 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.

• The Lancair is factory-covered with Top Flite

MonoKote®film.Should repairs ever be required, MonoK ote
can be patched with additional MonoKote purchased
separately.MonoKote is packaged in six-foot rolls, b ut 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.

White–TOPQ0204, Black–TOPQ0208

Sapphire Blue–TOPQ0226, Metallic Gold–TOPQ0404

Fuse = Fuselage

Stab = Horizontal Stabilizer

Fin = Ver tical Fin

LE = Leading Edge

TE = Trailing Edge
LG = Landing Gear
Ply = Plywood

" = Inches

COMMON ABBREVIATIONS

5

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

To convert inches to millimeters, multiply inches by 25.4

To order replacement parts for the Great Planes Lancair ARF, use the order numbers in the Replacement Parts List that
follows. Replacement parts are available only as listed. Not all parts are available separately (an aileron cannot be
purchased separately, but is only available with the wing kit). Replacement par ts are not available from Product Support,
but can be purchased from hobby shops or mail order/Internet order firms. Hardware items (screws, nuts, bolts) are also
available from these outlets. If you need assistance locating a dealer to purchase parts, visit www.greatplanes.com and
click on “Where to Buy.” If this kit is missing parts, contact Great Planes Product Support.

Replacement Parts List

Or

der Number Description How to Purchase

Missing pieces............................Contact Product Suppor t

Instruction manual ......................Contact Product Support

Full-size plans............................Not available

GPMA2320............................................Wing Kit

GPMA2321............................................Fuse Kit

GPMA2322............................................Tail Set

GPMA2323............................................Cowl

GPMA2327............................................Canopy

GPMA2324............................................Landing Gear

GPMA2325............................................Wheel Pants

GPMA2326............................................Tail Joiner Tube End Rod

ORDERING REPLACEMENT PARTS

.............

Contact Your Hobby
Supplier to Purchase
These Items

6

1. Fiberglass Fuselage
2 Left Wing/Aileron and Flap

3. Right Wing/Aileron and Flap

4. Left Stabilizer

5. Right Stabilizer

6. Rudder

7. Cowl

8. Fiberglass Wing Tips

9. Fiberglass Wheel Pants

10. Main Landing Gear

11. Wheels

12. Nose Gear Wire

13. Fiberglass Exhaust Air Panel

14. Spinner

15. Pushrod Wires

16. Engine Mount

17. Carbon Fiber Anti-Rotation Pin

18. Aluminum Tube

19. Wing Bolt Plate

20. Flap Covers

21. Forward Former

22. Rear Former

23. Serv o Tray (2)

24. Receiver/Battery Tra y (2)

25. Engine Baffle

26. CA Hinge Strip Mater ial

27. Wing Joiner (2)

28. Nose Wire Fairing

29. Aileron Covers

30. Nylon Hardware Bag

31. Metal Hardware Bag

32. Outer Pushrod Tubes

(4) 5/16" x 3/4" 7/8" Ser vo Mount Blocks
(2) 5/32" x 2" Axle
(1) Brass Screw-Lock Pushrod Connector
(2) 4-40 Blind Nuts
(4) 8-32 Blind Nuts
(2) 5/16-24 Lock Nut
(2) 1/4-20 Blind Nuts
(3) Large Nylon Control Hor n
(4) Small Nylon Control Hor n
(1) Nose Gear Bearing
(2) 1/4-20 Nylon Wing Bolt
(1) Nylon Steering Control Ar m
(8) Nylon Clevis

(1) Nylon Landing Gear Strap
(1) Nylon Retainer For Screw-Lock Pushrod

Connector
(1) 2" x 9" CA Hinge Material
(8) Nylon FasLinks
(8) Silicone Clevis Retainer
(1) 4-40 x 1/8" Socket Head Cap Screws
(4) 2-56 x 5/8" Machine Screw
(8) #4 x 1/2" Sheet Metal Screw
(5) 6-32 X 1/8" Set Screw
(3) 6-32 x 1/4" Socket Head Cap Screws
(2) #4 x 5/8" Sheet Metal Screw
(2) 4-40 x 5/8" Phillips Pan Head Screws

(40) #2 x 3/8" Sheet Metal Screw
(4) 2-56 x 3/4" Socket Head Cap Screws
(4) 6-32 x 1" Socket Head Cap Screws
(4) 8-32 x 1" Socket Head Cap Screws
(4) #2 x 1/2" Sheet Metal Screw
(8) 5/32" Wheel Collar
(4) .074 x 36" Wire Threaded One End
(4) .074 x 6" Pushrod Wire
(5) #6 Flat Washers
(22) #2 Flat Washers
(4) #8 Lock Washers
(4) #8 Flat Washers
(4) #6 Lock Washers

Kit Contents (Photographed)

Kit Contents (Not Photographed)

Before starting to build, use the Kit Contents list to 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 Great Planes Product Support. When reporting defective or missing parts, use the part
names exactly as they are written in the Kit Contents list on this page.

Great Planes Product Support:

Telephone: [phone]

Fax: [phone]

E-mail: air

[e-mail]

KIT CONTENTS

1

2

3

4

5

7

9

24

23

32

25

26

27

29

28

31

30

22

19

21

20

16

12

11

13

10

14

17

18

15

6

8

8

If you have never worked with fiberglass there are a few
basic things you should be aware of:

• When you are cutting into fiberglass, be sure you are

cutting the correct place. Unlike wood, you are not able to
go back and easily fix a mistake.

• Whenever you are gluing a part to the inside of fiberglass

it is important to roughen the inside surface of the
fiberglass with 220-grit sandpaper and then wipe the area
with alcohol. The molding process leaves a waxy residue
that can prevent a good bond between the glue and the
parts being glued.

• If you do not have a high-speed rotary tool such as a

Dremel®tool you should consider purchasing one or
borrowing one from a fellow modeler.This combined with
a fiberglass cut-off wheel is going to be extremely helpful
in the assembly process.

WARNING:The cowl, wheel pants and fuselage included in
this kit are made of fiberglass, the fibers of which may cause
eye, skin and respiratory tract irritation. Never blow into a
part 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.

❏ 1. If you have not done so already, remove the major

parts of the kit from the box and inspect for damage. If any
parts are damaged or missing, contact Product Suppor t at
the address or telephone number listed in the“Kit

Contents”

section on page 6.

❏ 2. Remove the tape and separate the ailerons and flaps

from the wing and the elevators from the stab. Use a
covering iron with a covering sock on high heat to tighten

the covering if necessary. Apply pressure over sheeted
areas to thoroughly bond the covering to the wood.

Do the right wing first so your work matc hes the photos
the first time through.You can do one wing at a time , or
work on them together.

❏❏1.Drill a 3/32" [2.4mm] hole, 1/2" [12.7mm] deep in the

center of each hinge slot to allow the CA to “wick”in. Follow­up with a #11 blade to clean out the slots.Hint: If you have
one, use a high-speed rotary tool to drill the holes.

❏❏2.Use a sharp #11 blade to cut a strip of covering from

the hinge slots in the wing and aileron.

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

CA hinge strip. Snip off the corners so they go in easier.

DRILL A 3/32" HOLE

1/2" DEEP, IN CENTER

OF HINGE SLOT

Install the Flaps & Ailerons

BUILD THE WING

PREPARATIONS

IMPORTANT INFORMATION ABOUT

WORKING WITH FIBERGLASS

7

1" [25mm]

3/4" [19mm]

Trim the Corners

❏❏4.T est fit the ailerons to the wing with the hinges .If the

hinges don’t remain centered, stick a pin through the middle
of the hinge to hold it in position.

❏❏5. Remove any pins you may have inserted into the

hinges. Adjust the aileron so there is a small gap between
the LE of the aileron and the wing.The gap should be small,
just enough to see light through or to slip a piece of paper
through.

❏❏6. Apply six drops of thin CA to the top and bottom of

each hinge. Do not use CA accelerator. After the CA has
fully hardened, test the hinges by pulling on the aileron.

❏❏7. Repeat this procedure for installing the flap using

four CA hinges.Note that the hinge slots on the flap are not
centered as the ailerons are.

❏❏8. Find the hole for the aileron servo by feeling the

covering on the bottom of the wing. Cut the covering 1/8"
[3mm] inside the opening in the wing for the aileron servo.
Use a trim iron to seal the covering to the inner edges of the
opening. Repeat this same procedure in the opening for the
flap servo.

❏❏9. On the top of the wing, cut the covering away from

the hole at the wing center-section. This hole is for the
aileron and flap servo wires to come through, into the
fuselage.

❏❏10. Locate the string from inside of the aileron ser vo

bay and tape it to the wing. Do not pull the string out of the
wing! Do the same with the string in the flap servo bay.

❏ 11. Repeat steps 1-10 for the left wing panel.

The following steps for installing the servos may be
somewhat different from other servo installations you are
familiar with. You may find it helpful to read through the
servo installation instructions to familiarize yourself with the
process before beginning the installation. Important!
Following these instructions will assure a safe and solid
servo installation.

❏❏1. Installing the ser vos in the wing will require the use

of one 24" [610mm] servo extension for the aileron.
Depending on your brand of servos you may find it
necessary to use one 6" [152mm] servo extension for each
of the flaps.Two Y-harness connectors are required and are
used to allow the aileron servos to plug into one slot in your

Install the Flaps & Aileron Servo

8

receiver and for the flaps to be plugged into another slot in
your receiver. You may have a computer radio that allows
you to plug the servos into separate slots and then mix them
together through the radio transmitter. If you choose to mix
them with the radio rather than Y-harnesses, refer to the
instructions for your particular brand of radio.

❏❏2. Attach the servo extensions to the aileron and flap

servos. Secure the connectors together using a large piece
of heat shrink tubing, tape or other suitable method. Lay the
servos, receiver and battery on your work bench, placing
the servos just as they will be when installed in the wing.
Remember that you are laying the servos on your bench just
as they will be placed into the bottom of the wing.(Note: You
will not need to install the rubber grommets and eyelets on
the servos for the aileron and flap installation). The servo
arms on the flap servos need to move the same direction.
The aileron servo arms must move opposite one another.
(Note the orientation in the above photograph; remember
you are looking at the bottom of the wing).

❏❏3. Turn your radio system on, allowing the servos to

center.Be sure that all of the radio trims are centered on the
transmitter.

❏❏4. Using the switch or rotary knob that you will be

using to activate the flaps, set the switch to the position that
will bring the flaps into the “up” position (normal flying
mode). Install the ser vo arms onto the servo with the arm
forward. This will allow the servo to push against the flap
control horn to keep the flap retracted.When the flap switch
is in the “flaps down” position (landing mode) the ar m will
rotate in the opposite direction, pulling the flaps down.
Operate the servo using the flap switch to be sure they are
moving the correct way.

Hint: On many brands of servo
arms you will find that each arm has a small number on it.
Each arm has a slightly different position on the servo spline
once it is installed. You will find it helpful for setting up the
flaps if you use two arms with the same number on it (see
above sketch).

❏❏5.Install the servo arms on the aileron servos , making

sure the arms are positioned as shown in the photograph in
step 2. Using your transmitter, operate the aileron servos
making sure that the arms are moving in directions opposite
of one another.When you are satisfied e verything is working
properly, turn off the radio system. Unplug the aileron and
flap servos from the receiver.

❏❏6. Locate the ABS aileron servo cover for the right

wing. Cut out the opening in the cover for the aileron servo
arm. The cut lines for the opening are on the inside of the
cover. Drill a 1/16" hole [1.6mm] in each corner of the
aileron cover.

❏❏7. The side of the aileron servo case that will rest

against the top of the wing inside of the servo bays needs to
be cleaned with rubbing alcohol. Do Not Omit This Step!
This surface must be free of any fuel or oil residue in order

9

to assure a good bond between the servo and the servo
tape that will be used for holding the servo to the wing.

❏❏8. Tie the string inside the aileron servo bay to the

aileron servo wire. Pull the ser vo wire out towards the wing
root with the string. Feed the end of the wire through the
hole in the top of the wing center-section.Remove the string
from the servo lead and tape the servo lead to the top of the
wing to prevent it from falling back into the wing.

❏❏9.Place the aileron servo into the servo bay.

Temporarily
place the aileron cover ov er the servo to help locate the final
position for the servo.Remove the cover and mak e a couple
of reference marks inside the servo bay for the servo
location. This will help you relocate the servo when it is
installed in the next step.

❏❏10. Using 6-minute epoxy, permanently glue the servo

in place inside the servo bay, gluing it to the wing skin.

Note:

We understand that some modelers may resist gluing a
servo permanently to the wing. Because of the very thin
airfoil it becomes difficult to make a removable servo
mounting assembly. Fortunately the ser vo required for the
aileron are the standard, inexpensive type and permanently

installing them should not be cost prohibitive.

The Expert

Tip

that follows presents an alternative method of gluing in
the servos.

❏❏11. Place the aileron servo cover over the servo,

making
sure the servo arm is centered in the cut out. Using the
cover as a guide, drill a 1/16" [1.6mm] hole into the wing

skin

through each of the holes in the cover. Remove the

cover.

❏❏12.Thread a #2 x 3/8" [9.5mm] sheet metal screw into

each of the four holes.Remove the screw, then saturate the
holes with thin CA. Enlarge the holes in the cover only with
a 3/32" [2.4mm] drill. Allow the CA to cure and then install
the cover into place over the servo.

❏❏13.Locate the wood flap servo cover f or the right wing.

Cut the covering from the opening for the servo in the cover.
Temporarily place the cover into position with the slot
towards the wing tip. Note: On the left wing, the slot in the
cover is towards the wing root. Drill a 1/16" hole [1.6mm]
through each corner of the aileron cover and through the
hardwood tabs

in the wing. Remove the cover. Drill a 3/32"

[2.4mm]

clearance hole through each of the holes in the

servo cover only!

Should you ever need to remove the servo simply cut the
heat shrink tubing and remove the servo. If you do not
have heat shrink tubing readily av ailab le , y ou can achie v e
similar results by wrapping the servo with electrical tape
and then gluing it in position.

One method for gluing the servo in place while still having
the option to remove it is to wrap 2-1/2" [64mm] heat
shrink tubing around the servo (PARC1625). This heat
shrink is commonly used for making battery packs. After
the servo is tightly encapsulated with the heat shrink
tubing, glue the servo in place in the wing.

10

❏❏14. Dr ill 1/16" [1.6mm] holes in two 5/16" x 3/4" x 7/8"

[7.9 x 19.1 x 22.2mm] servo mount blocks and mount the
aileron servo to the blocks using the screws that came with
the servo. Glue the ser vo mount blocks to the inside of the
flap servo cover with 6-minute epoxy.

❏❏15. After the epoxy has hardened, remove the screws

that mount the servos to the blocks. Apply a few drops of
thin CA to the holes and allow to harden.Remount the servo
to the blocks.

❏❏16. Tie the string inside the flap ser vo bay to the flap

servo wire. Pull the servo wire out the root of the wing with
the string. Feed the end of the wire through the hole in the
top of the wing center-section. Remove the string from the
servo wire and tape it to the top of the wing to prevent the
servo wire from falling back into the wing.

❏❏17.Use four #2 x 3/8" [9.5mm] sheet metal screws and

four #2 flat washers to attach the cover to the wing.

❏ 18. Repeat steps 1-17 for the left wing panel.

❏❏1. Position a small nylon control horn on the aileron,

positioning it as shown in the sketch and aligning it with the
servo.Mark the location for the screw holes.Drill through the
marks you made with a 3/32" [2.4mm] drill bit. Mount the
nylon control horn to the aileron by inserting two 2-56 x 5/8"
[2-56 x 16mm] machine screws through the control horn
and into the nylon mounting plate on the top of the aileron.

❏❏2. Locate a .074" x 6" [1.9 x 152mm] pushrod wire

threaded on one end. Thread a nylon clevis onto the
threaded end of the wire 20 turns. Install a silicone clevis
retainer onto the clevis.Then, install the clevis on the aileron
control horn.

❏❏3.Be sure the aileron servo is centered (plug the servo

into the receiver and turn the radio on to re-center it properly
if you are unsure). Enlarge the hole in the ser vo arm with a
Hobbico Servo Horn Drill (or a #48 or 5/64" [2mm] drill bit).
Center the aileron and align the wire pushrod with the hole
in the end of the servo arm. Using a marker, mark the

location
where the wire aligns with the hole in the servo arm. On that
mark make a 90° bend.From the bend measure an

additional

3/8" [9.5mm] and then cut off the excess pushrod wire.

❏❏4. Install the wire into the hole in the servo arm using

a nylon FasLink as shown in the sketch.

❏❏5. Position a small nylon control horn on the flap,

positioning it in the same manner as you did the aileron.

Mark

Install the Flap & Aileron Hardware

& Pushrods

11

the location for the screw holes.Dr ill through the mar ks you
made with a 1/16" [1.6mm] drill bit, drilling through the
plywood plate in the bottom of the flap. Do not drill all the
way through the flap. Install the screw, then remove it.
Harden the holes with thin CA.Mount the nylon control horn
to the flap with two #2 x 3/8" [#2 x 9.5mm] sheet metal

screws.

❏❏6. Locate a .074" x 6" [1.9 x 152mm] pushrod wire

threaded on one end. Thread a nylon clevis onto the
threaded end of the wire 20 turns. Install a silicone clevis
retainer onto the clevis. Then, install the clevis to the flap
control horn.

❏❏7.Be sure the flap servo arm is forward, in the position

that will pull the flap into the retracted position. (Plug the
servo into the receiver and turn the radio on to re-position it
properly if you are unsure). Enlarge the hole in the servo
arm with a Hobbico Servo Horn Drill (or a #48 or 5/64"
[2mm] drill bit). Position the flap to the retracted (neutral)
position and align the wire pushrod with the hole in the end
of the servo arm. Using a mar ker, mark the location where
the wire aligns with the hole in the servo arm. On that mark
make a 90° bend.From the bend measure an additional 3/8"
[9.5mm] and then cut off the excess pushrod wire.

❏❏8. Install the wire into the hole in the servo arm using

a nylon FasLink.

❏ 9. Repeat steps 1-8 for the left wing panel.

❏ 1. Locate the two 1/8" [3mm] plywood wing joiners.

Using 6-minute epoxy, glue them together, forming one 1/4"
[6mm] wing joiner.

❏ 2. Test fit the wing joiner into each wing panel, making

sure that it is not too tight. Sand the joiner as needed to get
a good fit.

❏3.Apply 30-minute epoxy to both sides of the wing joiner,

the joiner pocket in both wing panels and to the root rib of

each wing panel. Push the wing panels together and hold
them in place with masking tape. Before the glue cures, set
the wing flat on your bench and measure the dihedral.The
distance from the top of the bench to the bottom of the wing
should be approximately 4-1/8" [105mm].Block the wing tip
up while the glue cures.

Note: Due to production techniques
there may be some variance in the actual dihedral of each
model. Our prototypes flew well with the dihedral anywhere
between 3-7/8" and 4-1/4" [98mm and 108mm].

Minor

differences will not affect the flight characteristics.

❏ 4. Set the wing aside allowing the glue to cure.

❏ 5. Locate two 3/8" x 1-3/4" [9.5mm x45mm] wood

dowels. Apply 6-minute epoxy to the portion of the dowel
that will be inserted into the holes in the leading edge at the
center-section of the wing. Apply epoxy into the holes in the
center-section of the wing. Then, inser t the dowels into the
holes until they stop. Wipe away excess glue from the
dowels and set the wing aside to dry.

❏ 6. Locate the 1/4" [6mm] holes under the covering at the

trailing edge of the wing center-section. Cut the covering
away on both the top and bottom of the wing.

❏7.Lay the wing on your bench with the bottom of the wing

facing you. Locate the hardwood wing hold down plate.
Place the hold down plate in position at the wing trailing
edge with the tapered edge of the plate facing the front of

Join the Wings

12