Great Planes GPMA1350 User Manual

INSTRUCTION MANUAL

Wingspan: Top Wing: 71.5 in [1815mm] Bottom Wing: 69 in [1755mm]

Wing Area: Top WIng: 762 sq in [49.1 dm2] Bottom Wing: 704 sq in [45.4 dm2]

Weight: 14.5-15.5 lb [6580-7030 g]

Wing Loading: 23-24 oz/sq ft [69-74 g/dm2] Length: 57 in [1450mm]

Radio: 4-channel with 5-7 servos

Engine: .91-1.08 cu in [15-17.5cc] two-stroke, 1.20-1.40 cu in [19.5-23cc] four-stroke

WARRANTY

Great Planes® Model Manufacturing Co. guarantees this kit to		If the buyer is not prepared to accept the liability associated
be free from defects in both material and workmanship at the date		with the use of this product, the buyer is advised to return
of purchase. This warranty does not cover any component parts		this kit immediately in new and unused condition to the place
damaged by use or modification. In no case shall Great Planes’		of purchase.
liability exceed the original cost of the purchased kit. Further,
		To make a warranty claim, send	Hobby Services
Great Planes reserves the right to change or modify this warranty
			3002 N. Apollo Dr. Suite 1
without notice.		the defective part or item to
			Champaign IL 61822
		Hobby Services at this address.
			USA
In that Great Planes has no control over the final assembly or		Include a letter stating your name, return shipping address, as
material used for final assembly, no liability shall be assumed nor		much contact information as possible (daytime telephone number,
accepted for any damage resulting from the use by the user of the		fax number, e-mail address), a detailed description of the problem
final user-assembled product. By the act of using the user-		and a photocopy of the purchase receipt. Upon receipt of the
assembled product, the user accepts all resulting liability.		package the problem will be evaluated as quickly as possible.

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

Champaign, Illinois Telephone: [phone] ext. 5

[e-mail]

Entire Contents © Copyright 2004

GPMZ0295 for GPMA1350 V1

TABLE OF CONTENTS

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

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

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

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

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

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

KIT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

ORDERING REPLACEMENT PARTS . . . . . . . . . . . . . . 6

PREPARATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

BUILD THE WING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Install the Ailerons . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Join the Wing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Install the Aileron Servos & Pushrods . . . . . . . . . . . . . 9

BUILD THE FUSELAGE . . . . . . . . . . . . . . . . . . . . . . . 11

Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Install the Stab, Elevator, Fin & Rudder . . . . . . . . . . . 12

Attach the Wing & Cabanes . . . . . . . . . . . . . . . . . . . 14

Install the Aileron Connection Rod . . . . . . . . . . . . . . 17

Build the Carry Handle . . . . . . . . . . . . . . . . . . . . . . . 19

Install the Engine & Throttle Servo . . . . . . . . . . . . . . 20

Install the Cowl & Dummy Engine . . . . . . . . . . . . . . . 22

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

Assemble the Nose Weight Box . . . . . . . . . . . . . . . . 25

Install the Wheels & Wheel Pants . . . . . . . . . . . . . . . 26

Install the Radio System . . . . . . . . . . . . . . . . . . . . . . 28

Finishing Touches . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

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

GET THE MODEL READY TO FLY . . . . . . . . . . . . . . . 35

Check the Control Directions . . . . . . . . . . . . . . . . . . 35

Set the Control Throws . . . . . . . . . . . . . . . . . . . . . . . 35

Balance the Model (C.G.) . . . . . . . . . . . . . . . . . . . . . 36

Balance the Model Laterally . . . . . . . . . . . . . . . . . . . 36

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

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

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

Balance Propellers . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Ground Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Range Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

ENGINE SAFETY PRECAUTIONS . . . . . . . . . . . . . . . 37

AMA SAFETY CODE . . . . . . . . . . . . . . . . . . . . . . . . . 38

IMAA SAFETY CODE . . . . . . . . . . . . . . . . . . . . . . . . . 38

CHECK LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

FLYING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Mount the Wing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Fuel Mixture Adjustments . . . . . . . . . . . . . . . . . . . . . 39

Takeoff . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Flight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Landing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

INTRODUCTION

The Stearman has a long and colorful history in both military and civilian use. The Great Planes® Super Stearman ARF represents the best performing version of the civilian modifications made. You will thoroughly enjoy the wide range of capabilities of this plane as well as its good looks. We think you will be pleased with the attention to detail and its flight characteristics. For the latest technical updates or manual corrections to the Super Stearman visit the Great Planes web site at www.greatplanes.com. Open the “Airplanes” link, then select the Super Stearman 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.

IMAA

The Great Planes Super Stearman is an excellent sportscale model and is eligible to fly in IMAA events. The IMAA (International Miniature Aircraft Association) is an organization that promotes non-competitive flying of giantscale models. If you plan to attend an IMAA event, obtain a copy of the IMAA Safety Code by contacting the IMAA at the address or telephone number below, or by logging on to their web site at:

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

205 S. Hilldale Road

Salina, KS 67401 [phone]

PROTECT YOUR MODEL,YOURSELF & OTHERS...FOLLOW THESE IMPORTANT SAFETY PRECAUTIONS

1.Your Super Stearman 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 Super Stearman, 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.

2

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.

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

NOTE: We, as the kit manufacturer, provide you with a top quality kit and great instructions, but ultimately the quality 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.

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:

Academy of Model Aeronautics

5151 East Memorial Drive

Muncie, IN 47302-9252

Tele. [phone]

Fax [phone]

Or via the Internet at: http://www.modelaircraft.org

ADDITIONAL ITEMS REQUIRED

Hardware and Accessories

This is the list of hardware and accessories required to finish the Super Stearman. Order numbers are provided in parentheses.

Engine (refer to the engine size requirements on the cover of the manual)

4-Channel radio

(1) standard servo (throttle)

(4)servos with minimum of 54 oz/in torque (2-ailerons, 1-elevator, 1-rudder)

(2)12" [300mm] servo extensions (for aileron servos, HCAM2711 for Futaba® )

(1) Y-harness (for aileron servos, HCAM2751 for Futaba)

(1) minimum 1,000mAh receiver battery

Propeller and spare propellers (refer to your engine manufacturer's recommendations)

2' [600mm] large, silicone fuel tubing (GPMQ4133)

Optional: If building the Super Stearman with four aileron servos, in addition to the items previously mentioned you will also need two more aileron servos, two more servo extensions and one more Y-harness.

Adhesives and Building Supplies

In addition to common household tools and hobby tools, this is the “short list” of the most important items required to build the Super Stearman. Great Planes Pro™ CA and Epoxy glue are recommended.

R/C foam rubber (1/4" [6mm] - HCAQ1000, or 1/2" [13mm] - HCAQ1050)

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

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

Pro 30-minute epoxy (GPMR6047)

Pro 6-minute epoxy (GPMR6045)

Drill bits: 1/16" [1.6mm], 5/64" [2mm], 3/32" [2.4mm], 1/8" [3.2mm], #29 or 9/64" [3.6mm], 3/16" [4.8mm],

3 pkgs Stick-on segmented lead weights (GPMQ4485)

#1 Hobby knife (HCAR0105)

#11 blades (5-pack, HCAR0211)

Small T-pins (100, HCAR5100)

R/C-56 canopy glue (JOZR5007)

CA applicator tips (HCAR3780)

Denatured Alcohol (for epoxy cleanup)

Flat Black Fuelproof Paint (for cockpit)

8-32 Tap (GPMR8103)

8-32 Tap Handle (GPMR8120)

3

Optional Supplies and Tools

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

2 oz. [57g] spray CA activator (GPMR6035)

-or -

4 oz. [113g] aerosol CA activator (GPMR634)

Epoxy brushes (6, GPMR8060)

Mixing sticks (50, GPMR8055)

Mixing cups (GPMR8056)

Builder’s Triangle Set (HCAR0480)

Curved-tip canopy scissors for trimming plastic parts (HCAR0667)

Pliers with wire cutter (HCAR0630)

Robart Super Stand II (ROBP1402)

Hobbico® Duster™ can of compressed air (HCAR5500)

Masking tape (TOPR8018)

Microballoons (TOPR1090)

Threadlocker thread locking cement (GPMR6060)

Denatured alcohol (for epoxy clean up)

Rotary tool such as Dremel™

Rotary tool reinforced cut-off wheel (GPMR8200)

Servo horn drill (HCAR0698)

Dead Center™ Engine Mount Hole Locator (GPMR8130)

AccuThrow™ Deflection Gauge (GPMR2405)

CG Machine™ (GPMR2400)

Precision Magnetic Prop Balancer™ (TOPQ5700)

Fuel filler valve for glow fuel (GPMQ4160)

Important Building Notes

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" [19mm]

This is a number six screw that is 3/4" [19mm] long.

Machine screws are designated by a number, threads per inch, and a length.

For example 4-40 x 3/4" [19mm]

This is a number four screw that is 3/4" [19mm] 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 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 30minute (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 Super Stearman 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.

White	TOPQ0204
Black	TOPQ0208
True Red	TOPQ0227

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

Metric Conversions

1" = 25.4mm (conversion factor)

1/64"	= .4mm	1"	= 25.4mm
1/32"	= .8mm	2"	= 50.8mm
1/16"	= 1.6mm	3"	= 76.2mm
3/32"	= 2.4mm	6"	= 152.4mm
1/8"	= 3.2mm	12"	= 304.8mm
5/32"	= 4mm	15"	= 381mm
3/16"	= 4.8mm	18"	= 457.2mm
1/4"	= 6.4mm	21"	= 533.4mm
3/8"	= 9.5mm	24"	= 609.6mm
1/2"	= 12.7mm	30"	= 762mm
5/8"	= 15.9mm	36" = 914.4mm
3/4"	= 19mm

4

KIT INSPECTION

Before starting to build, take an inventory of this kit to make

Great Planes Product Support

sure it is complete, and inspect the parts to make sure they

3002 N Apollo Drive, Suite 1

are of acceptable quality. If any parts are missing or are not

Champaign, IL 61822

of acceptable quality, or if you need assistance with

assembly, contact Product Support. When reporting

Telephone: [phone], ext. 5

defective or missing parts, use the part names exactly as

Fax: [phone]

they are written in the Kit Contents list on this page.

E-mail: [e-mail]

Parts Layout

2

10

20

11

21

14

16

12

4

7

	PARTS NOT PHOTOGRAPHED
PARTS PHOTOGRAPHED
		Qty		Qty
1. Fuselage	4-40 Threaded Metal Clevis	. . . . . 4	8-32 x 3/4” SHCS . . . . . . . . .	. . . .5
2. Cowl	3/16 x 2”Axle . . . . . . . . . . . .	. . . . .2	4-40 x 1/2” SHCS . . . . . . . . .	. . .16
3. Fin & Rudder	BrassEZConnector . . . . . . .	. . . . .1	4-40 x 1/2” Phillips Head M/S	. . . .8
4. Stab & Elevator	4-40 Blind Nuts . . . . . . . . . .	. . . .20	#2 x 3/8” WoodScrew . . . . . . .	. . . .8
5. Top, Left Wing & Aileron	4-40 Nuts . . . . . . . . . . . . . .	. . . . .4	8-32 x 1-1/4” SHCS . . . . . . . .	. . . .4
6. Top, Right Wing & Aileron	8-32 Blind Nuts . . . . . . . . . .	. . . . .9	8-32 x 1”SHCS . . . . . . . . . . . .	. . .4
7. Bottom, Left Wing & Aileron	5/16-24 Axle Nut . . . . . . . . .	. . . . .2	#2 x 1/2” SMS . . . . . . . . . . . . .	. . .4
8. Bottom, Right Wing & Aileron	1/4-20 Blind Nut . . . . . . . . .	. . . . .2	#4 x 1” MS . . . . . . . . . . . . . . .	. . .4
9. Fuel Tank	4-40 Nylon Lock Nuts . . . . .	. . . . .8	3/32” Wheel Collar . . . . . . . . . .	. . .1
10. Engine Mount	Large Nylon Control Horn . .	. . . . .7	5/32” Wheel Collar . . . . . . . . . .	. . .2
11. Spinner	Small Nylon Control Horn . .	. . . . .4	3/16” Wheel Collar . . . . . . . . . .	. . .4
12. Wheel Pants	1/4-20 Nylon Bolt . . . . . . . . .	. . . . .2	1-1/4” Tail Wheel . . . . . . . . . . .	. . .1
13. Landing Gear	Nylon Clevis . . . . . . . . . . . .	. . . . .7	.074 x 17-1/2”” Pushrod Wire . .	. . .1
14. Cowl Ring	Nylon Retainer . . . . . . . . . .	. . . . .1	.074 x 36” Pushrod Wire . . . . .	. . .3
15. Wheels	2” x 9” Hinge material . . . . .	. . . . .1	.074 x 6” Pushrod Wire . . . . . .	. . .4
16. Turtle Deck	Faslink . . . . . . . . . . . . . . . .	. . . . .7	#4 Lock Washers . . . . . . . . . . .	. .16
17. Windshields	Clevis Retainer . . . . . . . . . .	. . . .11	#4 Flat Washer . . . . . . . . . . . .	. .24
18. Cockpit Coaming	#4 x 1/2” SMS . . . . . . . . . . .	. . . . .4	#2 FlatWasher . . . . . . . . . . . . .	. .10
19. Tail Wheel Assembly	6-32 x1/4” SHCS . . . . . . . . .	. . . . .6	#8 Lock Washers . . . . . . . . . . .	. . .8
20. Cabanes	4-40 x 1/8” Set Screw . . . . .	. . . . .1	#8 FlatWasher . . . . . . . . . . . . .	. . .8
21. Struts	4-40x 1/4”SHCS . . . . . . . . .	. . . . .1	4-40 x 3/4” SHCS . . . . . . . . . .	. . .4
	#2 x 3/8” SMS . . . . . . . . . . .	. . . .28

5

Ordering Replacement Parts

Replacement parts for the Great Planes Super Stearman 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. Parts may also be ordered directly from Hobby Services, but full retail prices and shipping and handling charges will apply. Illinois and Nevada residents will also be charged sales tax.

To locate a hobby dealer, visit the Hobbico web site at www.hobbico.com. Choose "Where to Buy" at the bottom of the menu on the left side of the page. Follow the instructions provided on the page to locate a U.S., Canadian or International dealer. If a hobby shop is not available, replacement parts may also be ordered from Tower Hobbies at www.towerhobbies.com, or by calling toll free [phone], or from Hobby Services by calling [phone], or via facsimile at [phone]. If ordering via fax, include a Visa or MasterCard number 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.

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

[e-mail]

REPLACEMENT PARTS LIST

Order Number	Description	How to purchase
GPMA2460 . . . . .	Bottom Wing Set . . .	. . Hobby Supplier
GPMA2461 . . . . .	Top Wing Set . . . . .	. . Hobby Supplier
GPMA2462 . . . . .	Fuselage Kit . . . . . .	. . Hobby Supplier
GPMA2463 . . . . .	Tail Surface Set. . . .	. . Hobby Supplier
GPMA2464 . . . . .	Landing Gear . . . . .	. . Hobby Supplier
GPMA2465 . . . . .	Cowl Set . . . . . . . . .	. . Hobby Supplier
GPMA2466 . . . . .	Wheel Pant Set. . . .	. . Hobby Supplier
GPMA2467 . . . . .	Cabane Set. . . . . . .	. . Hobby Supplier
GPMA2468 . . . . .	Strut Set . . . . . . . . .	. . Hobby Supplier
GPMA2469 . . . . .	Spinner . . . . . . . . . .	. . Hobby Supplier
GPMA2470 . . . . .	"Dummy" Radial Eng. . Hobby Supplier
GPMA2471 . . . . .	Decal Sheet . . . . . .	. . Hobby Supplier
GPMA2472 . . . . .	Windscreen Set . . . . . Hobby Supplier
GPMA2473 . . . . .	Metal Brackets . . . .	. . Hobby Supplier
GPMZ0293 . . . . .	Instruction Manual. .	. . Hobby Supplier
	Missing pieces. . . . .	. Product Support
	Instruction manual . .	. Product Support
	Full-size plans. . . . .	. . . . Not available

Important Information about

Working with Fiberglass

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

1.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.

2.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, 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.

3.If you do not have a high-speed motor 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.

PREPARATIONS

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 Support at the address or telephone number listed in the “Kit Inspection” section on page 5.

2. Carefully remove the tape and separate the ailerons from the wing and the elevators from the stab. If necessary, use a covering iron with a covering sock on high heat to tighten the covering. Apply pressure over sheeted areas to thoroughly bond the covering to the wood.

6

BUILD THE WING

Install the Ailerons

Do the right wing first so your work matches 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" [13mm] 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 fourteen 3/4" x 1" [19 x 25mm] hinges from the CA hinge strip. Snip off the corners so they go in easier.

4. Test 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 cured, test the hinges by pulling on the aileron.

7. Repeat steps 1- 6 for the left wing panel.

8. Follow the same procedure for installing the ailerons on the top wing panels. Install the ailerons to the top wing panel with three hinges in each aileron.

Join the Wing

Before installing the aileron servos you must make a decision on whether you will use two or four servos to drive the four ailerons. A separate servo bay is located in each wing panel for a four-servo installation. Should you choose to use the two-servo installation an aileron connecting rod goes between the top and bottom ailerons. The use of a connecting rod between the top and bottom wing is “scale” for a Stearman. If you choose to use the four servos you will not be able to use the aileron connecting rod due to the differential that is created between the top and bottom aileron. You will not have any noticeable performance difference with either option. If you do use two servos you will need to make sure they are at least 54 oz-in servos. Using four servos allows you to use less powerful servos (and most likely less expensive servos) but they will need to be at least 30 oz-in servos.

The following steps are required whether you install two or four servos.

1. Cut away the covering from the servo bay in the bottom of the right bottom wing panel. Turn the wing over and cut the covering from the hole in the top of the wing at the wing root.

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2. A string is taped inside the servo bay. Carefully remove the string from the servo bay and tape it to the outside of the wing to prevent it from dropping back into the wing. The other end of the string is taped to the root rib. Remove the tape, thread the string through the small holes you cut the covering from on the bottom of the wing and tape the string to the wing.

3. Repeat steps 1 and 2 for the left bottom wing.

If you are installing servos in the top wing, proceed with steps 4 and 5. If not, skip ahead to step 6.

4. Starting with the right wing panel for the top wing, cut away the covering from the servo opening on the bottom of the wing and the covering from the hole at the root of the wing. Remove the tape from the root rib, thread the string through the hole and tape the string to the wing. Tape the string in the servo bay to the wing, too.

5. Repeat step 4 for the left wing.

6. Locate three 1/8" [3mm] straight plywood wing joiners and three 1/8" [3mm] plywood wing joiners that are angled. Using 6-minute epoxy, glue the straight ones together to form one 3/8" [10mm] joiner and glue the three angled ones together forming the 3/8" [10mm] angled wing joiner.

7. After the glue has cured, test fit the angled joiner into the bottom wing panels and the straight joiner into the top wing panels. Sand the joiners as needed to get a good fit.

8. When you are satisfied with the fit of the joiners, glue the angled joiner into the bottom wing panels with 30-minute epoxy. Be sure that the top of the joiner is towards the top of the wing. When gluing the wing panels together be sure to get glue into the joiner pockets in the wing. This can be done by applying the glue into the pocket with a small stick. Apply glue to the pocket, the joiner and the root rib of the wing.

Before the glue cures, set one wing half flat on your bench. Insert the 1/2" x1/2" x 3" [13 x 13 x 75mm] balsa block under the trailing edge of the wing that sits flat on the workbench. Block up the wing tip of the other wing half with the 2-1/16" x 2-1/16" x 2-1/16" [52 x 52 x 52mm] balsa block included in the kit. Put small weights on the wing half that is flat on the bench to keep it lying flat and leave the block under the wing tip of the other wing half while the glue cures.

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9. Hold the wing together with masking tape while the glue is curing. Excess epoxy can be cleaned away with denatured alcohol and a paper towel.

10. Glue the top wing together using the straight wing joiner and following the same gluing procedure used on the bottom wing. Note: There is no dihedral on the top wing. After gluing the wing together be sure it remains flat on the workbench while the glue cures.

Install the Aileron Servos & Pushrods

1. On the lower wing, install a 12" [305mm] servo extension onto the servo lead. Secure the extension to the lead with tape, a piece of shrink tube or some other method to keep them from coming unplugged.

2. Tie the string to the servo extension. At the root of the wing the other end of the string is taped. Pull the string and the servo lead through the wing. Untie the string from the lead and insert the lead through the small hole you cut the covering from. Tape the lead to the wing to prevent it from falling back into the wing.

3. Install the servo into the servo opening. Drill through the servo mounting holes with a 1/16" [1.6mm] drill bit. Remove the servo from the servo opening. Install and then remove a servo mounting screw into each of the holes you have drilled. Apply a drop of thin CA into the holes to harden the threads. Once the glue has cured install the servo into the servo opening using the hardware included with your servo. Center the servo, then install a servo arm as shown. The arm should be pointing towards the wingtip.

4. Place a nylon clevis in line with the last hole in the servo arm. When positioned properly the control horn will rest on a hardwood plate in the aileron. Mark the location of the mounting holes onto the aileron. Drill a 1/16" [1.6mm] hole on the marks, drilling through the plywood plate but not through the top of the aileron. Insert and remove a #2 x3/8" [10mm] screw into each of the holes. Apply a couple drops of thin CA into the holes to harden the threads. Once the glue has cured attach the horn to the aileron with two #2 x 3/8" [10mm] screws.

5. Thread a nylon clevis onto a .074 x 6" [152mm] threaded wire 20 turns. Slide a silicone clevis retainer onto the clevis. Install the clevis into the second hole from the end of the control horn, then slide the silicone retainer over

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the clevis. Drill a 5/64" [2mm] hole in the outer hole of the servo arm. Center the servo and the aileron. With a fine-tip marker, mark the wire where it aligns with the outer hole of the servo arm. Make a 90 degree bend on the mark. Cut the wire so the wire is 3/8" [10mm] in length after the bend. Insert the wire into the servo arm and lock it in place with a nylon Faslink.

6. Repeat steps 1-5 for the left wing panel.

If you are installing servos in the top wing, repeat steps 1-6 for the top wing. If not, skip ahead to Step 12. Steps 7- 11 are only if you are installing servos in the top wing.

7. A “Y” harness is required to connect the servos in the upper wing to the receiver. Plug the two servo leads in the top wing into a “Y” harness compatible with your radio system. To provide a plug into the receiver we have used a slightly modified Ernst Charge Receptacle (ERN3124 for Futaba) and a 12" [305mm] servo extension.

8. Cut the charge receptacle in half just above the locking fingers.

9. Put a couple of small drops of medium CA on the sides of the female end of the servo extension. Then slide the servo extension into the charge receptacle.

10. Near one of the cabanes, cut a hole in the top of the fuselage just large enough for the servo extension and the

charge receptacle to fit into. Drill a 1/16" [16mm] hole into the fuselage through each of the mounting holes in the charge receptacle. Thread and remove the screws from the charge receptacle into the holes you drilled. Apply thin CA into the holes to harden the threads. Glue the charge receptacle to the fuselage with R/C 56 canopy glue. Install the mounting screws in the charge receptacle, into the holes you have drilled.

Later, when you are installing the radio system, this servo extension will be plugged into the proper channel of your receiver. When preparing the airplane to fly you will be able to plug the upper wing servos into the receptacle, completing the the connection from the upper wing to the receiver.

11. On the bottom wing, cut the covering away from the holes in the leading edge of the wing for the nylon wing dowels. Glue them in place with 6-minute epoxy. Wipe any excess epoxy away with denatured alcohol. When properly positioned the wing dowels should extend approximately 3/8" [10mm] beyond the leading edge of the wing.

12. Cut the covering from the holes on the plywood wing bolt plate.

13. Cut the covering from the holes at the wing trailing edge on both the top and bottom of the wing.

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14. Place the wing bolt plate in position over the holes in the bottom wing. Use the nylon wing bolts to help you align the holes in the plate with the holes in the wing. Trace the outline of the plate onto the covering with a felt-tip pen. Use a sharp #11 blade or the expert tip that follows to cut the covering inside the lines you have drawn. Use caution not to cut through the surface of the wing skin. Remove the covering.

HOW TO CUT COVERING FROM BALSA.

Use a soldering iron to cut the covering. The tip of the soldering iron doesn't have to be sharp, but a fine tip does work best. Allow the iron to heat fully. Use a straightedge to guide the soldering iron at a rate that will just melt the covering and not burn into the wood. The hotter the soldering iron, the faster it must travel to melt a fine cut. Peel off the covering.

15. Glue the wing bolt plate to the wing using epoxy. Use small clamps to hold the wing bolt plate in position while the glue cures.

BUILD THE FUSELAGE

Preparations

1. Remove the belly pan from the bottom of the fuselage. Install the landing gear to the fuselage with five 8-32 x 3/4" [19mm] socket head cap screws. Apply a drop of thread locker to each bolt before installing them.

2. Glue the belly pan back in place with a few dabs of silicone glue. Using silicone will allow you to remove the belly pan easily should you ever have to get access to the landing gear bolts.

We will come back and do the installation of the wheels and wheel pants later. Having the landing gear installed at this time will make it easier to handle the fuselage on the workbench.

3. Cut the covering from the fuselage where the horizontal stabilizer fits into the fuselage.

4. Cut the covering and the wood block from the back of the horizontal stabilizer saddle.

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Install the Stab, Elevator, Fin & Rudder

1. Temporarily attach the lower wing to the fuselage with the 1/4-20 nylon bolts. Slide the horizontal stabilizer into the slot in the fuselage. Stand back and look at the stab in relation to the wing. The stab should be parallel with the wing. If not, sand the stab saddle until the stab and wing are aligned.

2. Measure the distance from the tip of the stab to the tip of each wing. Adjust the position of the stab until they are equal.

3. Using a felt-tip pen, mark the outline of the fuselage on the top and the bottom of the stab.

4. Cut the covering on the top and bottom of the stab inside the line you have drawn. Use the same technique for removing the covering from the wing.

5. Glue the stab in place with 30-minute epoxy. Excess epoxy can be cleaned away with a paper towel and denatured alcohol. After the stab is positioned and all excess epoxy has been cleaned away, temporarily install the vertical fin part of the way into the slot. Just put it into place enough to verify that you have not pushed the wood fuselage fairings too close together and that the slot in the stab is aligned with the opening for the fin. Remove the fin and allow the glue to cure. If any glue has gotten on the fin, remove it with denatured alcohol.

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