Great Planes GPMA1411 User Manual

WARRANTY

Great Planes®Model Manufacturing Co. guarantees this kit to be free from defects in both material and workmanship at the date of purchase.
This warranty does not cover any component parts damaged by use or modification. In no case shall Great Planes’ liability exceed the
original cost of the purchased kit. Fur ther, Great Planes reserves the right to change or modify this warranty without notice.

In that Great Planes has no control over the final assembly or material used for final assembly, no liability shall be assumed nor accepted for
any damage resulting from the use by the user of the final user-assembled product.By the act of using the user-assembled product, the user
accepts all resulting liability.

If the buyer is not prepared to accept the liability associated with the use of this product, the buyer is advised to return this kit
immediately in new and unused condition to the place of purchase.

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

Hobby Services

3002 N. Apollo Dr., Suite 1

Champaign, IL 61822

USA

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.

READ THROUGH THIS MANUAL BEFORE STARTING
CONSTRUCTION.IT CONT AINS IMPOR T ANT INSTR UCTIONS
AND WARNINGS CONCERNING THE ASSEMBLY AND
USE OF THIS MODEL.

GPMZ0187 for GPMA1411 V1.1Entire Contents © Copyright 2006

Champaign, Illinois

[phone], Ext 5

[e-mail]

INSTRUCTION MANUAL

Wingspan: 81 in [2055 mm]
Wing Area: 1138 sq in [73.4 dm2]
Weight: 12.5 – 15.25 lb [5670 – 6860 g]
Wing Loading: 25 – 30 oz/sq ft [77 – 93 g/dm2]
Length: 68 in [1727 mm]
Radio: 4–6 channel, 7 ser vos minimum
Engine: 1.5 – 1.8 cu in [25 – 30 cc] two-stroke glow engine,

1.8 – 2.1 cu in [30 – 36 cc] four-stroke glow engine,

1.9 – 2.6 cu in [32 – 43 cc] gasoline engine

2

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

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

IMAA..................................................................................3

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

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

Fuel Tank Setup...........................................................3

Building Stand.............................................................4

Radio Equipment .........................................................4

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

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

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

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

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

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

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

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

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

KIT INSPECTION..............................................................7

KIT CONTENTS ................................................................7

PREPARATIONS ...............................................................8

ASSEMBLE THE WING ....................................................8

Install the Ailerons.......................................................8

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

Finish the Wing..........................................................10

ASSEMBLE THE FUSELAGE.........................................11

Install the Rudder & Tail Gear...................................11

Assemble & Install the Main Gear.............................12

Install the Elevators & Stabilizer ................................13

Install the Elevator Servos & Linkage.......................15

Install the Rudder Servos & Linkage

(Recommended Glow Engine Installation)......................16

Install the Rudder Servos & Linkage

(Recommended Gas Engine Installation)........................18

INSTALL THE ENGINE & FUEL TANK ...........................19

Glow Engine Installation............................................19

Install the Throttle Servo (Glow Engine)...................19

Install the Fuel Tank (Glow Engine) ..........................20

Optional Gas Engine Installation ...............................21

Install the Throttle Servo (Gas Engine) .....................23

Prepare the Cowl.......................................................23

FINISH THE MODEL .......................................................25

Install the Radio System ...........................................25

Install the Cowl..........................................................26

Install the Spinner .....................................................27

Attach the Wing & Canopy........................................27

Apply the Decals .......................................................28

GET THE MODEL READY TO FLY .................................28

Check the Control Directions ....................................28

Set the Control Throws..............................................29

Balance the Model (C.G.)..........................................29

Balance the Model Laterally ......................................30

PREFLIGHT.....................................................................30

Identify Your Model ....................................................30

Charge the Batteries .................................................30

Balance the Propellers..............................................30

Ground Check...........................................................30

Range Check.............................................................30

ENGINE SAFETY PRECAUTIONS.................................31

AMA SAFETY CODE (excerpts)....................................31

IMAA SAFETY CODE (excerpts)...................................32

CHECK LIST ...................................................................33

FLYING ............................................................................34

Fuel Mixture Adjustments..........................................34

Takeoff.......................................................................34

Flight..........................................................................34

Landing......................................................................34

ENGINE MOUNTING TEMPLATES ........Back Cover Page

The Yak 54 1.60 ARF is a great 3D model mixed with a b lend
of precision aerobatics.The Yak is fully capable of doing any
3D maneuver that exists or that you can dream of.The Yak
is also capable of doing “IMAC” style aerobatics and would
be fully acceptable for flying in the “Unlimited”class.The Yak
54 1.60 ARF is the perfect airplane for the modeler that
wants to improve his or her 3D skills or wants to start flying
IMAC with a low cost budget in mind.

The Yak 54 1.60 ARF is capable of doing blenders, torque rolls,
harriers inverted and upright, harrier rolls, waterfalls, walls,
parachutes and anything else you can dream up. It is also
designed to fly exceptionally precise for doing IMAC aerobatics.

For the latest technical updates or manual corrections to the
Yak 54 1.60 ARF, visit the Great Planes web site at
www.greatplanes.com. Open the “Airplanes” link, then
select the Yak 54 1.60 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.

We urge you to join the AMA (Academy of Model
Aeronautics) and a local R/C club.The AMA is the governing
body of model aviation and membership is required to fly at
AMA clubs.Though joining the AMA provides many benefits,
one of the primary reasons to join is liability protection.
Coverage is not limited to flying at contests or on the club
field. It even applies to flying at public demonstrations and
air shows. Failure to comply with the Safety Code (excerpts
printed in the back of the manual) may endanger insurance
coverage.Additionally, training programs and instructors are
available at AMA club sites to help you get started the right
way. There are over 2,500 AMA chartered clubs across the
country. Contact the AMA at the address or toll-free phone
number below.

IMPORTANT!!! T wo of the most important things you can do
to preserve the radio controlled aircraft hobby are to avoid
flying near full-scale aircraft and avoid flying near or over
groups of people.

Academy of Model Aeronautics

5151 East Memorial Drive

Muncie, IN 47302

Tele: [phone]

Fax [phone]

Or via the Internet at:

http://www.modelaircraft.org

AMA

INTRODUCTIONTABLE OF CONTENTS

The Great Planes Yak 54 1.60 ARF 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.

IMAA

205 S. Hilldale Road

Salina, KS 67401

[phone]

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

1.Your Yak 54 1.60 ARF 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 Yak 54 1.60 ARF, 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 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 , y our local hobb y
shop has information about clubs in your area whose
membership includes experienced pilots.

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, or 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 .

9. WARNING: The cowl and wheel spats 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
(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.

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

This is a partial list of items required to finish the Yak 54 1.60
ARF that may require planning or decision-making before
starting to build. Order numbers are provided in parentheses.

The fuel tank included with this kit is suitable for use with
glow fuel.However, if using a gas engine, the fuel tank must
be converted to work with gasoline. This can be done by
purchasing a Sullivan #484 Gasoline/Diesel fuel tank
conversion kit (SULQ2684), a package of Du-Bro #813 1/8"
[3.2 mm] I.D. fuel line barbs (DUBQ0670) and 3' of Great
Planes gasoline fuel tubing (GPMQ4135). Without the fuel
line barbs, some types of gas-compatible fuel line may slip
off the metal fuel tubes. If the Sullivan conversion kit is not
available, the Du-Bro #400 gas conversion stopper
(DUBQ0675) and one 12" [300 mm] piece of K+S 1/8" [3.2
mm] soft brass tubing (K+SR5128–box of 5) could also be
used to make the conversion.

Fuel T ank Setup

DECISIONS YOU MUST MAKE

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

PRO TECT YOUR MODEL,YOURSELF

& OTHERS...FOLLOW THESE

IMPORTANT SAFETY PRECAUTIONS

IMAA

3

A building stand or cradle comes in handy during the build.We
use the Robart Super Stand II (ROBP1402) for all our projects
in R&D , and it can be seen in pictures throughout this manual.

Since the Yak 54 1.60 ARF is a large model capable of
extreme aerobatics, standard servos should not be used to
operate the control surfaces.Servos with a minimum torque
rating of 98 oz-in [7.1 kg-cm] are required except for the
throttle servo, which may be operated by a standard servo.

The following servo extensions and Y-harnesses were also
used to build the Yak 54 1.60 ARF as shown in the manual.

• (2) 36" [910mm] servo extensions for elevator servos
(HCAM2726 for Futaba J-connector)

• (2) 36" [910mm] servo extension for tail mounted rudder
servos (HCAM2726 for Futaba J-connector)

• (2) 24" [610mm] servo extensions for aileron servos
(HCAM2721 for Futaba J-connector)

• (2) 6" [150mm] servo extensions for forward mounted
rudder servos (HCAM2701 for Futaba J-connector)

• (1) 12" [305mm] servo extension for throttle servo
(HCAM2711 for Futaba J-connector)

Optional: (If using a radio system that does not support
mixing of the elevator, rudder, and aileron servos,
Y-harnesses will be required)

• (2) Hobbico®Pro HD Y-Harness (HCAM2751 for Futaba
J-connector)

• (1) Reversing Y-Har ness (for elevator servos)

• A battery pack with a minimum of 1500mAh should also
be used. When flying large models such as this,
ALWAYS check the battery condition before each flight.

The recommended engine size range for the Yak 54 1.60
ARF is 1.5 to 1.8 cu in [25–30 cc] two-stroke glow engine,

1.8 to 2.1 cu in [30–36 cc] four-stroke glow engine, or 1.9 to

2.6 cu in [32–43 cc] gasoline engine.We recommend either

the O.S.®1.60 FX glow engine (OSMG0661) or the Fuji­Imvac™BT-43 EI™gasoline engine (FJIG0143).Both of these
engines will allow the Yak 54 1.60 ARF to perform the 3D
maneuvers it was designed for and the installations of both
engines are covered in this manual. Do not install an

engine larger than recommended!

This is the list of Adhesives and Building Supplies that are
required to finish the Yak 54.

❏ Pro

™

30-minute epoxy (GPMR6047)

❏ Pro 6-minute epoxy (GPMR6045)
❏ 1/2 oz.[15 g] Thin Pro CA (GPMR6001)
❏ 1/2 oz.[15 g] Medium Pro CA+ (GPMR6007)
❏ Hobbico 60 watt soldering iron (HCAR0776)
❏ Hobby Heat

™

Micro Torch II (HCAR0755)

❏ Silver solder w/flux (GPMR8070)
❏ Petroleum jelly (Vaseline

®

)

❏ 3' [900 mm] Standard silicone fuel tubing (GPMQ4131)
❏ R/C foam rubber (1/4" [6 mm] – HCAQ1000)
❏ Microballoons (TOPR1090)
❏ Drill bits: 1/16" [1.6 mm], 3/32" [2.4 mm], 7/64" [2.8 mm],

9/64" [3.6 mm], 5/32" [4 mm]

❏ Denatured alcohol (for epoxy clean up)
❏ 8-32 Tap and drill set (GPMR8103)
❏ #1 Hobby knife (HCAR0105)
❏ #11 Blades (5-pack, HCAR0211)

Here is a list of optional tools mentioned in the manual and
others items that will help you build the Yak 54 1.60 ARF.

❏ Fuel filler valve for glow fuel (GPMQ4160)
❏ Fuel filler valve for gasoline (GPMQ4161)
❏ 1/2 oz.[15 g] Thick Pro CA- (GPMR6013)
❏ Milled fiberglass (GPMR6165)
❏ Tap handle (GPMR8120)
❏ Stick-on segmented lead weights (GPMQ4485)
❏ Large scale single-sided servo arm (GPMM1100)
❏ Epoxy brushes (6, GPMR8060)
❏ Mixing sticks (50, GPMR8055)
❏ Mixing cups (GPMR8056)
❏ Builder’s Triangle Set (HCAR0480)
❏ 36" Metal ruler (HCAR0475)
❏ Pliers with wire cutter (HCAR0630)
❏ Hobbico Duster

™

can of compressed air (HCAR5500)

❏ Masking tape (TOPR8018)
❏ Panel Line Pen (TOPQ2510)
❏ Rotary tool such as Dremel

®

❏ Rotary tool reinforced cut-off wheel (GPMR8200)
❏ Servo horn drill (HCAR0698)
❏ Dead Center

™

Engine Mount Hole Locator (GPMR8130)

Optional Supplies & Tools

Adhesives & Building Supplies

ADDITIONAL ITEMS REQUIRED

Engine Recommendations

Radio Equipment

Building Stand

4

❏ CG Machine

™

(GPMR2400)

❏ #64 Rubber bands (1/4 lb [113 g] box, HCAQ2020)
❏ Semi-Flexible Pushrod System (GPMQ3714)

• There are two types of screws used in this kit:

• Sheet metal screws (SMS) are designated by a number

and a length. For example #6 x 3/4" [19 mm]

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

• Machine screws (MS) are designated by a number,

threads per inch, and a length. For example 4-40 x
3/4" [19 mm].

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

with forty threads per inch.

• Socket head cap screws (SHCS) are designated by a

number, threads per inch, and a length. For example
4-40 x 1-1/2" [38 mm]

This is a number four screw that is 1-1/2" [38 mm] long

with forty threads per inch.

• When you see the term

test fit

in the instructions, it
means that you should first position the part on the
assembly without using any glue, then slightly modify or

custom fit

the part as necessar y for the best fit.

• Whenever the term

glue

is written, you should rely upon
your experience to decide what type of glue to use.When a
specific type of adhesive works best for that step, the
instructions will make a recommendation.

• Whenever just

epoxy

is specified, you may use either
30-minute (or 45-minute) epoxy 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 Yak 54 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.

Metallic Blue – TOPQ0402

Metallic Red – TOPQ0405

White – TOPQ0204

• 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.

Replacement parts for the Great Planes Yak 54 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 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.

Parts may also be ordered directly from Hobby Services by
calling [phone], or via facsimile 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

®

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.

ORDERING REPLACEMENT PARTS

IMPORTANT BUILDING NOTES

5

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

Replacement Parts List

Order Number Description How to Purchase

Missing pieces Contact Product Support
Instruction manual Contact Product Support

Full-size plans Not available
GPMA2871 Wing Kit Contact Hobby Supplier
GPMA2872 Fuse Kit Contact Hobby Supplier
GPMA2873 Tail Set Contact Hobby Supplier
GPMA2874 Cowl Contact Hobby Supplier
GPMA2875 Canopy Contact Hobby Supplier
GPMA2876 Landing Gear Contact Hobby Supplier
GPMA2877 Wheel Spats Contact Hobby Supplier
GPMA2878 Tail Wheel Assembly Contact Hobby Supplier
GPMA2879 Decal Sheet Contact Hobby Supplier

Fuse = Fuselage

Stab = Horizontal Stabilizer

Fin = Ver tical Fin

LE = Leading Edge

TE = Trailing Edge
LG = Landing Gear
Ply = Plywood

" = Inches

mm = Millimeters

1" = 25.4 mm (conversion factor)

METRIC CONVERSIONS

COMMON ABBREVIATIONS

6

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

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

1/4" = 6.4 mm

3/8" = 9.5 mm

1/2" = 12.7 mm

5/8" = 15.9 mm

3/4" = 19.0 mm

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

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

7

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]

KIT INSPECTION

(8) 4-40 Steel Threaded Clevis
(6) Solder Clevis
(2) 3/16" [4.8 mm] Axles
(1) Screw-Lock Pushrod Connector

(for throttle pushrod)

(4) Heavy-Duty Screw-Lock Pushrod

Connector (for rudder servos)
(8) 4-40 Hex Nuts
(6) 6-32 Blind Nuts
(2) 5/16" x 24 Lock Nuts
(4) 3/32" [2.4 mm] Push Nuts (retainers

for heavy-duty screw-lock connectors)
(1) Nylon Clevis (for throttle pushrod)
(6) Heavy-Duty Nylon Control Horn
(1) Retainer for Screw-Lock Pushrod

Connector
(13) 1/4" [6 mm] Clevis Retainers
(8) 2-56 x 3/8" [9.5 mm] Phillips Screw
(4) 6-32 x 1/4" [6 mm] SHCS
(24) #4 x 5/8" [16 mm] SMS

(5) 4-40 x 1/4" [6 mm] SHCS (for screw-

lock pushrod connectors)
(6) 6-32 x 5/8" [16 mm] SHCS
(4) 4-40 x 1" [25 mm] SHCS
(10) 4-40 x 1/2" [13 mm] SHCS
(4) 8-32 x 1-1/4" [32 mm] SHCS
(4) 8-32 x 1" [25 mm] SHCS
(2) 1/8" x 3" [3 x 76 mm] Heat-Shrink Tubing
(6) 3/8" x 3" [9.5 x 76 mm] Heat-Shrink

Tubing
(4) 3/16" [4.8 mm] Wheel Collars
(1) .074 x 12" [305 mm] Wire Threaded

One End
(6) 4-40 x 12" [305 mm] Wire Threaded

One End
(10) #4 Lock Washers
(10) #4 Flat Washers
(8) #2 Flat Washers
(8) #8 Split Ring Lock Washers
(8) #8 Flat Washers

(6) #6 Lock Washers
(19) Hinge Points
(4) 5/16" [8 mm] Anti-Rotation Pins
(2) Long Tie-Straps
(10) Cowl Alignment Disks
(1) Throttle Servo Tray
(1) 3/8"-24 Spinner Adapter
(1) 5 x 54 mm Spinner Screw
(1) 5 x 70 mm Spinner Screw
(1) 5 mm Nut
(2) 1/4"-20 Nylon Wing Bolts
(2) Canopy Alignment Pegs
(1) Pull-Pull Rudder System (includes

pull-pull cable, brass couplers,
swages, aluminum servo arm
extensions, and joiner rods

Kit Contents (not photographed)

KIT CONTENTS

1

4

3

9

10

13

14

15

16

11

18

17

2

7

Kit Contents

1. Aluminum Spinner

2. Cowl

3. Canopy

4. Fuselage

5. Cowl Ring

6. Fuel Tank

7. Main Wheels (2)

8. Wheel Spats (L&R)

9. Main Landing Gear (L&R)

10. Engine Mount (L&R)

11. Aft Receiver/Battery Tray

12. Aluminum Wing Tube

13. Horizontal Stabilizer & Elevators

14. Hook & Loop Material

15. Rudder

16. Tailwheel Assembly

17. Left Wing Panel & Aileron

18. Right Wing Panel & Aileron

5

6

12

8

❏ 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

Inspection”

section on page 7.

❏ 2. Carefully remove the tape and separate all the control

surfaces.Use a cov ering iron with a covering sock to tighten
the covering if necessary. Apply pressure over sheeted
areas to thoroughly bond the covering to the wood.

Do the left 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.Test fit the included hinge points into the pre-drilled

holes in the wing panel and aileron.Press the hinge points
into the holes.

❏ ❏ 2.The hinge points should seat into the hinge holes all

the way to the metal pin in order to minimize the gap
between the aileron and wing. Use a hobby knife to enlarge
the surface of the hinge holes as necessary until the proper
fit is achieved.Test fit the aileron to the wing.The hinge gap
between the aileron and wing should only be wide enough
to allow a small line of light through. Excessive gap will
decrease the effectiveness of the ailerons.

❏ ❏ 3. Apply a small amount of petroleum jelly or something

similar to the center of each hinge to prevent epo xy from sticking
to the joints and preventing the hinge from operating smoothly.

Read all of Step 4 before proceeding.

❏ ❏ 4. Mix up a 1/2 oz. [15 cc] of 30-minute epoxy. Using a

toothpick or wood scrap, apply epoxy to the inside of each
hinge point hole. The holes are drilled through to the open
cavity in the wing, so be careful that you do not apply too much
to the walls of the holes as it will simply drip into the wing.
Apply a light coat of epoxy to one end of all the hinges for one
wing panel. Insert the hinge points into the holes in the wing
panel. Wipe away excess epoxy with a paper towel and
denatured alcohol. Be sure the hinges are inserted in the
correct orientation.Apply epoxy to the other ends of the hinges
and slide the aileron into position. Use masking tape to hold
the aileron in place while the epoxy cures.

❏ ❏ 5. Cut the covering 1/8" [3 mm] 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.

❏ 6. Repeat these steps for the right wing panel.

Install the Ailerons

ASSEMBLE THE WING

PREPARATIONS

8

❏ ❏ 1. Installing the servos in the wing will require the use

of one 24" [610 mm] servo extension for each aileron servo.
One Y-harness connector is required and is used to allow
the aileron servos to plug into one 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
together with the radio rather than a Y-harness, refer to the
manual with your particular model radio system.

❏ ❏ 2. Attach the 24" [610 mm] servo extension to the

aileron servo and secure it with a piece of the included large
heat-shrink tubing.Only 1-1/2" [38 mm] of heat-shrink tubing
is required for each connector.

❏ ❏ 3.Tie the string from inside the opening for the aileron

servo to the end of the servo extension. Remove the tape
holding the other end of the string to the wing root rib and
pull the servo wire and extension through the wing.

❏ ❏ 4.Temporarily position the aileron servo into the servo

bay. Drill a 1/16" [1.6 mm] hole through the four mounting
holes of the servo, drilling through the plywood mounting

plate in the wing.Install and remove a servo mounting screw
into each of the four holes. Apply a drop of thin CA into the
holes to harden the wood. After the glue has cured, install
the servo into the opening using the hardware that came
with your servo.Center the servo with your radio system and
install a servo arm as shown.

The next three images are used for steps 5 and 6.

❏ ❏ 5.The aileron has a plywood plate for mounting the control

horn. You can see the outline of it under neath the covering by
looking at the aileron at a shallow angle.If you cannot see it, the
plate is approximately 1-5/8" [41 mm] wide and will be centered
with the servo arm. Use a T-pin to lightly puncture the covering
to be sure you are over the plywood plate.

❏ ❏ 6. Place a heavy-duty nylon control horn on the aileron,

positioning it over the hinge line as shown in the sketch and
aligning it with the servo arm. Mar k the location for the screw
holes. Drill through the mar ks you made with a 3/32" [2.4 mm]
drill bit. (Be sure you are drilling into the plywood plate mounted
in the bottom of the aileron.) Drill through the plate only. Do not

Install the Aileron Servos & Pushrods

9

drill all the way through the aileron!) Using a #4 x 5/8" [16 mm]
sheet metal screw , install and then remo ve a screw into each of
the holes.Harden the holes with thin CA.Install the control horn
with four #4 x 5/8" [16 mm] sheet metal screws.

❏ ❏ 7. Locate a .095" x 12" [2.4 x 305 mm] pushrod wire

threaded on one end. Thread a 4-40 nut, a silicone clevis
retainer and a threaded metal clevis onto the threaded end
of the wire 20 turns. Tighten the nut against the clevis and
then install the clevis on the middle hole of the aileron
control horn.

❏ ❏ 8. Be sure the aileron servo is centered. Install a 4-40

metal solder clevis onto the outer most hole in the servo
arm. Center the servo arm and center the aileron. Using the
solder clevis as a guide, mark where to cut the pushrod wire.
Remove the pushrod and clevis from the control horn and
the solder clevis from the servo arm. Cut the pushrod to
length. Install another silicone clevis retainer onto the wire
and solder the clevis to the pushrod using the

Expert Tip

that follows.

❏ ❏ 9. Install the pushrod and clevises to the outer hole in

the servo arm and the middle hole in the control horn. Adjust

the linkage until the aileron and the servo arm are both
centered. Then, tighten the nut against the clevis. Slide the
two silicone clevis retainers to the end of each clevis.

❏ 10. Repeat these steps for the right wing panel.

❏ 1. Locate the four 5/16" [8 mm] diameter anti-rotation pins.

❏ 2.Using 6-minute epo xy, coat half of the anti-rotation pins

and insert them into the forward and aft holes in the wing
panel root ribs. It may be necessary to carefully tap them
into place. The pins should extend out approximately 1/2"
[13 mm]. Wipe away any excess epoxy with a paper towel
and denatured alcohol before the epoxy cures.

❏ 3. Use sandpaper to bevel the ends of the anti-rotation

pins to ease their insertion into the fuselage.

Finish the Wing

How to solder the clevis to the pushrod

1. Where the pushrod will make contact with the solder
clevis, roughen the wire with 220-grit sandpaper.

2. Use a denatured alcohol to remove any oil residue
from the wire pushrod.

3. Apply a couple of drops of flux to the wire. Slide the
solder clevis onto the wire. Using a small torch or
soldering iron, heat the wire, allowing the heated wire
to heat the solder clevis. Apply a small amount of
solder to the joint. When the wire and clevis are hot
enough, the solder will flow into the joint. Avoid using
too much solder, causing solder to flow out of the joint
and clump. Use just enough solder to make a good
joint. Allow the wire and clevis to cool.

4. Put a couple of drops of oil onto a rag and wipe the
joint.This will prevent rust from forming on the joint.

10

❏ 1. Trim the covering from the fuselage for the tail

wheel bushing.

❏ 2. Apply CA or epoxy to the bushing and then, insert it

into the hole by gently tapping it into place until fully seated.
Be sure not to get glue into the hole in the bushing.

❏ 3. Just as you did with the ailerons, prepare the hinge

point holes in the rudder and fuselage by test fitting the
hinges and enlarging the holes as necessary.

❏ 4. Cut away 3/8" [10mm] from one end of the hinge that

will be installed in between the small blue and red stripes (the
hinge that is second from the bottom on the rudder).The end
that has been cut should be the end that gets installed into
the fuselage.Doing so will prevent this hinge from interfering
with the installation of the horizontal stabilizer.

❏ 5. Mix up 1/4 oz. [7.5 cc] of 30-minute epoxy. Using a

toothpick or wood scrap, apply epoxy to the inside of each
hinge point hole.Apply a light coat of epoxy to one end of all
the hinges for the rudder. Insert the hinge points into the
holes, wiping away excess epoxy with a paper towel and
denatured alcohol. Be sure the hinges are inserted in the
correct orientation. Apply epoxy to the other ends of the
hinges and slide the rudder into place. Use masking tape to
hold the rudder in position while the epoxy cures.

❏ 6. Measure 1-1/2" [38 mm] back from the leading edge

bevel of the rudder and make a mark on the underside
center of the rudder.

❏ 7. Use a 5/32" [4 mm] drill bit to make a 1/2" [13 mm] deep

hole at the mark. Insert the nylon retainer into the hole by
tapping it gently, leaving 3/16" [4.8 mm] extending outside the
hole. Align the hole to run parallel with the rudder.

Install the Rudder &Tail Gear

ASSEMBLE THE FUSELAGE

11