Great Planes GPMA1580 User Manual

INSTRUCTION MANUAL

Wingspan: 84.5 in [2140mm]
Wing Area: 1556 in
Weight: 14 – 17 lb [6350 – 7710g]
Wing Loading: 21 – 25 oz/ft2 [63 – 77g/dm2]
Length: 85 in [2160mm]

2

[100.4dm2]

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 modifi cation. 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 fi nal assembly or
material used for fi nal assembly, no liability shall be assumed nor
accepted for any damage resulting from the use by the user of
the fi nal user-assembled product. By the act of using the user­assembled 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.

Radio: 5-channel minimum computer radio with mixing

functions, eight servos
Motor/Engine: 1.60 – 2.10 cu in [26 – 34cc] two-stroke,

2.00 – 2.20 cu in [33 – 36cc] four-stroke,

2.5 – 3.0 cu in [43 –50cc] gas
RimFire

™

80-75-230 out-runner brushless motor

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 n umber,
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 CONTAINS IMPORTANT
INSTRUCTIONS AND WARNINGS CONCERNING THE ASSEMBLY AND USE OF THIS MODEL.

Champaign, Illinois

[phone], Ext 5

[e-mail]

Entire Contents © Copyright 2008 GPMA1420MNL V1.0

TABLE OF CONTENTS

INTRODUCTION

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

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

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

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

Gas Engine Option & Required Parts ...............................3

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

Electric Motor Option & Required Parts ............................3

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

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

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

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

ORDERING REPLACEMENT PARTS ...................................4

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

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

METRIC CONVERSIONS ......................................................5

KIT INSPECTION ...................................................................6

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

PREPARE FOR ASSEMBLY .................................................7

BUILD THE WINGS ................................................................7

Hinge the Ailerons ............................................................7

Install the Aileron Servos ..................................................8

Assemble the Pushrods ....................................................9

Install the Control Horns .................................................10

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

Main Landing Gear Installation .......................................11

Install the Horizontal Stabilizer........................................12

Hinge the Horizontal Stabilizer........................................14

Hinge the Rudder ............................................................14

Install the Elevator & Rudder Servos ..............................15

Install the Control Horns .................................................16

Tail Gear Installation .......................................................17

ENGINE/MOTOR INSTALLATION .......................................18

Gas Engine Installation ...................................................18

Glow Engine Installation .................................................23

Electric Brushless Motor Installation ...............................26

RADIO INSTALLATION .......................................................28

Radio System Installation – Gas Engine ........................28

Radio System Installation – Glow Engine .......................31

Radio System Installation – Electric Brushless ...............32

FINAL ASSEMBLY ..............................................................34

Cowl & Prop Installation ..................................................34

Wing Installation .............................................................36

Canopy Installation .........................................................37

GET THE MODEL READY TO FLY ......................................37

Check the Control Directions ..........................................37

Set the Control Throws ...................................................38

Balance Your Model (C.G.) ..............................................38

Balance Your Model Laterally ..........................................39

PREFLIGHT .........................................................................39

Identify Your Model ..........................................................39

Charge Your Radio Batteries ...........................................39

Ground Check & Range Check .......................................39

ENGINE & MOTOR SAFETY PRECAUTIONS ....................40

LITHIUM BATTERY HANDLING & USAGE ........................40

Battery Precautions/Connecting Batteries ......................41

AMA SAFETY CODE (excerpts) .........................................41

CHECK LIST ........................................................................42

FLYING .................................................................................43

Fuel Mixture Adjustments ...............................................43

Takeoff ............................................................................43

Flight ...............................................................................43

Landing ...........................................................................43

3D FLYING ...........................................................................44

For the latest technical updates or manual corrections to the

1.60 – 50cc Reactor 3D visit the Great Planes web site at
www.greatplanes.com. Open the “Airplanes” link, then
select the 1.60 – 50cc Reactor 3D ARF. If there is new
technical information or changes to this model a “tech notice”
box will appear in the upper left corner of the page.

AMA

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

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

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

PROTECT YOUR MODEL, YOURSELF

& OTHERS....FOLLOW THESE

IMPORTANT SAFETY PRECAUTIONS

1. Your 1.60 – 50cc Reactor 3D 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, this airplane, if not assembled and
operated correctly, could possibly cause injury to yourself or
spectators and damage to property.

2. Y ou must assemble the model accor ding to the instructions.
Do not alter or modify the model, as doing so may result in an
unsafe or unfl yable model. In a few cases the instructions may
differ slightly from the photos. In those instances the wr itten
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 good condition,
a correctly sized engine, and other components as specifi ed
in this instruction manual. All components must be correctly
installed so that the model operates correctly on the ground
and in the air. You must check the operation of the model and
all components before every fl ight.

2

5. If you are not an experienced pilot or have not fl own
this type of model before, we recommend that you get the
assistance of an experienced pilot in your R/C club for
your fi rst fl ights. If you’re not a member of a club, your local
hobby shop has information about clubs in your area whose
membership includes experienced pilots.

6. While this kit has been fl ight tested to exceed normal use,
if the plane will be used for extremely high stress fl ying, 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.

❏ (4) 1/4-20 x 1-1/2" [38mm] SHCS (for DA-50)
❏ (4) 1/4" [6.4mm] Washers
❏ (4) 1/4" [6.4mm] Lock washers
❏ (4) 1/4-20 Blind nuts

Glow Engine Option & Required Parts

The glow engine option offers the easiest setup for good
sport fl ying and the lightest fl ying weight. Flying weight with
an O.S.® 1.60 FX two-stroke is 14 lbs [6350g]. If you are
using a glow engine, you will need:

7. WARNING: The cowl and wheel pants in this kit are made
of fi berglass, the fi bers of which may cause eye, skin and
respiratory tract irritation. Never blow into a part to remove
fi berglass 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 fi berglass parts.
V acuum the parts and the work area thoroughly after working
with fi berglass parts.

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

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

DECISIONS YOU MUST MAKE

This is a partial list of items required to fi nish the 1.60 – 50cc
Reactor 3D that may require planning or decision making before
starting to build. Order numbers are provided in parentheses .

Gas Engine Option & Required Parts

The gas engine option offers great 3D power, less clean-up,
and the economy of gas. With a DA-50 engine installed, fl ying
weight is 16 lbs [7260g]. We expect most users will choose
this option. If you are using a gas engine, you will need:

❏ A suitable engine mount for engines greater than 1.80 cu

in [29 cc]

❏ A suitable Pitts muffl er (O.S. 1.60 FX uses SLIG6018 or

BISG4116)

❏ A suitable propeller per engine manufacturer’s

recommendation

❏ Medium fuel line (GPMQ4131)

Electric Motor Option & Required Parts

The electric option weighs 17 lbs [7711g]. With the prop
listed below, this setup delivers 4750 watts of power. This is
more than enough power to accomplish most 3D maneuvers.
For a sport setup, please use a smaller prop. DO NOT use
a larger prop or more than 12S. If you choose the electric
option, you will need:

❏ Great Planes RimFire

motor (GPMG4800)

™

80-75-230 out-runner brushless

❏ Great Planes 80mm motor standoff style motor

mount (GPMG1275)

❏ Kontronik

™

63V 120a ESC (KONM3140)

❏ (1) 12" [300mm] Servo extension (HCAM2711)
❏ (2) FlightPow er 5000mAh 6S LiP o (FPWP0364) (wired in

series for 12S)

–OR–

❏ (3) Great Planes 5000mAh 4S LiPo (GPMP0636) (wired

in series for 12S)

❏ A suitable series connector (GPMM3143)
❏ A suitable battery safety jumper
❏ Zinger Pro propeller 22" x 8 (ZINQ1602)
❏ FlightPower V-Balance cell balancer & charge harness

set (FPWM0120)

❏ TME Xtrema LiPo charger (TMEP3000)
❏ RC Electronics Watt’s Up Watt Meter (RELP0101)

❏ DA-50 engine must be ordered with 3" standoffs
❏ Fuel tank conv kit (SULQ2684)
❏ (2) Dubro 1/8" I.D. Fuel Line Barb (DUBQ0670)
❏ (1) 1/8" Tygon fuel line 3' (DUBQ0493)
❏ (1) Neoprene gas fuel line (in-tank) (DUBQ0455)
❏ 1500mAh 4.8V battery (for ignition) (FUTM1285)
❏ (1) Pro HD switch harness Futaba

®

J (HCAM2761)

❏ (1) Ernst charge jack FUT J (ERNM3001)

Radio System Recommendations

Because the split elevators require one servo each, you will
need to have a radio system that perf orms mixing functions. We
recommend using at least a 6-channel computer radio. We set
up our Futaba radio so that channel 5 is assigned to the second
elevator and channel 6 is assigned to the second aileron.

3

We provide several places to mount your radio equipment
based on the engine type. The servo extension lead lengths
we recommend will allow you to mount your radio in all of the
positions suggested in this manual. If you know that your radio
equipment is to be mounted in the aft equipment tray, you may
choose shorter servo leads for the tail and eliminate the 6"
[152mm] leads we recommend for the inboard aileron servos.

❏ 6-channel computer radio system (5ch w/ mixing min)
❏ (7) Futaba S9155 servos for fl ight controls (FUTM0215)

–OR– min 150 oz-in [11 kg-cm] torque metal gear
standard servos

❏ (1) Futaba S3004 standard servo for throttle (FUTM0004)
❏ (2) 6" HD extensions (ails inboard) (HCAM2000)
❏ (2) 24" HD extensions (ailerons) (HCAM2200)
❏ (3) 36" HD extensions (tail servos) (HCAM2726)
❏ (2) Y-harness HD digital (FUTM4135)
❏ 4200mAh 4.8V battery (HCAM6335) –OR– 4200mAh 6V

battery (HCAM6355)

❏ Pro HD switch harness Futaba J (HCAM2761)
❏ Ernst charge jack Futaba J (ERNM3001)

ADDITIONAL ITEMS REQUIRED

In order to fi nish your Reactor, you will need:

❏ (7) Great Planes large scale 1.5" single-side servo arm

(GPMM1105)

❏ Dubro #4 plastic washers (for cowl) (DUBQ3240)
❏ R/C foam rubber 1/4" [6mm] (HCAQ1000)

Adhesives & Building Supplies

❏ Tap handle (GPMR8120)
❏ Pliers with wire cutter (HCAR0625)
❏ Hobbico heavy-duty diagonal cutter 7" (HCAR0627)
❏ Electric drill
❏ Hobbico ball-end hex wrench set – metric (HCAR0521)
❏ Hobbico ball-end hex wrench set – SAE (HCAR0520)
❏ Ratchet with #1 Phillips bit & 1/4" [6mm] socket
❏ Center punch –OR– scratch awl
❏ (2) 1" [25mm] C-clamps
❏ Masking tape (TOPR8018)
❏ Medium T-pins (100, HCAR5150)
❏ Great Planes Easy-Touch

5-1/2" [140mm] (GPMR6169)

™

hand sander

❏ Sandpaper assortment

®

❏ 3M

green Scotch-Brite™ abrasive pad

❏ Electrical tape
❏ Toothpicks, round
❏ Petroleum jelly
❏ Denatured alcohol (for epoxy clean up)

Optional Supplies & Tools

❏ Robart Super Stand II (ROBP1402)
❏ C.G. Machine

™

(GPMR2400)

❏ 36" [914mm] Metal ruler (HCAR0475)
❏ Hobbico Builder’s Protractor (HCAR0490)
❏ Great Planes 4-in-1 Tool (GPMR8035)
❏ Precision Magnetic Prop Balancer (TOPQ5700)
❏ 1" [25mm] Double-sided foam mounting tape (GPMQ4442)
❏ Hobby saw & handle (ZONR2060)
❏ Stick-on segmented lead weights (GPMQ4485)
❏ 38% Extra 330S Pilot Figure (GPMA3207)
❏ R/C-56 Glue 4oz (JOZR5007)

❏ 21st Century

®

sealing iron (COVR2700)

❏ 21st Century iron cover (COVR2702)
❏ Drill bits: 1/16" [1.6mm], 5/64" [2mm], 3/32" [2.4mm],

5/32" [4mm], 3/16" [4.8mm], 1/4" [6.4mm],
9/32" [7.1mm]

❏ 1 oz. [30g] Medium Pro

™

CA+ (GPMR6008)

❏ 1 oz. [30g] Thin Pro CA (GPMR6002)
❏ CA applicator tips (HCAR3780)
❏ CA debonder (GPMR6039)
❏ Pro 30-minute epoxy (GPMR6047)
❏ Epoxy brushes (6, GPMR8060)
❏ Mixing sticks (50, GPMR8055)
❏ Mixing cups (GPMR8056)
❏ Builder’s triangle set (HCAR0480) –OR– metal template

set (30/60/90 and 45° triangles, HCAR0500)

❏ Threadlocker
❏ Hobby Heat

™

threadlocking compound (GPMR6060)

™

micro torch (HCAR0755)

❏ Silver solder w/fl ux (STAR2000)
❏ Panel Line Pen (TOPQ2510)
❏ 18" [457mm] Flexible steel ruler (HCAR0460)
❏ Hobbico retractable fabric tape measure (HCAR0478)
❏ Rotary tool such as Dremel

®

❏ Rotary tool reinforced cut-off wheel (GPMR8200)
❏ 8-32 Tap and drill set (GPMR8103)

ORDERING REPLACEMENT PARTS

Replacement parts for the Great Planes 1.60 – 50cc
Reactor 3D 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
number and expiration date for payment.

4

®

or MasterCard®

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 Product
Support by e-mail at [e-mail],
or by telephone at [phone].

Replacement Parts List

Description How to Purchase

Missing pieces Contact Product Support
Instruction manual Contact Product Support
Full-size plans Not available

30-minute epoxy is specifi ed it is highly recommended that
you use only 30-minute (or 45-minute) epo xy, 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 stabilizer and wing incidences and motor 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 fl y,
please expect slight deviations between your model and
the published values.

COMMON ABBREVIATIONS

Contact your hobby supplier for the following parts:

GPMA3090 Fuselage
GPMA3091 Wing Set
GPMA3092 Cowl
GPMA3093 Wheel Pants
GPMA3094 Tail Surface Set
GPMA3095 Landing Gear
GPMA3096 Canopy
GPMA3097 Wing Tube
GPMA3098 Decal
GPMA3099 Spinner

IMPORTANT BUILDING NOTES

• When you see the term test fi t in the instructions,
it means that you should fi rst position the part on the
assembly without using any glue, then slightly modify
or custom fi t the part as necessary for the best fi t.

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

• Whenever just epoxy is specifi ed you may use either
30-minute (or 45-minute) epoxy or 6-minute epoxy. When

Stab = Horizontal Stabilizer
Fin = Vertical Fin
LE = Leading Edge
TE = Trailing Edge
LG = Landing Gear
Ply = Plywood
" = Inches
mm = Millimeters
SHCS = Socket Head Cap Screw
ESC = Electronic Speed Control

METRIC CONVERSIONS

1" = 25.4mm (conversion factor)

1/64" = .4mm
1/32" = .8mm
1/16" = 1.6mm
3/32" = 2.4mm
1/8" = 3.2mm
5/32" = 4.0mm
3/16" = 4.8mm
1/4" = 6.4mm
3/8" = 9.5mm
1/2" = 12.7mm
5/8" = 15.9mm

3/4" = 19.0mm
1" = 25.4mm
2" = 50.8mm
3" = 76.2mm
6" = 152.4mm
12" = 304.8mm
18" = 457.2mm
21" = 533.4mm
24" = 609.6mm
30" = 762.0mm
36" = 914.4mm

5

KIT INSPECTION

KIT INSPECTION

KIT CONTENTS

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 CONTENTS

2

1

3

4

5

6

7 7

8

11

12 13

9

10

Kit Contents

1 Cowl
2 Canopy
3 Fuselage
4 Spinner
5 Main Landing Gear (L&R)
6 Wheel Pants (L&R)
7 Main Wheels (2)
8 Fuel Tank

9 Horizontal Stabilizer & Elevators
10 Rudder
11 Wing Tube
12 Right Wing Panel w/Aileron
13 Left Wing Panel w/Aileron

6

PREPARE FOR ASSEMBLY

❏ La y out all of your cov ered parts like the fuselage, wings, and

control surfaces. Inspect the covering for wrinkles and peeled
edges. Use a cov ering iron set for low to medium/high heat and
tack down the covering. Medium heat may be necessary to
stretch out any wrinkles, but be careful not to apply too much
heat to areas where covering is applied over co v ering.

The tip should be 1/2" [13mm] from the rib. Test fi t six-point type
hinges into the wing so that the hinge pin is aligned with the
hinge line. Defl ecting each hinge 90° will help you determine
when the hinge pin is parallel with the hinge line. If the hinge is
too tight, you may use y our hobby knif e or a 5/32" [4mm] drill bit
to carefully enlarge the hole.

BUILD THE WINGS

Hinge the Ailerons

❏ 1. You will need the following supplies: Denatured alcohol,

30-minute epoxy, epoxy mixing cups, mixing sticks, round
toothpicks, petroleum jelly, masking tape, and some paper towels.

❏ ❏ 3. Fit the aileron tightly up against the wing and defl ect

it up and down a few times checking for binding.

❏ ❏ 4. Remove the aileron and the hinges. Prepare each

hinge fi rst by cleaning off any mold release compound left
on the parts during manufacture. Use denatured alcohol for
this. Prepare each hinge for gluing by thoroughly coating the
center section with petroleum jelly.

❏ ❏ 2. Start with the right wing and aileron. Install one 1-3/8"

[35mm] anti-rotation dowel in the location shown using epoxy.

❏ ❏ 5. Mix up a batch of 30-min ute epoxy and use a toothpick

to generously coat the inside of each hole or “pocket.” Apply
epoxy to both the wing pockets and the aileron pockets.
Warning: This glue joint is critical and you must take the
time to ensure it is done properly.

7

7

❏ ❏ 6. Dip both ends of each hinge (about tw o barbs deep)

into your epoxy cup.

❏ ❏ 7. Fit the hinges into the wing, making sure that you

align each one. Fit the aileron tightly and defl ect it a few
times in both directions. This will straighten any hinges that
are slightly out of alignment.

Install the Aileron Servos

T o get the best performance from your Reactor , we recommend
that you use four Futaba 9155 digital servos. These precision
servos have the right amount of torque (153 oz-in [11 kg-cm])
and will give you the best control. As a budget alternative you
can use a metal geared servo with a minimum 100 oz-in [7.2
kg-cm] torque rating but you should e xpect a slow er response
and some control blow-back at higher speeds. DO NOT use
only one aileron servo per wing, no matter what the torque
rating.

❏ ❏ 8. Clean up any excess epoxy that has squeezed out

of the pocket using a paper towel. Check both sides of the
hinge line.

❏ ❏ 9. Use masking tape to hold the aileron sn ug up against

the hinge line. Set the wing aside and allow the epo xy to fully
cure before you remove the tape or move the ailerons.

❏ 10. Repeat steps 2 through 9 for the left wing.

❏ ❏ 1. Prepare your outboard aileron servo with a 24"

[610mm] extension. Prepare the inboard servo with a 6"
[152mm] extension. Use heat shrink tubing to secure the
connectors so they do not come loose. Note: If you anticipate
mounting your radio equipment in the aft-most equipment
bay, you do not need the 6" [152mm] extensions installed.

❏ ❏ 2. Locate the aileron servo bays on the underside of

the wing and trim away the cov ering. If you have not done so
already , use a co vering iron to tack do wn the cov ering before
you trim.

8

8

❏ ❏ 3. Starting with the outboard servo bay, tie the guide

string to the 24" [610mm] servo lead extension. Pull the
extension through the wing.

❏ ❏ 4. Place the aileron servos in position and use a 1/16"

[1.6mm] bit to drill the mounting holes for your servos into
the wing. Temporarily remove each servo and wick a few
drops of thin CA into the holes you drilled.

Assemble the Pushrods

In this section you will build the aileron pushrods as well as the
elevator and rudder pushrods. We’ll start with the four identical
aileron pushrods and fi nish with the others which you can set
aside to be used later. For this section you’ll need to have
some silver solder and liquid silver-solder fl ux. We recommend
using the Stay-Brite silver soldering kit (STAR2000).

❏ ❏ 1. Locate the seven 4-40 x 12" [305mm] threaded

one end pushrods. You’ll need to cut the rods down to the
following lengths:

❏ ❏ 5. Install the aileron servos using the screws provided

with your servos.

❏ 6. Repeat steps 1 through 5 for the left wing.

A) Four (4) 3-1/2" [89mm] aileron pushrods
B) One (1) 4-1/2" [114mm] rudder pushrod
C) One (1) 5-1/4" [133mm] left elevator pushrod
D) One (1) 7-1/4" [184mm] right elevator pushrod

❏ ❏ 2. Starting with the aileron pushrods, gather the four

4-40 x 3-1/2" [89mm] threaded one end rods and four solid
metal (unthreaded) clevises. Roughen the unthreaded end
of each with some coarse 150-grit sandpaper or a coarse
Scotch Brite® pad.

❏ ❏ 3. Apply a f ew drops of soldering fl ux to the unthreaded

end of the pushrod. Position the clevis so that 1/8" [3mm] of
the pushrod protrudes past the barrel of the clevis.

9

❏ ❏ 4. Use a hobby torch to heat both the clevis and the

pushrod. Apply silv er solder to the joint. The heat of the clevis
and the pushrod should melt the solder, not the direct fl ame
of the torch.

Install the Control Horns

❏ 1. Use your radio to center your aileron servos. Attach a

1-1/2" [38mm] single-sided servo arm (GPMM1105) to each
servo so that the arm is parallel with the hinge line when the
servo is centered. Install the arms so that they point outward
toward the wing tip.

❏ ❏ 5. While the joint is still hot b ut after the solder solidifi es

use a clean, damp cloth to wipe the fl ux from the joint before
it hardens. Flux is corrosiv e and m ust be thoroughly cleaned
from the joint.

❏ ❏ 6. Coat the joint with a thin fi lm of oil to prevent corrosion.

❏ ❏ 7. Fit a silicone retainer onto the rod, a 4-40 hex nut,

another silicone retainer, and a 4-40 threaded cle vis onto the
rod in that order. The threaded end of your pushrod should
look like the picture above.

❏ 8. Repeat steps 2 through 7 for the remaining pushrods.

❏ ❏ 2. Attach the soldered clevis end of each pushrod to

the servo arm in the hole that is 1-1/4" [32mm] out from the
center of the arm. Extend the pushrod straight back so that it
is 90° to the hinge line and draw a centerline on the aileron.
Use a builder’s triangle to ensure that the rod is 90° to the
hinge line.

10

❏ ❏ 3. Center a control horn over the line that you made,

making sure that the clevis holes are also centered over the
hinge line. Hold the horn in position and use a 1/16" [1.6mm]
drill bit to drill four 1/2" [13mm] deep holes in the aileron. You
can wrap a piece of tape around the drill shank to help keep
you from drilling the holes too deep.

❏ ❏ 4. Use four #4 x 1/2" [13mm] sheet metal screws to

mount the control horns. Remove the screws and use thin
CA to harden the threads you created in the wood. Reinstall
the control horn.

BUILD THE FUSELAGE

Main Landing Gear Installation

❏ 1. Locate the 3/16" x 2" [4.8 x 51mm] axles, four 3/16"

[4.8mm] wheel collars, four set screws , tw o axle nuts , and the
two main wheels. File fl at spots in the axle in the locations
shown above .

❏ 2. Install the inner wheel collar so that the outer face of

the wheel collar is 5/16" [8mm] from the base of the axle.
Apply threadlocking compound to the set screw and tighten
the wheel collar in position. Install the wheel and the other
wheel collar.

Repeat steps 2 through 4 for the remaining aileron
control horns.

❏ 5. When you’re done installing all of the control horns,

adjust the length of your pushrods using the threaded clevis
and attach them to the control horns. Tighten the lock nuts
and position the silicone retainers after you have centered
the fl ight controls.

❏ 3. Use a rotary tool with a cutoff wheel attachment to cut

off the excess portion of the axle.

❏ 4. Prepare the other axle the same way.

11

❏ 5. Attach the axles to the main landing gear legs using the

self-locking axle nut.

❏ 6. Trim the covering from the main landing gear slots in

the fuselage.

❏ 8. Attach the wheel pants to the landing gear legs using

four 4-40 x 1/2" [13mm] SHCS, four split ring lock washers,
and four #4 washers. Use threadlocking compound on the
screw threads.

Install the Horizontal Stabilizer

❏ 7. Use six 6-32 x 5/8" [16mm] SHCS, six #6 split ring lock

washers, and six #6 washers to attach the landing gear to
the fuselage. Use threadlocking compound on the screws.
Note: The landing gear is swept back.

❏ 1. Start by trimming the covering from the horizontal

stabilizer slot in the fuselage. Cut the covering from both
sides of the fuselage. Use your co vering iron to securely tack
the edges of the covering to the fuselage sides after you’re
done trimming.

❏ 2. Slide the stab into the fuselage . Center it from left to right

and fore and aft, making sure that the distances are equal.

12

❏ 3. Holding the stab in position, use a fi ne-point, felt-tip

marker to trace lines onto the stab. Don’t forget to trace lines
on the bottom side of the stab, too.

❏ 4. Trim the covering along a line that is 3/32" [2.4mm]

inside of the lines you drew on the stab . Refer to the “Expert
Tip” below on how to cut away covering. When you’re done

trimming, wipe away the lines using alcohol.

HOW TO CUT COVERING FROM BALSA

❏ 6. Temporarily install the wings onto the fuselage using

the wing tube and the plastic 1/4-20 x 1" [25mm] wing bolts.
Fit the stab once again and check the alignment of the stab
with the wings by leveling the wings with your work surface
and then measuring the distance between that and the tips
of the stab. The distances from each stab tip should be equal
and the stab should be parallel with the wings. If there is a
slight misalignment, you may apply weight to the high side or
lightly sand the fuselage sides until the stab aligns.

Use a thin metal straightedge and a regular (15W)
soldering iron instead of a hobby knife to trim away your
covering. While a hobby knife may work, it damages the
underlying wood fi bers and can cause the stabilizer to
fail. Allow the iron to heat up to operating temperature.
Gently run the tip of the iron across the covering using
the straightedge as a guide. Move the iron at a rate that
melts the covering but does not burn the wood fi bers. A
few gentle passes are preferable to slower passes that
can damage the wood.

❏ 5. T rim the covering for the wing tube and wing dowels on

the fuselage.

❏ 7. Apply 30-minute epoxy to the top and bottom of the stab

center section and slide it into the fuselage. Pull the stab through
the fuselage past center and re-coat the center section on the
opposite fuselage side. Slide the stab back into the fuselage,
and then center it and level it lik e y ou did earlier.

❏ 8. Use paper towels and denatured alcohol to wipe away

any excess epo xy from the stab to fuselage joint. Check to see
that the stab stays in position and allow the epo xy to cure.

13

Hinge the Horizontal Stabilizer

This section details the process for hinging the elevators.
We performed the operation using 30-minute epoxy. This is
generally enough time to do both elevators with one batch
if you are completely prepared. If you are worried about
accomplishing both sides, or you are working in a warm
climate, do one elevator at a time.

❏ 4. Fit the hinges into the stab, making sure to orient them

so that the hinge pin is parallel to the hingeline.

❏ 1. T est fi t eight hinges in the stab and then fi t the elevators.

Check for free movement of the elevators and that there is
a visible gap between the tip of the stab and the elevator
counterbalances. If the counterbalance interf ers with the stab ,
you should remove the covering from the tip of the stab and
sand off enough material until you get a good fi t You’ll have to
re-cover the area of wood you exposed. DO NOT attempt to

re-drill the hinge holes!

❏ 2. Remove the hinges and the elevators. Prepare the

hinges as you did earlier using petroleum jelly.

❏ 5. Install both elevators. Push each one up against the

hinge line. Defl ect them up and down so that the hinges align
properly. Use tape to hold the elevators level and up against
the hinge line like you did with the ailerons.

❏ 6. Allow the epoxy to cure before you remove the tape or

try to move the elevators.

Hinge the Rudder

❏ 3. Thoroughly coat the hinge pockets and the tips of each

hinge with 30-minute epoxy.

❏ 1. Test fi t the rudder using the four remaining hinges.

Check for free rudder movement and a visible gap between
the tip of the fi n and the rudder counterbalance.

❏ 2. Prepare the hinges as you did with the aileron and

elevator hinges.

14

❏ 3. Use 30-minute epoxy to glue your hinges in place.

Remember to align them and to defl ect the rudder both ways
when you install it.

❏ 4. Use tape to hold your rudder in place while the

epoxy cures.

Install the Elevator & Rudder Servos

For the elevator and rudder servos, we recommend that you
use Futaba 9155 digital servos. For the elevators only, you
can use a metal geared servo with a minimum 100 oz-in [7.2
kg-cm] torque rating but you should expect a slower response
and control blow-back at higher speeds. Note: You must use
a servo with a minimum 150 oz-in [11 kg-cm] torque rating for
the rudder.

❏ 2. Trim the covering from the elevator and rudder servo

bays on the left side of the fuselage.

❏ 3. Attach a 36" [914mm] servo lead extension to the three

tail servos. If you anticipate mounting your receiver in the
aft-most equipment tray, you may use shorter servo lead
extensions.

❏ 1. Trim the covering from the elevator servo bay on the

right side of the fuselage as shown.

❏ 4. Fit your rudder and elevator servos in place. Route the

wires under the formers as shown.

15