GREAT PLANES ZERO Instruction Manual
INSTRUCTION MANUAL
SPECIFICATIONS
Wingspan:
56.5 in [1435 mm]
Length: 46 in [1170 mm]
Wing Area: 537in
2
[34.6dm2]
Weight:
Wing
Loading:
Radio: 4−5 Channel
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 modication. 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 nal assembly or
material used for nal assembly, no liability shall be assumed nor
accepted for any damage resulting from the use by the user of
the nal 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
5 – 5.75 lbs [2270– 2610 g]
21– 25 oz /f t
2
Engine: .46−.55 cu in (7– 9 cc) 2-stroke
or .70 cu in (11.5 cc) 4 -stroke glow
[64–76 g/dm2]
Electric: RimFire .32, 4S 3300 mAh LiPo,
75 A ESC, 13 x 8E propeller
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 CONTAINS IMPORTANT
INSTRUCTIONS AND WARNINGS CONCERNING THE ASSEMBLY AND USE OF THIS MODEL.
© 2016 Great Planes Model Mfg. A subsidiary of Hobbico,® Inc.
Champaign, Illinois
(217) 398-8970, Ext 5
airsupport@greatplanes.com
GPMA1209
TABLE OF CONTENTS
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Know Before You Fly . . . . . . . . . . . . . . . . . . . . . . . . . . 2
ADDITIONAL ITEMS REQUIRED . . . . . . . . . . . . . . . . . .2
Radio / Servos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Glow Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Other Accessories for a Glow Engine . . . . . . . . . . . . .2
Brushless Electric Motor . . . . . . . . . . . . . . . . . . . . . . .3
LiPo Battery Charger. . . . . . . . . . . . . . . . . . . . . . . . . .3
ADHESIVES, HARDWARE AND
OTHER ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . .3
KIT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
REPLACEMENT PARTS LIST . . . . . . . . . . . . . . . . . . . . .3
KIT CONTENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
PREPARATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
ASSEMBLE THE WING . . . . . . . . . . . . . . . . . . . . . . . . . .5
ASSEMBLE THE FUSELAGE. . . . . . . . . . . . . . . . . . . . . .7
Install the Electric Motor . . . . . . . . . . . . . . . . . . . . . . .9
INTRODUCTION
Congratulations and thank you for purchasing the Great
Planes “Zero” Sport Fighter ARF. The Sport Fighter series is
an easy start to scale modeling, but with practical, sport ying
characteristics and the durability of an every-day sport yer.
For the latest technical updates or manual corrections nd
the Sport Fighter Zero ARF page on the Great Planes Model
Manufacturing web site at www.greatplanes.com. If there is
new technical information or changes to this model a “tech
notice” box will appear on the page.
Know Before You Fly
As a new owner of an unmanned aircraft system (UAS), you
are responsible for the operation of this vehicle and the safety
of those around you. Please contact your local authorities
to nd out the latest rules and regulations.
In the United States, please visit:
Mount the Glow Engine . . . . . . . . . . . . . . . . . . . . . . . 12
Hook Up the Throttle . . . . . . . . . . . . . . . . . . . . . . . . . 13
Mount the Cowl . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Install the Radio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
PREPARE THE MODEL FOR FLIGHT. . . . . . . . . . . . . . 16
Set the Control Throws . . . . . . . . . . . . . . . . . . . . . . . 16
Check the C.G. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Balance the Model Laterally . . . . . . . . . . . . . . . . . . . 17
PREFLIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Engine/Motor Safety Precautions . . . . . . . . . . . . . . . 17
Battery Precautions. . . . . . . . . . . . . . . . . . . . . . . . . .19
Range Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
AMA SAFETY CODE. . . . . . . . . . . . . . . . . . . . . . . . . . . .20
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Radio Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
FLYING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
❍ Tactic TR625 6-chanel receiver (TACL0625)
❍ HydriMax 4-cell 2000mAh NiMH receiver pack
(HCAM6321)*
❍ On-off receiver switch (TACM2000)*
*If powering your Zero with a brushless electric motor the BEC
in the ESC may be used to power your receiver and servos, so
no receiver battery or on/off receiver switch will be required.
Servos nowadays are smaller and stronger, so we’ve designed
the servo mounts in the Zero to accommodate mini servos.
Full-size servos may still be used simply by enlarging the
mounts with a hobby knife. Four or 5 servos are required
depending on whether your Zero is electric or glow-powered:
❍ Tactic TSX25 mini digital high-speed 2 ball bearing
servo (TACM0225)
OR
❍ Tactic TSX20 mini high-speed 2 ball bearing servo
(TACM0220)
OR
❍ Tactic TSX35 standard sport servo (TACM0235)
knowbeforeyou y.org faa.gov/uas
ADDITIONAL ITEMS REQUIRED
Radio / Servos
A minimum of 4-channels is required to y the Zero. The
Tactic TTX650 is recommended because of its simple, exible
computer programming and multiple model memory:
❍ Tactic TTX650 6-channel programmable radio
(TACJ2650)
If mixing the aileron servos through the radio electronically:
❍ (4) 6" [150mm] servo extensions (TACM2092) are
required for the aileron servos.
If mixing the servos with a Y-harness:
❍ (2) 6" [150mm] servo extensions (TACM2092)
and a Y-harness (FUTM4130) are required for the
aileron servos.
2
Glow Engine
The Zero is suited for a .46 – .55 2-stroke or .70 4-stroke. The
O.S. Max .55AX (O SM G0557) is illustrated in this manual with
a Bisson Pitts-style muf er (BISG4046).
Other Accessories for a Glow Engine
❍ 1/4" [6.4mm] R/C foam rubber (HCAQ1000)
❍ Great Planes Dead Center Hole Locator (GPMR8130)
❍ 6-32 tap and drill set (DUBR0510)
❍ Suitable propeller for your engine
Brushless Electric Motor
The electric setup for the Zero is straightforward: a Great
Planes ElectriFly RimFire .32 on a 13 x 8 E prop with a minimum
60A ESC powered by a 4S battery in the 3300 mAh – 4000mAh
range*. A Castle Creations Edge Lite 75 was selected and is
illustrated in the instruction manual because it is compact,
easily programmable and features data logging.
❍ 42-50-800 RimFire .32 (GPMG4700)
❍ APC 13 x 8 thin E prop (APCQ3080)
❍ Castle Creations Edge Lite 75 (CSEM1200)
❍ FlightPower 4S 3300 mAh 25C (FPWP2334)
OR
❍ FlightPower 4S 4000 mAh 25C (FPWP2404)
❍ 3/16" heat shrink tubing (GPMM1056)
❍ T-style Star connector (HCAM4001)
* Other propeller options are noted on page 19.
A Robart Super Stand II (ROBP1402) is also indispensable
for working on your Zero.
A covering iron with a cover sock may be required for
tightening and re bonding the covering to the model that may
have loosened between the time the plane was manufactured
and the time the model was removed from the box. The 21st
Century iron is preferred because of its long cord, contoured
shoe and precisely adjustable temperature range:
❍ Coverite 21st Century Sealing Iron (COVR2700)
❍ Coverite 21st Century Cover Sock (COVR2702)
KIT INSPECTION
Before starting to build, take an inventory of this kit to make
sure it is complete, and inspect the parts to make sure
they are of acceptable quality. If any parts are missing or
are not of acceptable quality, or if you need assistance
with assembly, contact Product Support. When reporting
defective or missing parts, use the part names exactly as
they are written in the Kit Contents list.
LiPo Battery Charger
To charge a 4S 4000mAh LiPo at 1C, a charger capable of
at least 70 watts is required (4S x 4.2V/cell = 16.8V x 4A =
67 watts). The Triton2 EQ is more than enough charger with
100 W output AC and 120 W output DC (GPMM3156).
ADHESIVES, HARDWARE AND
OTHER ACCESSORIES
Other than common hobby tools here is a list of the rest of
the items required:
❍ 30-minute epoxy (GPMR6043)
❍ Epoxy brushes (GPMR8060)
❍ Mixing cups (GPMR8056)
❍ Mixing sticks (GPMR8055)
❍ Threadlocker thread locking cement (GPMR6060)
❍ Thin CA (GPMR6001)
❍ Medium CA (GPMR6007)
❍ CA applicator tips (HCAR3780)
❍ Optional: Scale Military Pilot (GPMQ9117)
Great Planes Product Support
3002 N Apollo Drive, Suite 1 Ph: (217) 398-8970, ext. 5
Champaign, IL 61822 Fax: (217) 398-7721
E-mail: airsupport@greatplanes.com
REPLACEMENT PARTS LIST
GPMA5395 Wing
GPMA5396 Fuselage
GPMA5397 Tail Surface Set
GPMA5398 Cowl
GPMA5399 Spinner
GPMA5400 Landing Gear Set
GPMA5401 Gear Covers
GPMA5402 Canopy
GPMA5403 Decals
GPMA5404 EP Motor Mount Parts
GPMA5405 Belly Pan
3
KIT CONTENTS
1. Fuselage w/ Canopy Hatch
2. Cowl
3. Engine Mount
4. Wings
1
2
3
7
10
8
9
11
12
4
5
4
14
13
15
16
6
18
17
5. Horizontal Stab
6. Vertical Stab
7. Belly Pan
8. Main Wheels
9. Wheel Covers
10. Main Landing Gear Wires
11. H a r d w a r e
12. Nylon Hardware
13. Wing Joiner
14. Fuel Tank
15. EP Motor Mount Box
16. Tail Gear
17. Velcro Strap
18. Laser-cut Wood Parts
PREPARATIONS
Note: The covering on your Zero requires less heat than you
may be used to if you’re already familiar with iron-on coverings
– too much heat causes seams and edges to draw away from
each other causing wavy, uneven edges or exposed balsa.
1. Use a covering iron with a cover sock to tighten any
❏
loose covering. Wherever the covering is over wood (especially
on the sheet balsa tail surfaces) press down on the iron to
make sure the covering is thoroughly bonded to the balsa
underneath. The optimum temperature measured on the
surface of the cover sock is about 280F [140C] which requires
a dial setting of about 300F [150C] or “medium” heat on
most covering irons. If the covering blisters up over balsa
and cannot be pressed back down, the iron may be too hot
or you are leaving it in one location for too long—try reducing
the heat or moving the iron a little faster.
2. Give a generous tug on all control surfaces to check the
❏
hinges. Add thin CA where necessary to any loose hinges.
Residual CA or CA “fog” is removable with a paper towel
square dampened with CA debonder.
3. If powering
❏
your Zero with a glow
engine, apply a lm of
epoxy or CA to edges
of the covering around
the nose and rewall
to seal from fuel and
exhaust residue.
4
ASSEMBLE THE WING
Cut out
Enlarge the aileron
servo mount as necessary
to t your servos.
1/8" [ 3 mm ]
1. Attach a 6"
❏
[150mm] servo
extension to each
aileron servo and
secure with the
included 3" [75mm]
shrink tubing cut
into two 1-1/2"
[40mm] pieces.
4. Drill 1/16" [1.6mm] holes for the servo mounting screws
❏
in the wing and for the control horn screws on the aileron
(use care not to drill through the top of the aileron). Mount the
servo and horn, make the pushrod and hook up the aileron
using the hardware shown.
5. After mounting the aileron horns, remove the screws,
❏
harden the holes with a few drops of thin CA, allow to harden,
and then reinstall the screws.
6. Hook up the aileron servo in the right wing the same way.
❏
Refer to this image while mounting the aileron servos
and hooking up the ailerons.
Do the left wing rst…
2. If necessary, enlarge the servo cutout to t your servo.
❏
3. Use the string to pull the aileron servo wire through
❏
the wing (or just guide the servo wires down through the
holes without using the string) and t the servo into the
servo openings.
7. Use a at landing gear strap as a guide to drill 3/32"
❏
[2.4 mm] holes into the landing gear block in the left wing–
angle the straps so the holes will be 1/8" [3mm] from the
edge of the groove.
8. Mount the main landing gear to the rails with two straps
❏
and four M3 x 10 screws.
5
9. Use two M2 x 8 machine-thread screws, washers, M2
❏
nuts and a little threadlocker to loosely fasten two hump
straps to the outside of one of the wheel covers.
12. Lightly wet the threads of four M3 set screws with
❏
threadlocker and mount the main wheels to the main landing
gear wire with a wheel collar on both sides—a 1.5mm
machined hex driver is recommended for securely tightening
the set screws (rather than a stamped “L” hex key wrench).
13. Glue together both pieces of the plywood wing
❏
joiner—epoxy may be used to provide more working time
for alignment, or CA may be used for faster assembly.
10. Fasten the cover to the landing gear wire with two
❏
more screws, washers, nuts and threadlocker and tighten
all the screws.
11. Mount the other landing gear, wheel and cover to the
❏
right wing the same way.
14. Once the glue on the joiner halves has hardened, test-
❏
t the wings together with the joiner and the nylon alignment
pin. Make any adjustments necessary for a good t.
6
15. A few paper towels cut into small squares and denatured
❏
alcohol will be useful for cleaning off excess epoxy during the
next step while gluing the wing halves together.
17. After the epoxy has hardened remove the clamps
❏
and tape.
ASSEMBLE THE FUSELAGE
16. Apply 30-minute epoxy to all joining surfaces including
❏
the root ribs and the “Joiner Pockets” inside the wings where
the joiner goes. Securely hold the wing halves together with
masking tape and small clamps or clips on the tabs. As you
proceed, use paper towel squares dampened with denatured
alcohol to wipe away excess epoxy.
1. Cut and remove the spacer from the slot for the horizontal
❏
stabilizer at the back of the fuselage.
2. Mount the wing to the fuselage with two 10-24 x 2" nylon
❏
wing bolts (for convenience, you may shorten the wing bolts
by cutting them to a length of 1-1/2" [40 mm ]).
7
5. Remove the stab and n from the fuselage. Use
❏
30-minute epoxy to glue the tail gear wire into the rudder
and glue the stab and n into the fuselage. Use more paper
towel squares dampened with denatured alcohol to wipe
away residual epoxy. If any weight was required to level the
stab with the wing don’t forget to reposition the weight and
double-check the alignment before the epoxy hardens.
3. Test t the tail gear wire into the rudder and t the vertical
❏
and horizontal stabilizers into the fuselage.
6. Use the holes in the tail gear bracket as a guide to
❏
drill 1/16" [1.6mm] holes into the bottom of the fuselage for
the mounting screws. Screw three M2.5 x 8 screws into the
holes, remove the screws, add a few drops of thin CA to the
holes, allow to fully harden, then mount the gear bracket to
the fuse with the screws. Mount the tail wheel with a small
collar and a M3 set screw and threadlocker.
4. View the model from behind and check the alignment
❏
between the horizontal stabilizer and the wing. If necessary,
adjust the slot in the fuselage to get the stab horizontally
aligned with the wing—in most cases, all that will be required
is a small amount of weight on the high side of the stab.
7. Tighten the collar up against the tail gear bracket with
❏
an M3 set screw wetted with threadlocker.
8
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