Hangar 9 Easy Fly 40 Instruction Manual

Wing Span .64-3/4 inches

Wing Area .712-1/4 inch2

Approx. Weight .4-3/4-5 1/2 lbs.

Engine Requirements .40-.46 2-cycle

.40-.50 4-cycle

• True UltraCote™ covering

• Positive self-righting flight characteristics

• 90% pre-built

• Extensive hardware kit included

• Break away motor mount prevents engine damage during minor nose-overs

Specifications

Raising the Standard of Quality in Almost-Ready-To-Fly Aircraft

ALMOST READY-TO-FLY

PRE-BUILT

HANGAR

INSTRUCTION MANUAL

TICKET TO FLY

R/C Pilot Program

The Total Training Package

Congratulations on your selection of the Hangar 9 Easy Fly 40! Your kit comes complete with the “T

ICKET

TO F

LY R/C

Pilot Program,” a detailed video instruction guide designed to help beginners become successful pilots.

This video guides you through every step of the learning process — from building tricks and tips through your first solo flights. The video shows in-depth procedures on radio setup, trimming the plane, and breaking-in and tuning your engine. It covers the basic flight concepts you need to know, like takeoffs, landings and, most importantly, how to find and work with a qualified instructor. You’ll find out just what to expect when you arrive at the flying field… before you even get there.

When you use the video in conjunction with the complete, photo-illustrated instruction manual, you’ll gain the confidence and ability to successfully meet the challenge of R/C flight. This video is an invaluable teaching aid which will shorten the time it takes to properly learn to operate and fly the Easy Fly 40.

Good Luck and Good Flying!

Table Of Contents

Introduction 3

Contents Of Kit 4

Equipment Required 5

Tools And Supplies Required 5

Field Equipment Required 6

Optional Field Equipment 7

Section 1: Assembling The Wings 8

Section 2: Joining The Wing Halves 9

Section 3: Hinging The Rudder And Elevator 12

Section 4: Installing The Aileron Servo Trays 13

Section 5: Assembling The Fuselage 16

Section 6: Installing The Nose Gear 17

Section 7: Installing The Wing Dowels 18

Section 8: Assembling The Fuel Tank 19

Section 9: Installing The Fuel Tank 21

Section 10: Installing The Control Horns 22

Section 11: Installing The Horizontal & Vertical Stabilizers 24

Section 12: Installing The Engine 26

Section 13: Installing The Radio 29

Section 14: Installing The Linkages 32

Section 15: Setting Up The Radio 38

Section 16: Balancing The Model 39

Pre-Flight Check 40

Pre-Flight At The Field 41

Flight Instructions 42

AMA Safety Codes 43

Glossary 44

Introduction

Congratulations!

You are the proud owner of the highest quality almost-ready-to-fly (ARF) sport trainer available. The Easy Fly 40 is professionally built and pre-covered by craftsmen using genuine UltraCote®covering. The positive selfrighting flight characteristics and excellent slow-speed handling make the Easy Fly 40 one of the easiest-to-fly airplanes available. Beyond its positive, gentle flight mannerisms, the Easy Fly 40 also offers outstanding sport aerobatic capabilities. Loops, rolls, sustained inverted flight, and even outside maneuvers are all well within its flight envelope.

In order for you to get the best performance and most enjoyment from your Easy Fly 40, it is important to carefully read and follow this manual. If you’re a first-time flier, we strongly suggest that you seek qualified help during your first flights. Your local hobby shop will be able to put you in touch with qualified pilots and a local club.

Note: Due to temperature changes during shipping, the covering on your Easy Fly may be slightly wrinkled. The careful use of a heat gun or iron is recommended to shrink the UltraCote

until its taut.

Warning

An R/C aircraft is not a toy! If misused, it can cause serious bodily harm and damage to property. Fly only in open areas, preferably AMA (Academy of Model Aeronautics) approved flying sites, and have an experienced modeler/pilot preflight your aircraft before its first flight and perform the aircraft’s first test flights. Please follow all instructions included with your radio and engine. We cannot stress strongly enough the importance of having an experienced pilot preflight your aircraft and be present during your first test flights!

The Easy Fly 40 is professionally built and pre-covered by craftsmen using genuine UltraCote® covering. UltraCote is completely reparable and can be found at your local hobby shop.

ULTRACOTE

UltraCote is a registered trademark of Carl Goldberg Models

Contents Of Kit

A. Fuselage (#HAN1401) B. Right wing half with aileron (#HAN1402) C. Left wing half with aileron (#HAN1402)

D. Vertical stabilizer with rudder (#HAN1403) E.

Horizontal stabilizer with elevator

(#HAN1404)

1. Pushrods

2. Aileron servo mounts (2)

3. Main landing gear

4. Nose landing gear

5. Spinner

6. Motor mounts and hardware

7. Wheels (3)

8. Fuel tank and hardware

9. Rubber bands (8)

10. Control horns

11. Wing joiner

R/C Radio System

4 Channels (minimum) 4 Standard Servos Standard 450-650 mAh Battery

Recommended JR Systems

JR F400 FM JR XP642 JR XP783 JR XP8103

R/C Engine

.40-.45 2-Cycle with Muffler

Recommended Thunder Tiger Engine

GP .42 with Muffler

R/C Aircraft Propeller

10-6 Prop with a .40-.46 Size Engine

Equipment Required

Adhesives

CA (cyanoacrylate) Glue (instant/thin and medium viscosity) CA Remover (dissolve) 5-Minute Epoxy 30-Minute Epoxy

Tools

Clips (e.g. clothespins, binder clips) Cloth Drill and Assorted Drill Bits Heat Gun Heat Iron Hobby Knife Masking Tape Needle Nose Pliers Paper Towels Pencil #1 and #2 Phillips Screwdrivers

Rubbing Alcohol Ruler (straight edge) Sandpaper Scissors Straight Screwdriver Thread Lock (e.g., Loc Tite Blue) Toothpicks 90-Degree Triangle Wax Paper Z-Bender Pliers

Tools And Supplies Required

Field Equipment Required

HAN3000 – 2-cycle Performance Plug MDC101 Glow Driver Model Airplane Fuel

HAN 3005 – Extra Life Sport Plug

HAN104 12V Super Starter HAN102 12V Battery HAN118 Fuel Pump

HAN2510 Glow Plug Wrench

Optional Field Equipment

Extra Propellers Flight Box Power Panel

Prop Wrench Miscellaneous Tools Paper Towels

#64 Rubber Bands After Run Oil Extra Glow Plugs

❑ 1. Carefully remove the aileron from the right wing panel.

Note where the hinges and the aileron torque rod fit into the aileron.

❑ 2. Mix a small amount of 30-minute epoxy, carefully

following the instructions included with the epoxy.

❑ 3. Using a toothpick, apply epoxy into the ailerons’ torque

rod hole. Fill the hole 1/2 full.

❑ 4. Replace the aileron on the right wing half. Make sure

the hinges slide in place and the aileron torque rod inserts into its respective hole in the aileron. The gap between aileron and wing should be a constant 1/16”.

❑ 5. Wipe off any excess epoxy using a paper towel and

rubbing alcohol.

❑ 6. Deflect the aileron and apply a small amount of thin CA

glue to each hinge. Make sure that the CA glue penetrates into the aileron and wing while maintaining a 1/16” aileron gap.

❑ 7. Wipe off any excess CA glue using CA remover and a

paper towel.

❑ 8. Repeat this process for the left wing (Steps 1-7).

Note:

After the CA has dried completely, check to ensure that the hinges are secure by pulling firmly on the ailerons.

Important:

The ailerons are fitted in place but not glued in. They must be correctly glued prior to flying.

Left Wing Panel with Aileron and Hinges Right Wing Panel with Aileron and Hinges

CA Remover 30-Minute Epoxy

Thin Instant CA Glue

Paper Towels Rubbing Alcohol Toothpicks

Section 1: Assembling The Wings

Parts Needed Tools Needed

❑ 1. Using a pencil, mark both wing roots (the exposed

wood end of the wing halves) as shown.

❑ 2. Using a hobby knife, carefully cut out the marked

section.

Important:

Do not cut into hard wood wing joiner section.

Aileron Servo Mounts (2) Dihedral Brace Left Wing Half from Section 1 Right Wing Half from Section 1 Standard Servo (1)

30-Minute Epoxy Hobby Knife Masking Tape Paper Towels

Pencil Rubbing Alcohol Ruler Wax Paper

Section 2: Joining The Wing Halves

Parts Needed Tools Needed

❑ 3. Locate the dihedral brace (also called the wing joiner).

Using a ruler and pencil, mark the exact center of the brace as shown.

❑ 4. Mix approximately 2 ounces of 30-minute epoxy. In

this step, be sure to use plenty of epoxy. Using a scrap piece of wood, smear the epoxy into the wing joiner cavity of both wings. (Remember, use plenty of epoxy.)

❑ 5. Coat one half of the dihedral brace with epoxy up to the

line. Note the orientation of the V of the dihedral brace. Install the epoxy-coated side of the dihedral

brace into a wing half up to the line, making sure the V of the dihedral brace is positioned correctly as shown.

Section 2: Joining The Wing Halves

CONTINUED

❑ 6. Apply epoxy to the exposed area (other end) of the

dihedral brace. Uniformly coat both wing roots with 30-minute epoxy.

❑ 7. Carefully slide the two wing halves together. Firmly

press the two halves together, allowing the excess epoxy to run out. Using rubbing alcohol and a paper towel, clean off the excess epoxy.

Important:

Be sure the wings are pressed firmly together at the center section. Be sure that the leading and trailing edges line up properly. Use masking tape as necessary to hold the wing halves in position.

❑ 8. Place a 12” x 12” sheet of wax paper on the edge of a

flat table. Place the center section of the wing on the wax paper with the aileron torque rod hanging off the edge of the table. Prop up each wing tip 2-1/2 inches off the table as shown. Books work well for this.

❑ 9. Wipe off any excess epoxy using rubbing alcohol and

paper towels. Allow the wing to set undisturbed overnight to dry completely.

Section 2: Joining The Wing Halves

CONTINUED

Horizontal Stabilizer with Elevator and Hinges Vertical Stabilizer with Rudder and Hinges

CA Remover Paper Towels Thin Instant CA Glue

Section 3: Hinging The Rudder And Elevator

Parts Needed Tools Needed

❑

1. Push the elevator and horizontal stabilizer together until there is a constant 1/16” gap between the two and the edges are lined up correctly.

❑ 2. Deflect the elevator and apply thin CA glue at the

hinges so that it absorbs both into the stabilizer and the elevator (4 places).

❑ 3. Using the same technique, hinge the rudder to the

vertical stabilizer.

❑ 4. Wipe off any excess CA using CA remover and a paper

towel. Set these assemblies aside for now.

Note: After CA has dried completely, check to ensure that the

hinges are secured by pulling firmly on the control surfaces.

❑ 1. Mix a small amount of 5-minute epoxy as per the

instructions included with the epoxy. Remember, once this epoxy is mixed, you have only 5 minutes of working time until it dries.

❑ 2. Spread a thin layer of epoxy over the entire surface of

one side of an aileron tray.

❑ 3. Join the two aileron trays as shown and clamp them

together using four clips. Be sure the two trays are properly aligned. Wipe off any excess epoxy with a paper towel and set aside to dry for 15 minutes.

❑ 4. Using a ruler, measure the distance on the bottom of

the wing at the center line 5-1/2 inches from the trailing edge and mark with a pencil.

❑ 5. Next, measure 3-3/4 inches from the leading edge back

to the center line and mark with a pencil.

Aileron Servo Trays (2) Wing Center Section Tape

Clips (e.g., clothespins,

binder clips) (4) 5-Minute Epoxy Hobby Knife

Masking Tape Paper Towels Pencil Ruler

Section 4: Installing The Aileron Servo Trays

Parts Needed Tools Needed

❑ 6. Unclamp the aileron tray when dry and position it on

the center line so the two marks are visible on the inside of the aileron tray.

❑ 7. Carefully trace around the outside of the aileron tray

using a pencil.

❑ 8. Remove the aileron tray. Using a sharp hobby knife,

carefully cut through the plastic covering. Be careful not to cut into the wood on the line you just made in Step 7.

❑ 9. Carefully remove the covering in the aileron tray area.

This is necessary so that the tray will properly adhere to the wing.

❑ 10. Mix a small amount of 5-minute epoxy and spread it

over the entire area of one side of the servo tray.

ection

4: Installing The Aileron Servo Trays

CONTINUED

+ 34 hidden pages

Hangar 9 Easy Fly 40 Instruction Manual

Specifications and Main Features

Frequently Asked Questions

User Manual