Section 14: Adjusting the Engine .....................................................49
Section 15: Range Testing Your Radio .................................................49
2008 Official AMA National Model Aircraft Safety Code ....................................50
2
Page 3
Using the Manual
This manual is divided into sections to help make assembly easier to understand, and to provide breaks between each
major section. In addition, check boxes have been placed next to each step to keep track of each step completed. Steps
with a single box (
repeating, such as for a right or left wing panel, two servos, etc. Remember to take your time and follow the directions.
) are performed once, while steps with two boxes ( ) indicate that the step will require
• Thin CA (cyanoacrylate) Glue (PAAPT07) • CA Remover/Debonder (PAAPT16)
UltraCote Covering Colors
• Turquoise HANU898 •Midnight Blue HANU885
• White HANU870
Before Starting Assembly
Before beginning the assembly of the Piper Pawnee 40, remove each part from its bag for inspection. Closely inspect
the fuselage, wing panels, rudder, and stabilizer for damage. If you find any damaged or missing parts, contact the
place of purchase.
If you find any wrinkles in the covering, use a heat gun or sealing iron to remove them. Use caution while working around
areas where the colors overlap to prevent separating the colors.
HAN101 – Sealing Iron
HAN100 – Heat Gun
HAN141 – Sealing Iron
Sock
HAN150 – Covering Glove
3
Page 4
Radio and Power Systems Requirements
• 5-channel radio system (minimum) w/receiver • Large Servo Arm (JSP98060) (for use on flap servos)
• 700mAh Ni-Cd 4-cell (JSP91010)
• JR Standard Switch (JSP98010) or JR Chargeswitch (JRPA004)
• DS821 Digital Sport Servo (JRPS821) (7) or equivalent (6 when building electric version)
• Evolution Propeller 11 x 5 (EVO11050) to 11 x 6 (EVO11060)
Recommended Setup–4-Stroke Glow
• Saito™ .82 AAC w/Muffler (SAIE082A or SAIE082AGK)
• Evolution Propeller 13 x 8 (EVO13080) or 14 x 6 (EVO14060)
Recommended Setup–Electric
• E-flite® Power 46 BL Outrunner Motor (EFLM4046A)
• Castle Creations 60A ESC (CSEPHX60)
• Thunder Power 4S 3850–4500mAh Li-Po Battery Pack
• APC Propeller 13x6.5-inch (APC13065E) to 14x7 (APC14070E)
FS One
Evolution .52NX
EVOE0520
Saito .82 AAC
SAIE082A
Power 46 Brushless
Outrunner Motor,670Kv
EFLM4046A
With FS One® you get more than photorealistic fields, gorgeous
skies and realistic-looking aircraft. You get incredibly advanced
aerodynamic modeling that simulates every possible aspect
of real-world flight.
Field Equipment
• Propeller • Fuel
• Glow Plug Wrench (HAN2510) • Extra Long Glow Plug Igniter w/Charger (HAN7115)
• Glow Plug (EVOGP1) • Manual Fuel Pump (HAN118)
• Flight Pack Field Box (HAN130) • PowerPro HD 12V Starter (HAN162)
Exclusive Warranty- Horizon Hobby, Inc., (Horizon) warranties that the Products purchased (the "Product") will be free
from defects in materials and workmanship at the date of purchase by the Purchaser.
Limited Warranty
(a) This warranty is limited to the original Purchaser ("Purchaser") and is not transferable. REPAIR OR REPLACEMENT
AS PROVIDED UNDER THIS WARRANTY IS THE EXCLUSIVE REMEDY OF THE PURCHASER. This warranty covers only
those Products purchased from an authorized Horizon dealer. Third party transactions are not covered by this warranty.
Proof of purchase is required for warranty claims. Further, Horizon reserves the right to change or modify this warranty
without notice and disclaims all other warranties, express or implied.
(b) Limitations- HORIZON MAKES NO WARRANTY OR REPRESENTATION, EXPRESS OR IMPLIED, ABOUT NONINFRINGEMENT, MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE OF THE PRODUCT. THE
PURCHASER ACKNOWLEDGES THAT THEY ALONE HAVE DETERMINED THAT THE PRODUCT WILL SUITABLY MEET
THE REQUIREMENTS OF THE PURCHASER’S INTENDED USE.
(c) Purchaser Remedy- Horizon's sole obligation hereunder shall be that Horizon will, at its option, (i) repair or (ii)
replace, any Product determined by Horizon to be defective. In the event of a defect, these are the Purchaser's exclusive
remedies. Horizon reserves the right to inspect any and all equipment involved in a warranty claim. Repair or replacement
decisions are at the sole discretion of Horizon. This warranty does not cover cosmetic damage or damage due to acts of
God, accident, misuse, abuse, negligence, commercial use, or modification of or to any part of the Product. This warranty
does not cover damage due to improper installation, operation, maintenance, or attempted repair by anyone other than
Horizon. Return of any goods by Purchaser must be approved in writing by Horizon before shipment.
Damage Limits
HORIZON SHALL NOT BE LIABLE FOR SPECIAL, INDIRECT OR CONSEQUENTIAL DAMAGES, LOSS OF PROFITS OR
PRODUCTION OR COMMERCIAL LOSS IN ANY WAY CONNECTED WITH THE PRODUCT, WHETHER SUCH CLAIM
IS BASED IN CONTRACT, WARRANTY, NEGLIGENCE, OR STRICT LIABILITY. Further, in no event shall the liability of
Horizon exceed the individual price of the Product on which liability is asserted. As Horizon has no control over use,
setup, final assembly, modification or misuse, no liability shall be assumed nor accepted for any resulting damage or
injury. By the act of use, setup or assembly, the user accepts all resulting liability.
If you as the Purchaser or user are not prepared to accept the liability associated with the use of this Product, you are
advised to return this Product immediately in new and unused condition to the place of purchase.
Law: These Terms are governed by Illinois law (without regard to conflict of law principals).
Safety Precautions
This is a sophisticated hobby Product and not a toy. It must be operated with caution and common sense and requires
some basic mechanical ability. Failure to operate this Product in a safe and responsible manner could result in injury
or damage to the Product or other property. This Product is not intended for use by children without direct adult
supervision. The Product manual contains instructions for safety, operation and maintenance. It is essential to read
and follow all the instructions and warnings in the manual, prior to assembly, setup or use, in order to operate correctly
and avoid damage or injury.
6
Page 7
Questions, Assistance, and Repairs
Your local hobby store and/or place of purchase cannot provide warranty support or repair. Once assembly, setup or
use of the Product has been started, you must contact Horizon directly. This will enable Horizon to better answer your
questions and service you in the event that you may need any assistance. For questions or assistance, please direct your
email to productsupport@horizonhobby.com, or call 877.504.0233 toll free to speak to a service technician.
Inspection or Repairs
If this Product needs to be inspected or repaired, please call for a Return Merchandise Authorization (RMA). Pack
the Product securely using a shipping carton. Please note that original boxes may be included, but are not designed
to withstand the rigors of shipping without additional protection. Ship via a carrier that provides tracking and insurance
for lost or damaged parcels, as Horizon is not responsible for merchandise until it arrives and is accepted at our facility. A Service Repair Request is available at www.horizonhobby.com on the “Support” tab. If you do not
have internet access, please include a letter with your complete name, street address, email address and phone number
where you can be reached during business days, your RMA number, a list of the included items, method of payment
for any non-warranty expenses and a brief summary of the problem. Your original sales receipt must also be included
for warranty consideration. Be sure your name, address, and RMA number are clearly written on the outside of the
shipping carton.
Warranty Inspection and Repairs
To receive warranty service, you must include your original sales receipt verifying the proof-of-purchase
date. Provided warranty conditions have been met, your Product will be repaired or replaced free of charge. Repair or
replacement decisions are at the sole discretion of Horizon Hobby.
Non-Warranty Repairs
Should your repair not be covered by warranty the repair will be completed and payment will be
required without notification or estimate of the expense unless the expense exceeds 50% of the retail
purchase cost. By submitting the item for repair you are agreeing to payment of the repair without notification. Repair
estimates are available upon request. You must include this request with your repair. Non-warranty repair estimates will
be billed a minimum of ½ hour of labor. In addition you will be billed for return freight. Please advise us of your preferred
method of payment. Horizon accepts money orders and cashiers checks, as well as Visa, MasterCard, American Express,
and Discover cards. If you choose to pay by credit card, please include your credit card number and expiration date. Any
repair left unpaid or unclaimed after 90 days will be considered abandoned and will be disposed of accordingly. Please note: non-warranty repair is only available on electronics and model engines.
Electronics and engines requiring inspection or repair should be shipped to the following address:
Horizon Service Center
4105 Fieldstone Road
Champaign, Illinois 61822
All other Products requiring warranty inspection or repair should be shipped to the following address:
Horizon Product Support
4105 Fieldstone Road
Champaign, Illinois 61822
Please call 877-504-0233 with any questions or concerns regarding this product or warranty.
7
Page 8
Safety, Precautions, and Warnings
This model is controlled by a radio signal that is subject to interference from many sources outside your control. This
interference can cause momentary loss of control so it is advisable to always keep a safe distance in all directions around
your model, as this margin will help to avoid collisions or injury.
• Always operate your model in an open area away from cars, traffic, or people.
• Avoid operating your model in the street where injury or damage can occur.
• Never operate the model into the street or populated areas for any reason.
• Never operate your model with low transmitter batteries.
• Carefully follow the directions and warnings for this and any optional support equipment (chargers, rechargeable
battery packs, etc.) that you use.
• Keep all chemicals, small parts and anything electrical out of the reach of children.
• Moisture causes damage to electronics. Avoid water exposure to all equipment not specifically designed and protected
for this purpose.
8
Page 9
Contents of Kit
Large Replacement Parts
A. HAN4031 Fuselage w/Hatch
B. HAN4032 Right Wing
C. HAN4033 Left Wing
D. HAN4034 Horizontal Stab and Elevator
E. HAN4035 Wing Struts
F. HAN4036 Rudder
G. HAN4037 Landing Gear
H. HAN4038 Wheels
I. HAN4039 Cowl
J. HAN4040 Canopy with Seat
K. HAN4043 Wing Tube Set
A
I
B
C
E
Small Replacement Parts
1. HAN4041 Assembled 11 oz fuel tank
2. HAN4044 Pushrod Set
3. HAN4045 Glow Motor Mount
4. HAN4046 EP Motor Mount Standoffs
5. HAN4047 Pin and Keeper Set
6. HAN4048 Tail Flying Wires
1
7. HAN4049 2
8. HAN4007 Tailwheel Assembly
/4-inch Spinner
J
F
D
G
K
H
1
2
7
4
3
8
5
6
9
Page 10
Section 1: Landing Gear and Rudder Installation
Required Parts
• Wheel assembly (2) • Landing gear
• Landing gear strap (4) • Tail gear assembly
• Rudder • Fuselage
• 5/32-inch wheel collar w/setscrew (2)
• 3mm x 10mm sheet metal screw (8)
Required Tools and Adhesives
• Hex wrench (supplied) • Petroleum jelly
• Phillips screwdriver: #1, #2 • Thin CA
• 30-minute epoxy • Sandpaper
• Drill bit: 1/16-inch (1.5mm) •Pin drill
o Step 1
Use a small flat screwdriver to remove the cap from the
outer wheel hub as shown.
o Step 3
Slide the inner wheel hub onto the landing gear. The wheel
collar is then installed by tightening the setscrew onto the
flat spot on the axle using the supplied hex wrench.
Note: Make sure to use threadlock on the
setscrews to prevent them from vibrating loose.
o Step 2
Use a #1 Phillips screwdriver to remove the four sheet
metal screws holding the inner and outer wheel hubs
inside the wheel.
o Step 4
Slide the wheel back onto the inner wheel hub.
10
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Section 1: Landing Gear and Rudder Installation
o Step 5
Slide the outer wheel hub back into the wheel. Slide the
supplied hex wrench into the screw hole in the outer
wheel hub, then into the screw hole in the inner wheel hub
to aid in aligning the screw holes.
o Step 6
Reinstall the four sheet metal screws to secure the inner
and outer wheel hubs in the wheel.
o Step 7
Snap the cap back in position on the outer wheel hub.
Step 8
Repeat Steps 1 through 7 to install the remaining wheel
onto the landing gear.
11
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Section 1: Landing Gear and Rudder Installation
Step 9
Attach the landing gear to the fuselage using four landing
gear straps and eight 3mm x 10mm sheet metal screws
and a #2 Phillips screwdriver.
Step 10
Use sandpaper to roughen the wire so the epoxy will have
a rough surface to bond to.
Step 11
Apply a small amount of petroleum jelly to the top and
bottom of the tail gear bushing. Work the jelly into the
bushing to prevent epoxy from entering the bushing and
locking the tail gear wire.
Step 12
Use 30-minute epoxy to glue the tail gear bushing into
the fuselage. Make sure the bushing is pressed tight in
the fuselage, and has been slid down toward the bottom
of the fuselage as far as possible.
12
Page 13
Section 1: Landing Gear and Rudder Installation
Step 13
Use a pin drill and 1/16-inch (1.5mm) drill bit to drill
a hole in the center of each hinge slot in the fin and
rudder. This will provide a tunnel for the CA to wick
into, providing a better bond between the hinge and
surrounding wood.
Step 14
Step 15
Slide each of the hinges into the rudder until the T-pin is
resting on the hinge line of the rudder.
Step 16
Test fit the rudder onto the tail gear wire, guiding the wire
into the pre-drilled hole in the rudder.
Place a T-pin in the center of each of the three CA
hinges. This will help in centering the hinges when they
are installed.
13
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Section 1: Landing Gear and Rudder Installation
Step 17
As you slide the rudder onto the tail gear wire, slide the
hinges for the rudder into the slots in the fin. The rudder
should fit tight against the fin, and should not bind at the
balance tab when the rudder is in operation.
Step 18
Once you have checked the fit of the hinges and tail
gear wire, remove the rudder from the fin. Apply a small
amount of 30-minute epoxy on the tail gear wire and into
the hole in the rudder to secure it in the rudder. Repeat
Steps 16 and 17 to place the rudder back into position.
Step 19
Remove the T-pins from the hinges. Apply thin CA to
both sides of the three hinges. Allow the CA to cure
(without using accelerator) before proceeding to the
following steps.
Note: The CA must be allowed to cure without
the use of accelerator. Using accelerator
will not allow the CA to fully soak into the
hinge, and could produce a poor bond
between the hinges and surrounding wood.
Step 20
Once the CA has fully cured, gently pull on the fin and
rudder to make sure all the hinges are glued securely.
14
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Section 1: Landing Gear and Rudder Installation
Step 21
Move the rudder right and left a number of times to
condition the hinges.
Step 22
Secure the tail wheel using two 1/16-inch wheel collars
and two setscrews. Tighten the setscrews using the
supplied hex wrench.
Note: Make sure to use threadlock on the
setscrews to prevent them from vibrating loose.
15
Page 16
Section 2: Aileron and Flap Servo Installation
Required Parts
• Snap link (4) • Nylon clevis (4)
• Clevis retainer (4)
• Flap servo cover (right and left)
• Aileron servo cover (right and left)
• #2 x 3/8-inch sheet metal screw (16)
3
• 3
/4-inch (95mm) threaded pushrod (4)
• Servo mounting blocks,
3/4 x 9/16 x 5/16-inch (19 x 14 x 8mm) (8)
Required Tools and Adhesives
• Sandpaper • Pencil
• Drill • Pin drill
• Drill bit: 5/64-inch (2mm) • 30-minute epoxy
• Long servo arm (4)
• Servo extension, 9-inch (229mm)
oo Step 1
Secure a 9-inch (229mm) servo extension to the aileron
servo. String or a commercially available connector is
suggested to prevent disconnection inside the wing.
ooo Step 2
Position the servo onto the servo cover. The servo horn
will be centered and in line with the outer edge of the
cover as shown.
ooo Step 3
Mark the locations for the servo mounting blocks on the
servo cover using a pencil or felt-tipped pen.
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Section 2: Aileron and Flap Servo Installation
ooo Step 4
Lightly sand the servo mounting blocks on the edge where
they will be glued to the servo cover. This will allow the
epoxy to hold onto the block, providing a more secure
bond between the cover and blocks.
ooo Step 5
Use 30-minute epoxy to attach the two mounting blocks to
the servo cover. Use clamps or tape to hold the blocks in
position until the epoxy fully cures.
ooo Step 6
Transfer the locations for the servo mounting screws onto
the servo mounting blocks using a pencil.
ooo Step 7
Drill four holes for the servo mounting screws using a
drill and 5/64-inch (2mm) drill bit.
17
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Section 2: Aileron and Flap Servo Installation
ooo Step 8
Apply 2–3 drops of thin CA into each of the holes to
harden the surrounding wood. This will make the screws
more secure and prevent them from vibrating loose.
ooo Step 9
Use the screws supplied with the servo and a #1 Phillips
screwdriver to secure the servo to the mounting blocks.
oo Step 10a (aileron servos only)
Remove the supplied servo arm from the aileron servo.
After centering the servo, attach a standard double arm
using the screw supplied with the servo. Use side cutters
to remove the portion of the arm that does not extend
beyond the servo cover.
oo Step 10b (flap servos only)
Remove the supplied servo arm from the flap servo. After
centering the servo, attach a long servo arm (JSP98060)
using the screw supplied with the servo.
18
Note: When installing the horn on the
flap servo, set the throw on the radio
to the center position for the flaps.
Page 19
Section 2: Aileron and Flap Servo Installation
ooo Step 11
Pass the servo extension through the wing and into the
bay for the flap servo. Use four #2 x 3/8-inch sheet metal
screws to attach the servo cover to the wing.
ooo Step 12
Continue to pass the aileron extension through the wing.
Use tape (or glue) to secure the aileron extension to
the top sheeting of the wing. This will prevent it from
interfering with the operation of the flap servo.
ooo Step 13
Use a pin drill and 5/64-inch (2mm) drill bit to enlarge
the outermost hole in the servo arm to accept the
pushrod wire.
ooo Step 14
Slide one of the pre-bent 3
the hole drilled in the previous step.
3
/4-inch (95mm) linkages into
19
Page 20
Section 2: Aileron and Flap Servo Installation
ooo Step 15
Secure the pushrod wire using one of the snap links
provided with your Piper Pawnee 40.
ooo Step 16
Slide a clevis retainer onto one of the nylon clevises.
Thread the clevis onto the pushrod wire.
ooo Step 17
Turn on the radio system and plug the aileron servo into
the receiver. Attach the clevis to the middle hole of the
control horn as shown. It will be necessary to thread the
clevis in or out on the pushrod wire to center the control
surface while the radio is on and the servo centered.
o Step 18
Repeat Steps 1 through 17 to install the remaining
aileron servos.
Step 19
Repeat Steps 2 through 18 to install the flap servos.
Please pay attention to the notes at Step 10 regarding the
centering of the flap servo and the servo arm installation.
The linkage attaches to the outer hole of the servo arm and
the middle hole of the control arm.
Note: When installing the flap linkage, make
sure to change the radio to the up flap position
before connecting and installing the linkage.
20
Note: On the flap we used the long
servo arm (JSP98060) and connected to
the middle hole on the control horn.
Page 21
Section 3: Wing Attachment
Required Parts
• Wing strut (front) (right and left)
• Wing strut (rear) (right and left)
• 3mm nut (4) • Strut end (4)
• Wing strut bracket (4) • #4 washer (4)
• Wing tube (small) • Wing tube (large)
• 4-40 lock nut (4) • Retainer pin clip (4)
• 1/4-inch (4mm) fuel tubing (4)
• Strut attachment pin (4)
• 4-40 x 1/2-inch socket head screw (18)
Required Tools and Adhesives
• Threadlock • Adjustable wrench
• Hex wrench: 3/32-inch
Step 1
Thread a 3mm nut onto each of the struts.
Step 2
Thread a strut end onto each of the struts.
Step 3
Attach the wing strut brackets to the wing using four
4-40 x 1/2-inch socket head screws.
Note: Make sure to use threadlock on the
screws to prevent them from vibrating loose.
21
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Section 3: Wing Attachment
Step 4
Attach the fuselage strut brackets using four
4-40 x 1/2-inch socket head screws and four #4 washers.
The bracket will angle down and point toward the wing
when installed.
Note: Make sure to use threadlock on the
screws to prevent them from vibrating loose.
o Step 6
Slide the wing tubes into the fuselage. Guide the servo
leads for the aileron and flap servos into the opening in
the fuselage while positioning the wing.
o Step 7
Secure the wing to the fuselage using a 4-40 x 1/2-inch
socket head screw and a 3/32-inch hex wrench.
Step 5
Slide the large and small wing tubes into the wing as
shown. The small tube will be at the rear of the wing, and
the large tube toward the front of the wing.
22
Page 23
Leading Edge of Strut
Section 3: Wing Attachment
o Step 8
Attach the wing struts to the wing strut brackets using
4-40 x 1/2-inch socket head screws and 4-40 lock nuts.
Note that the longer strut is positioned toward the rear
(trailing edge) of the wing. Also note the airfoil shape of
the strut during the installation.
o Step 10
Align the holes at the ends of the struts with the holes
in the fuselage bracket. It will be necessary to adjust
the length of the strut ends to attach the struts without
forcing them into position. Make sure that you will not be
inducing any twist in the wings when attaching the struts.
o Step 9
Slide the 1/4-inch (4mm) piece of fuel tubing onto a strut
attachment pin. Prepare two pins for the attachment of the
wing struts to the fuselage.
23
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Section 3: Wing Attachment
o Step 11
Attach the struts to the fuselage strut brackets using two
strut attachment pins and two retainer pin clips.
o Step 12
Once the length of the struts has been set, make sure to
use threadlock on the nuts and strut ends to prevent them
from vibrating loose. Also tighten the 3mm nut against the
strut end to lock everything into position.
Step 13
Repeat Steps 6 through 10 to install the remaining wing
panel by sliding it onto the wing tubes and securing it to
the fuselage.
Slide the stabilizer pins into one of the stabilizer halves.
The longer 1
leading edge, while the shorter 13/16-inch (21mm) pin is
inserted toward the elevator.
3
/16-inch (30mm) pin is inserted toward the
Step 2
Attach one half of the stabilizer using two 4-40 x 1/2-inch
socket head screws and two #4 washers. Leave the screws
loose until instructed to tighten them.
Step 3
Slide the remaining stabilizer into position and secure it
using two 4-40 x 1/2-inch socket head screws and two #4
washers. Tighten all four screws at this time.
Note: Make sure to use threadlock on the
screws to prevent them from vibrating loose.
25
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Section 4: Stabilizer/Elevator Installation
Step 4
Attach the tail rigging with the long and medium tabs to
the bottom of the fuselage using two #2 x 1/2-inch sheet
metal screws. The longest tabs go to the front, while the
medium length tabs go to the rear.
Step 5
Step 6
Attach the tabs to the top and bottom of the stabilizer
using four 4-40 x 1/2-inch socket head screws and four
4-40 lock nuts. Leave the bolts loose enough so the tabs
can be rotated.
Carefully bend the remaining rigging tabs using pliers.
26
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Section 4: Stabilizer/Elevator Installation
Step 7
Connect the rigging to the tabs on the stabilizer.
Step 8
Attach the remaining cables to the fin using two
4-40 x 1/2-inch socket head bolts and two 4-40 lock
nuts. Connect the clevises to the tabs on the stabilizer
at this time.
Step 9
Once all the cables have been attached, go back and
tighten the bolts holding the tabs at the stabilizer. Do
not crush the wood of the stabilizer by over-tightening
the screws.
Step 10
Adjust the flying wires so there is equal and light tension
on each wire. Make sure that the stabilizer and
fin have not been twisted during the tensioning of the
flying wires.
Step 11
To keep the rudder and elevators from moving, and to aid
in the installation of the linkages, use low-tack painters
tape to tape the rudder to the fin, and the elevators to the
stabilizers, at this time.
27
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Section 5: Radio Installation
Required Parts
• Fuselage assembly • Servo w/hardware (2)
• Receiver • Receiver battery
• Switch harness • Foam rubber
• Y-harness (2) • Hook and loop strap
• Nylon clevis (3) • Clevis retainer (3)
• Snap link (2)
• 5/32-inch wheel collar (2)
• 32-inch (813mm) pushrod
1
• 31
/4-inch (794mm) pushrod
1
• 32
/2-inch (825mm) pushrod
• 3mm x 8mm machine screw (2)
Required Tools and Adhesives
• Pin drill • Thin CA
• Phillips screwdriver: #1, #2
• 30-minute epoxy
• Drill bit: 1/16-inch (1.5mm)
o Step 1
Position the rudder servo into the radio tray. Transfer the
locations for the servo mounting screws onto the radio
tray using a pencil.
o Step 2
Drill four holes for the servo mounting screws using a
pin drill and 1/16-inch (1.5mm) drill bit.
o Step 3
Apply 2–3 drops of thin CA into each of the holes to
harden the surrounding wood. This will make the screws
more secure and prevent them from vibrating loose.
28
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Section 5: Radio Installation
o Step 4
Use the screws supplied with the servo and a #1 Phillips
screwdriver to secure the servo to the radio tray.
Step 5
Repeat Steps 1 through 4 to install the elevator servo.
Step 6
Wrap the receiver battery in foam and secure it to the
radio tray using the supplied hook and loop strap.
The receiver is mounted on the battery and should be
positioned to avoid vibrations from being transferred
through the airframe into the receiver. Install your switch
harness at this time as well.
Step 7
When using a remote receiver, place it as far as possible
from the main receiver and at a different level in the
fuselage for the best results. The higher the remote
receiver can be mounted in the fuselage, the better.
29
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Section 5: Radio Installation
o Step 8
Slide the 32
tube for the rudder. It is easiest to start by inserting the
pushrod in the opening in the firewall to prevent bending
it around the fuselage structure.
1
/2-inch (825mm) pushrod into the pushrod
o Step 9
Replace the standard servo arm on the elevator servo
with a standard double arm. Use a 5/64-inch (2mm)
drill bit and pin drill to enlarge the outer hole in the
rudder servo arm.
o Step 10
Secure the pushrod wire using one of the snap links
provided with your Piper Pawnee 40.
Note: The elevator and rudder pushrods are
connected to the outer hole on the standard
double arm that comes with the servo and
they are connected to the middle hole on the
control horns for both rudder and elevator.
o Step 11
Turn on the radio system and plug the servo into the
receiver. Attach the clevis to the middle hole of the control
horn as shown. It will be necessary to thread the clevis in
or out on the pushrod wire to center the control surface
while the radio is on and the servo centered.
30
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Section 5: Radio Installation
Step 12
Slide the two 5/32-inch wheel collars onto the 32-inch
(813mm) elevator pushrod. Secure the collars near the
bend using a 3mm x 8mm machine screw and #2 Phillips
screwdriver. The wheel collars will be positioned later.
Step 13
Repeat Steps 8 through 11 to install the elevator pushrod,
attaching the pushrod to the outer hole on the servo arm
and the center hole of the control horn.
Step 14
Thread a clevis on the remaining 31
pushrod. Slide the pushrod into the pushrod tube from
outside the fuselage and attach the clevis to the center
hole of the elevator control horn.
1
/4-inch (794mm)
Step 15
The pushrod will pass through the two wheel collars that
were installed in Step 12. The collars are then tightened to
hold the two pushrods together. Apply 30-minute epoxy to
the pushrods between the two collars as well at this time.
Note: Make sure to use threadlock on the
screws to prevent them from vibrating loose.
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Section 6: 2-Stroke Engine Installation
Required Parts
• Engine mount • 8-32 lock nut (4)
• Clevis • Clevis retainer
• Engine mount plate (2) • Fuel tank
3
• 11
/4-inch (300mm) throttle pushrod tube
• 8-32 x 3/4-inch machine screw (4)
• 8-32 x 1-inch machine screw (4)
3
• 17
/4-inch (450mm) throttle pushrod
Required Tools and Adhesives
• Threadlock • Ruler
• Foam rubber • Fuel dot
• Pencil • Side cutter
• Drill • Sandpaper
• Drill bit: 11/64-inch (4.5mm)
Step 1
Attach the mount to the firewall using four 8-32 x 3/4-inch
machine screws and four #8 washers.
Step 2
Temporarily install the rear 8-32 x 1-inch machine screws
and 8-32 lock nuts to attach the mounting plates to the
mount. Finger-tighten the screws at this time.
Note: The motor mount plates have a textured
side that faces the mount when installed.
Note: Make sure to use threadlock on the
screws to prevent them from vibrating loose.
Step 3
Slide the engine between the mount and mounting
plates. Install the remaining 8-32 x 1-inch machine
screws and 8-32 lock nuts at the front of the mounting
plates. Position the engine so the drive washer is
5
4
/8-inch (118mm) forward of the firewall. Tighten
all four 8-32 x 1-inch machine screws evenly to secure
the position of the engine.
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Section 6: 2-Stroke Engine Installation
Step 4
Use a pencil to mark the location of the throttle pushrod
tube on the firewall.
Step 5
Use a drill and 11/64-inch (4.5mm) drill bit to drill the
hole for the throttle pushrod tube.
Step 6
Roughen the outside of the 11
pushrod tube using sandpaper. Slide the tube into the
hole, leaving around 1-inch (25mm) of the tube forward
of the firewall.
3
/4-inch (300mm) throttle
Step 7
Use side cutters to trim the pushrod tube at the rear of the
fuel tank tray as shown.
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Clunk
Vent line
Top View
Side View
Vent line (faces top of fuselage)
To Muffler
To Carburetor
Section 6: 2-Stroke Engine Installation
Step 8
Slide a clevis retainer onto a clevis, then thread the clevis
onto the 17
3
/4-inch (450mm) throttle pushrod.
Step 9
Slide the pushrod into the tube and connect the clevis to
the carburetor arm.
Step 10
Attach the muffler to your engine following the instructions
provided with your particular engine.
Step 11
Look carefully at the fuel tank to determine which tubes
are for the carburetor and vent. Also check the direction
of the vent line inside the fuel tank. The vent will face the
top of the fuselage when the fuel tank is installed. Use the
drawings below as a reference for the fuel lines.
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Section 6: 2-Stroke Engine Installation
Step 12
Slide the tank into the fuselage, making sure the vent
line faces toward the top of the fuselage.
Step 13
Install a brace and foam padding around the fuel tank
to keep it in position inside the fuselage and protect it
from vibration.
Step 14
Connect the lines from the fuel tank to the engine and
muffler. We used a fuel dot to allow fueling the tank from
outside the cowling.
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Section 7: 4-Stroke Installation
Required Parts
• Engine mount • 8-32 lock nut (4)
• Engine mount plate (2) • Fuel tank
3
• 11
/4-inch (300mm) throttle pushrod tube
• 8-32 x 3/4-inch machine screw (4)
• 8-32 x 1-inch machine screw (4)
3
• 17
/4-inch (450mm) throttle pushrod
Required Tools and Adhesives
• Threadlock • Ruler
• Foam rubber • Fuel dot
• Pencil • Side cutter
• Drill • Sandpaper
• Drill bit: 11/64-inch (4.5mm)
Step 1
Attach the mount to the firewall using four 8-32 x 3/4-inch
machine screws and four #8 washers.
Step 2
Temporarily install the rear 8-32 x 1-inch machine screws
and 8-32 lock nuts to attach the mounting plates to the
mount. Finger-tighten the screws at this time.
Note: The motor mount plates have a textured
side that faces the mount when installed.
Note: Make sure to use threadlock on the
screws to prevent them from vibrating loose.
Step 3
It may be necessary to rotate the carburetor on your
engine in order to attach the throttle linkage. If the
carburetor arm and linkage will interfere with the engine
mount, rotate the carburetor as shown.
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Section 7: 4-Stroke Installation
Step 4
Slide the engine between the mount and mounting plates.
Install the remaining 8-32 x 1-inch machine screws and
8-32 lock nuts at the front of the mounting plates.
Step 5
Use a pencil to mark the location of the throttle pushrod
tube on the firewall.
Step 6
Remove the engine from the engine mount. Use a drill
and 11/64-inch (4.5mm) drill bit to drill the hole for the
throttle pushrod tube.
Step 7
Roughen the outside of the 11
pushrod tube using sandpaper. Slide the tube into the
hole, leaving around 1/4-inch (4mm) of the tube forward
of the firewall.
3
/4-inch (300mm) throttle
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Section 7: 4-Stroke Installation
Step 8
Use side cutters to trim the pushrod tube as shown.
Step 9
Make a Z-bend in the 17
pushrod. Make the bend on the end without the threads.
3
/4-inch (450mm) throttle
Step 10
Attach the Z-bend to the carburetor by inserting the
Z-bend in the outer hole of the carburetor arm as shown.
Step 11
Slide the engine back into position on the mounts. (See
Step 4 for details.) Position the engine so the drive washer
5
is 4
/8-inch (118mm) forward of the firewall. Tighten all
four 8-32 x 1-inch machine screws evenly to secure the
position of the engine.
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Clunk
Vent line
Top View
Side View
Vent line (faces top of fuselage)
To Muffler
To Carburetor
Section 7: 4-Stroke Installation
Step 12
Attach the muffler to your engine following the instructions
provided with your particular engine.
Step 13
Look carefully at the fuel tank to determine which tubes
are for the carburetor and vent. Also check the direction
of the vent line inside the fuel tank. The vent will face the
top of the fuselage when the fuel tank is installed. Use the
drawings below as a reference for the fuel lines.
Step 14
Slide the tank into the fuselage, making sure the vent line
faces toward the top of the fuselage.
Step 15
Install a brace and foam padding around the fuel tank
to keep it in position inside the fuselage and protect it
from vibration.
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Section 7: 4-Stroke Installation
Step 16
Connect the lines from the fuel tank to the engine and
muffler. We used a fuel dot to allow fueling the tank from
outside the cowling.
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Section 8: Throttle Servo Installation
Required Parts
• Fuselage assembly • Servo
• Snap link
• Plywood pushrod standoff
Required Tools and Adhesives
• Pencil • Thin CA
• Drill bit: 5/64-inch (2mm) • Pliers
• Side cutters • Pin drill
• Phillips screwdriver • Medium CA
Step 1
Slide the plywood pushrod standoff onto the pushrod
tube. The exact location will be determined later in this
section of the manual.
Step 3
Use a felt-tipped pen to mark the pushrod where it crosses
the outer hole on the servo horn.
Step 4
Use a pair of pliers to make a 90-degree bend in the
pushrod at the mark made in the previous step.
Step 2
Follow Steps 1 through 4 under Section 5: Radio
Installation to install the throttle servo into the fuselage.
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Section 8: Throttle Servo Installation
Step 5
Use a pin drill and a 5/64-inch (2mm) drill bit to
enlarge the outer hole in the servo arm. Slide the
pushrod wire through the hole in the servo horn. Slide
the snap link onto the pushrod wire, then rotate it until
it snaps onto the wire.
Step 7
Slide the plywood pushrod standoff so it can be glued to
the side of the fuselage using medium CA as shown.
Step 6
Use side cutters to remove the excess wire. Leave at least
1/16-inch (1.5mm) exposed beyond the connector to
prevent the wire from coming out of the connector.
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Section 9: Electric Motor Installation
Required Parts
• Fuselage assembly • Motor w/hardware
• Electronic speed control • Hook and loop strap
• Hook and loop tape •Motor battery
• 2-inch (50mm) aluminum standoff (4)
• 8-32 x 2
Required Tools and Adhesives
• Hobby knife • Covering iron
• Drill bit: 5/32-inch (4mm) • Drill
1
/2-inch (64mm) machine screw (4)
Step 1
Use a hobby knife to remove the plywood from the firewall
to provide cooling air to pass through the fuselage. The
plywood has been partially cut so all that is required is to
score the plywood along the lines.
Step 2
Use a hobby knife and a covering iron to open the cooling
air exit in the bottom of the fuselage. Cutting the covering
1/8-inch (3mm) inside the opening and ironing the
covering into the fuselage will leave a clean look to the
bottom of the fuselage as shown.
Step 3
Use a drill and 5/32-inch (4mm) drill bit to enlarge the
outer holes in the X-mount as shown.
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Section 9: Electric Motor Installation
Step 4
Attach the X-mount to the motor using the screws
provided with the motor.
Note: Make sure to use threadlock on the
screws to prevent them from vibrating loose.
Step 5
Attach the motor to the firewall using four 1
(50mm) aluminum standoffs and four 8-32 x 2
(64mm) machine screws.
5
/8-inch
1
/2-inch
Step 6
Secure the speed controller to the bottom of the fuselage
using hook and loop tape as shown. Secure the wires
between the motor and speed control so they do not
interfere with the operation of the motor.
Step 7
Secure the motor battery inside the fuselage using the
two hook and loop straps. If the battery moves fore or aft,
use hook and loop (not provided) mounted directly to the
battery and the tank floor to keep the battery secure inside
the fuselage.
Note: Make sure to use threadlock on the
screws to prevent them from vibrating loose.
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Section 10: Cowling and Canopy Installation
Required Parts
• Fuselage assembly • Cowling
• 1/4-inch (4mm) tubing (4) • #4 washer (4)
• Spinner w/hardware • Canopy
• Pilot seat
• 4-40 x 1/2-inch socket head screws
Required Tools and Adhesives
• Hex wrench: 3/32-inch • Canopy glue
• Phillips screwdriver: #1 • Medium CA
• Hobby scissors • Low-tack tape
• Rotary tool w/sanding drum
Step 1
Slide a #4 washer onto each of the four 4-40 x 1/2-inch
cowl mounting screws. A piece of 1/4-inch tubing is then
slid onto each of the screws.
Step 2
Secure the cowling to the fuselage using the screws
prepared in the previous step.
Step 3
Use the instructions provided with your engine to install
the spinner. The spinner cone is attached to the spinner
backplate using two 3mm x 12mm sheet metal screws and
a #1 Phillips screwdriver.
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Section 10: Cowling and Canopy Installation
Step 4
Use the following images as a guide for cutting the
cowling for a 4-stroke engine. Make sure to make cutouts
for the rocker box covers, exhaust and needle valve. You
will need to drill a 3/8-inch (9.5mm) hole in the cowl for
mounting the fuel dot as well.
Step 5
Use the following images as a guide for cutting the
cowling for a 2-stroke engine. Make sure to make cutouts
for glow plug access, muffler and needle valve. You will
need to drill a 3/8-inch (9.5mm) hole in the cowl for
mounting the fuel dot as well.
46
Note: We used a Dubro Exhaust
Deflector (DUB697) to allow the exhaust
to exit the rear opening in the cowl.
Page 47
Section 10: Cowling and Canopy Installation
Step 6
Use medium CA to glue the pilot seat in the cockpit. Note
that the seat does fit slightly forward of the rear of the
cockpit as shown.
Step 7
Use canopy glue to secure the canopy to the fuselage. Use
low-tack tape to hold the canopy in position until the glue
fully cures. If you are planning on installing a pilot figure
then install now before attaching the canopy.
Section 11: Recommended Center of Gravity (CG)
An important part of preparing the aircraft for flight is
properly balancing the model. This is especially important
when various engines are mounted.
Caution: Do not inadvertently skip this step!
The recommended Center of Gravity (CG) location
for the Piper Pawnee 40 is 3
leading edge of the wing against the fuselage. If necessary,
move the battery pack or add weight to either the nose
or the tail until the correct balance is achieved. Stick-on
weights are available at your local hobby store and work
well for this purpose. The range for the Center of Gravity
7
is 2
/8– 33/8 inches (73mm–85mm).
Note: The Center of Gravity can also be
measured as 6
3
/4 inches (171mm) behind the
cuff of the wing against the fuselage, with a
range of 6
1
/2– 7 inches (165mm–178mm).
1
/8 inches (79mm) behind the
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Section 12: Control Throws
The amount of control throw should be adjusted as closely
as possible using mechanical means, rather than making
large changes electronically at the radio. By moving
the position of the clevis at the control horn toward the
outermost hole, you will decrease the amount of control
throw of the control surface. Moving it toward the control
surface will increase the amount of throw. Moving the
pushrod wire at the servo arm will have the opposite
effect, moving it closer to center will decrease throw,
and away from center will increase throw. Work with a
combination of the two to achieve the closest or exact
control throws listed.
Charge both the transmitter and receiver pack for your
airplane. Use the recommended charger supplied with
your particular radio system, following the instructions
provided with the radio. In most cases, the radio should
be charged the night before going out flying.
Check the radio installation and make sure all the
control surfaces are moving correctly (i.e. the correct
direction and with the recommended throws). Test run
the engine and make sure it transitions smoothly from
idle to full throttle and back. Also ensure the engine is
tuned according to the manufacturer’s instructions,
and it will run consistently and constantly at full throttle
when adjusted.
Check all the control horns, servo horns and clevises to
make sure they are secure and in good condition. Replace
any items that would be considered questionable. Failure
of any of these components in flight would mean the loss
of your aircraft.
Section 14: Adjusting the Engine
Step 1
Step 3
Completely read the instructions included with your
engine and follow the recommended break in procedure.
Step 2
At the field, adjust the engine to a slightly rich setting at
full throttle and adjust the idle and low-speed needle so
that a consistent idle is achieved.
Before you fly, be sure that your engine idles reliably,
transitions and runs at all throttle settings. Only when this
is achieved should any plane be considered ready
for flight.
Section 15: Range Testing Your Radio
Range check your radio system before each flying
session. This is accomplished by turning on your
transmitter with the antenna collapsed. Turn on the radio
in your airplane. With your airplane on the ground, you
should be able to walk 30 paces away from your airplane
and still have complete control of all functions. If not,
don’t attempt to fly! Have your radio equipment checked
out by the manufacturer.
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2008 Official AMA
National Model Aircraft Safety Code
GENERAL
1. A model aircraft shall be defined as a non-humancarrying device capable of sustained flight in the
atmosphere. It shall not exceed limitations established
in this code and is intended to be used exclusively for
recreational or competition activity.
2. The maximum takeoff weight of a model aircraft,
including fuel, is 55 pounds, except for those flown
under the AMA Experimental Aircraft Rules.
3. I will abide by this Safety Code and all rules
established for the flying site I use. I will not willfully
fly my model aircraft in a reckless and/or dangerous
manner.
4. I will not fly my model aircraft in sanctioned events,
air shows, or model demonstrations until it has been
proven airworthy.
5. I will not fly my model aircraft higher than
approximately 400 feet above ground level, when
within three (3) miles of an airport without notifying the
airport operator. I will yield the right-of-way and avoid
flying in the proximity of full-scale aircraft, utilizing a
spotter when appropriate.
6. I will not fly my model aircraft unless it is identified
with my name and address, or AMA number, inside or
affixed to the outside of the model aircraft. This does
not apply to model aircraft flown indoors.
7. I will not operate model aircraft with metal-blade
propellers or with gaseous boosts (other than air),
nor will I operate model aircraft with fuels containing
tetranitromethane or hydrazine.
8. I will not operate model aircraft carrying pyrotechnic
devices which explode burn, or propel a projectile
of any kind. Exceptions include Free Flight fuses or
devices that burn producing smoke and are securely
attached to the model aircraft during flight. Rocket
motors up to a G-series size may be used, provided
they remain firmly attached to the model aircraft during
flight. Model rockets may be flown in accordance with
the National Model Rocketry Safety Code; however,
they may not be launched from model aircraft. Officially
designated AMA Air Show Teams (AST) are authorized
to use devices and practices as defined within the Air
Show Advisory Committee Document.
9. I will not operate my model aircraft while under the
influence of alcohol or within eight (8) hours of having
consumed alcohol.
10. I will not operate my model aircraft while using any
drug which could adversely affect my ability to safely
control my model aircraft.
11. Children under six (6) years old are only allowed on
a flightline or in a flight area as a pilot or while under
flight instruction.
12. When and where required by rule, helmets must be
properly worn and fastened. They must be OSHA, DOT,
ANSI, SNELL or NOCSAE approved or comply with
comparable standards.
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2008 Official AMA
National Model Aircraft Safety Code
Radio Control
1. All model flying shall be conducted in a manner to
avoid over flight of unprotected people.
2. I will have completed a successful radio equipment
ground-range check before the first flight of a new or
repaired model aircraft.
3. I will not fly my model aircraft in the presence of
spectators until I become a proficient flier, unless I am
assisted by an experienced pilot.
4. At all flying sites a line must be established, in front of
which all flying takes place. Only personnel associated
with flying the model aircraft are allowed at or in front
of the line. In the case of airshows demonstrations
straight line must be established. An area away from
the line must be maintained for spectators. Intentional
flying behind the line is prohibited.
5. I will operate my model aircraft using only radiocontrol frequencies currently allowed by the Federal
Communications Commission (FCC). Only individuals
properly licensed by the FCC are authorized to operate
equipment on Amateur Band frequencies.
6. I will not knowingly operate my model aircraft within
three (3) miles of any preexisting flying site without
a frequency-management agreement. A frequencymanagement agreement may be an allocation of
frequencies for each site, a day-use agreement between
sites, or testing which determines that no interference
exists. A frequency-management agreement may exist
between two or more AMA chartered clubs, AMA
clubs and individual AMA members, or individual
AMA members. Frequency-management agreements,
including an interference test report if the agreement
indicates no interference exists, will be signed by all
parties and copies provided to AMA Headquarters.
7. With the exception of events flown under official AMA
rules, no powered model may be flown outdoors closer
than 25 feet to any individual, except for the pilot and
located at the flight line.
8. Under no circumstances may a pilot or other person
touch a model aircraft in flight while it is still under
power, except to divert it from striking an individual.
9. Radio-controlled night flying is limited to lowperformance model aircraft (less than 100 mph).
The model aircraft must be equipped with a lighting
system which clearly defines the aircraft's attitude and
direction at all times.
10. The operator of a radio-controlled model aircraft shall
control it during the entire flight, maintaining visual
contact without enhancement other than by corrective
lenses that are prescribed for the pilot. No model
aircraft shall be equipped with devices which allow it
to be flown to a selected location which is beyond the
visual range of the pilot.