Horizon Hobby Ultra Stick Lite Assembly Manual
ASSEMBLY MANUAL
Specifications
Wingspan:.............................................................. 76 in (1676mm)
Length: .................................................................... 55 in (1397mm)
Wing Area: ............................................................ 2 AIL:1210 sq in (5934.5 sq dm)
4 AIL:1230 sq in (6025.5 sq dm)
Weight (approximate):........................................ 9–11 lb (2.7–3.15 kg)
Recommended Engines:..................................... 2-cycle:1.08–.150 cu in
4-cycle:1.00–1.80 cu in
TM
WE GET PEOPLE FLYING
TM
®
2
Table of Contents
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Additional Required Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Contents of Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Additional Required Tools and Adhesives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Other Items Needed (not included in the kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Using the Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Before Starting Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Section 1: Conventional Wing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Section 1a: Quad-Flap Wing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Section 2: Joining the Wing Halves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Section 3: Aileron/Flap Servo Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Section 4: Bolting the Wing to the Fuselage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Section 5: Horizontal Stabilizer Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Section 6: Vertical Stabilizer (Fin) Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Section 7: Rudder and Tail Wheel Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Section 8: Hinging the Horizontal Stabilizer and Elevator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Section 9: Rudder and Elevator Control Horn Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Section 10: Main Landing Gear Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Section 11: Fuel Tank Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Section 12: Mounting the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Section 13: Radio System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Section 14: Aileron and/or Quad-Flap Linkage Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Section 15: Rudder, Elevator, and Throttle Pushrod Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Section 17: Balancing the Ultra Stick Lite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Section 16: Control Throw Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Section 18: Quad Flaps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Section 19: Radio Programming Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Programming Guide — JR XP652/642 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Programming Guide — JR XP783/XP347/XP388S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Programming Guide — JR XP8103 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Programming Guide — JR 10X/10SXII/10SX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Programming Guide — Futaba 8UA/S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Range Testing the Radio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Adjusting the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Preflight at the Field . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
2003 Official AMA National Model Aircraft Safety Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
3
Contents of Kit
Large Parts
A. Fuselage HAN2327
B. Wing Set with Joiner HAN2326
C. Tail Set HAN2328
D. Landing Gear HAN2329
E. Quad-Flap Set HAN2330
Additional Required Equipment
Radio Equipment
• 4-channel radio system (minimum)
(6 if using Quad Flaps)
• 4 standard servos (JRPS537 recommended or
equivalent)
(6 servos required if using Quad Flaps)
Recommended JR™ Systems
• PCM10X
• XP8103
• X-378
• XP662
• XF631
• XF421
Recommended Engines
• 1.08–1.50 2-stroke
• 1.00–1.80 4-stroke
Additional items sold separately
Decal Set (not shown) HAN2331
JR XP8103
JR PCM10X
Saito™
180 Golden Knight AAC
SAIE180 GK
MDS 1.48 Pro (Ring)
MDSE14800
A
B
C
D
E
4
Warning
Other Items Needed (not included in the kit)
Additional Required Tools and Adhesives
Tools
• Canopy Scissors
• Drill
• Drill Bit: 1/16", 3/32", 1/8", 7/32", 1/4"
• Flat blade screwdriver
• Hobby knife
• Phillips screwdriver (large and small)
• Pliers
• Square
Adhesives
• 6-minute epoxy
• 30-minute epoxy
• Thin CA (cyanoacrylate) glue
• Thick CA (cyanoacrylate) glue
• CA remover/debonder
• Pacer Z-42 Threadlock
• Canopy glue (RC-56)
• Masking tape (3M blue recommended)
Other Required Items
• Epoxy brushes
• Felt-tipped pen or pencil
• File
• Foam: 1/2"
• Measuring device (ruler, tape measure)
• Mixing sticks for epoxy
• Paper towels
• Petroleum jelly
• Rubbing alcohol
• Sanding bar
• Sandpaper (medium)
• String
• T-pins
• Wax paper
• Propeller (consult engine instructions)
• 537 Standard Servo (JRPS537) or equivalent (4–6)
• 12” Servo Lead Extension (JRPA098) (2)
An RC aircraft is not a toy! If misused, it can cause serious bodily harm and damage to property. Fly only in open
areas, preferably at AMA (Academy of Model Aeronautics) approved flying sites, following all instructions included
with your radio and engine.
• 24” Servo Lead Extension (JRPA102) (2)
• Large Arms w/Screws (JRPA212) (3)
• Extra RX Pack 1100mAh 6V Flat (JRPB4250)
5
Before Starting Assembly
Using the Manual
Before beginning the assembly of the Ultra Stick™ Lite, 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 covering iron to remove them. Use caution while
working around areas where the colors overlap to prevent separating the colors.
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 are provided to help you to keep track of each step completed.
Steps with two boxes indicate that the step will require repeating, such as for a right or left wing panel, two
servos, etc. Remember to take your time and follow the directions.
Warranty Information
Horizon Hobby, Inc. guarantees this kit to be free from defects in both material and workmanship at the date of
purchase. This warranty does not cover any parts damage by use or modification. In no case shall Horizon Hobby's
liability exceed the original cost of the purchased kit. Further, Horizon Hobby reserves the right to change or modify
this warranty without notice.
In that Horizon Hobby has no control over the final assembly or material used for the final assembly, no liability
shall be assumed nor accepted for any damage of the final user-assembled product. By the act of using the product,
the user accepts all resulting liability.
Once assembly of the model has been started, you must contact Horizon Hobby, Inc. directly regarding any warranty
question that you have. Please do not contact your local hobby shop regarding warranty issues, even if that is where
you purchased it. This will enable Horizon to better answer your questions and service you in the event that you may
need any assistance.
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.
Horizon Hobby
4105 Fieldstone Road
Champaign, Illinois 61822
(217) 355-9511
www.horizonhobby.com
6
Section 1: Conventional Wing Assembly
Required Parts
• Left wing panel with aileron and hinges
• Right wing panel with aileron and hinges
Required Tools and Adhesives
• Paper towels
• Instant thin CA glue
• CA remover/debonder
• T-pins (one for each hinge)
• Hobby knife with #11 blade
Before beginning construction, decide what style of wing
is desired (conventional or quad-flap) and what type of
engine will be mounted on the model. The conventional
aileron wing will be presented in this section. Each
aileron will be controlled by its own servo. You will
need two servos when you begin Section 3.
For a standard wing configuration, we recommend a
servo that has 40 ounce inch of torque or greater,
such as the JR™ 537 servo that now comes standard with
JR radio systems. The JR 531 or 8101 servos are also
excellent to use for aileron servos in the wing.
Note: The control surfaces, including the
ailerons, flaps, elevator and rudder, come with
the hinges installed, but the hinges are not
glued in place. It’s imperative that you use a
high quality thin CA glue to properly adhere
the hinges and control surfaces in place.
Step 1
Carefully remove one of the wing panels from its
protective plastic. Save the plastic, as it will be used
later in Section 2 to protect the wing panel surface
from epoxy smears. Remove the aileron from the wing
panel. Note the position of the hinges.
Step 2
Remove each hinge from the wing panel and place a
T-pin in the center outside edge of each hinge. Slide
each hinge into the wing panel until the T-pin is snug
against the wing.
Step 3
Slide the aileron onto the wing until there’s only a slight
gap (approx. 1/32" or less). The hinges are now centered
on the wing panel and aileron. Remove the T-pin and
snug the aileron against the wing panel. This will
ensure that the hinges are centered.
Note: The hinge is constructed of a special
material that allows the CA to wick (or
penetrate) and distribute throughout the hinge,
securely bonding it to the wood structure.
Before applying CA, make sure the aileron
moves freely without binding on the wing.
Section 1: Conventional Wing Assembly
7
Step 4
Deflect the aileron and completely saturate the hinge with
thin CA glue. The aileron’s front surface should lightly
contact the wing during this procedure. Ideally, when the
hinge is glued in place, a 1/32" gap or less will be
maintained throughout the length of the aileron.
Step 5
Turn the wing panel over and deflect the aileron in the
opposite direction from the previous step. Again apply
thin CA glue to each aileron hinge, making sure the CA
penetrates into both the aileron and the wing.
Step 6
Using CA remover/debonder and a paper towel,
remove any excess CA glue that may have accumulated
on the wing or in the aileron hinge area.
Step 7
Repeat Steps 1 through 6 for the opposite wing half
before moving on to Step 8.
Step 8
After both ailerons are securely hinged, firmly grasp
the wing and aileron to check that the hinges are
securely glued and cannot be pulled apart. To do this,
apply medium pressure to try to separate the aileron
from the wing, using caution to be certain you don’t
crush the wing structure.
Step 9
Move the aileron up and down to “work in” the hinges
and check for proper movement.
8
Section 1a: Quad-Flap Wing Assembly
Required Parts
• Left wing aileron/flap
• Right wing aileron/flap
• Left wing panel with aileron and hinges
• Right wing panel with aileron and hinges
Required Tools and Adhesives
• Sealing iron • Paper towels
• Instant thin CA glue
• CA remover/debonder
• T-pins (one for each hinge)
• Hobby knife with #11 blade
Note: The procedure for hinging the
flap/aileron in each wing panel is the same as
described for the conventional wing.
Step 1a
Locate the plastic bag containing the flap/aileron
pieces for each wing panel and remove from the
package. Carefully remove one of the wing panels from
the protective plastic bag. Save the plastic bag for use
in Section 2. Remove the conventional aileron from the
wing panel.
Step 2a
Remove the hinges from the wing panel and place a
T-pin in the center outside edge of each hinge. Slide
each hinge into the wing panel until the T-pin is snug
against the wing.
Step 3a
Slide the aileron and flap control surface onto the wing
panel until there’s only a slight gap (approximately 1/32").
The hinges are now centered on the wing panel and the
control surfaces. Remove the T-pins and snug each
control surface to the wing panel. This will ensure the
hinges are centered.
Note: The hinge is constructed of a special
material that allows the CA to wick (or
penetrate) and distribute throughout the hinge,
securely bonding it to the wood structure.
Before applying CA, make sure the flap and
aileron move freely without binding on the
wing or with each other.
Step 4a
Deflect the aileron and flap and completely saturate each
hinge with thin CA glue. The aileron and flap’s front
surface should lightly contact the wing during this
procedure. Ideally, when the hinges are glued in place,
a 1/32" gap or less will be maintained throughout the
length of the aileron and flap.
Section 1a: Quad-Flap Wing Assembly
9
Step 5a
Turn the wing panel over and deflect the aileron and flap
in the opposite direction from the previous step. Apply
thin CA glue to each aileron hinge, making sure the CA
penetrates into the aileron, flap and the wing.
Step 6a
Using CA remover/debonder and a paper towel, remove
any excess CA glue that may have accumulated on the
wing aileron or flap hinge area.
Step 7a
Repeat Steps 1A through 6A for the opposite wing panel.
Step 8a
After both the aileron and flap control surfaces are
securely hinged, firmly grasp the wing, flap, and aileron
to check that they are securely glued and cannot be
pulled apart. To do this, apply medium pressure to try to
separate the control surfaces from the wing. Use caution
to be certain you don’t crush the wing structure.
Step 9a
Move the control surfaces up and down to “work in” the
hinges and check for proper movement.
Important: If any binding has developed
between the control surfaces, it must be
removed. You may have to trim away some
covering or balsa to make each control
surface move freely.
10
Section 2: Joining the Wing Halves
Required Parts
• Right/left wing panels
• Plastic wing bags (optional)
• Wing joiner brace
Required Tools and Adhesives
• 30-minute epoxy • Epoxy brush
• Mixing stick • T-pin
• Masking tape • Hobby knife
• Rubbing alcohol • Paper towels
• Wax paper • Ruler
• Pencil
Step 1
Locate the wing joiner. Using a ruler, determine the center
of the brace and mark it with a pencil.
Step 2
Trial fit the wing joiner into one of the wing panels. It
should insert smoothly up to the centerline marked in
Step 1. Now slide the other wing panel onto the wing
joiner until the wing panels meet. If the fit is overly tight,
it may be necessary to sand the wing joiner.
Step 3
The Ultra Stick™ Lite is designed with "0" dihedral. Place
the wing on a large flat surface. The spar, (high point of
the wing), should be flat on the surface.
Step 4
Separate the wing halves and remove the wing joiner.
Once you’re satisfied with the trial fit of the wing panels,
you can prepare to epoxy the wing panels together.
Note: Use the plastic wing bags as a means
of keeping epoxy from smearing on the wings.
Just slip one on each panel and use masking
tape to hold them in place.
Important: Read through each of the
remaining steps of this section before
proceeding to epoxy the wing halves together.
Step 5
Mix approximately 1 ounce of 30-minute epoxy.
Note: It’s extremely important to use plenty of
epoxy when gluing the wing halves together.
0"
at last rib without
tip section
Section 2: Joining the Wing Halves
11
Step 6
Place one wing half right side up on a flat work surface.
Using an epoxy brush, smear a generous amount of
epoxy into the wing joiner cavity in the wing panel.
Note: It’s helpful to put wax paper under
the wing.
Step 7
Coat one half of the wing joiner with epoxy up to the
pencil line drawn in Step 8. Install the epoxy-coated
half of the wing joiner into the wing joiner cavity up to
the marked centerline. Any excess epoxy can be cleaned
up with rubbing alcohol and paper towels.
Note: You will need to mix an additional
1–2 ounces of epoxy to complete the wing
joining process.
Step 8
Apply a generous amount of epoxy into the wing joiner
cavity of the other wing panel.
Step 9
Install a T-pin into the wing joiner at the center mark. This
will allow you to keep the brace in the center of the wing
when joining the two wing halves. Next, apply epoxy to all
sides of the exposed area of the wing joiner and uniformly
coat both wing roots with epoxy.
12
Section 2: Joining the Wing Halves
Step 10
Carefully slide the two wing halves together and firmly
press them together, allowing the excess epoxy to run out.
Check to make sure the wing panels align properly. Wipe
any excess epoxy away with rubbing alcohol and paper
towels. The plastic wing bag can be removed from the
wing halves after the epoxy has been applied.
Note: It’s helpful to use wax paper underneath
the wing center while the epoxy is curing to
prevent excess epoxy from adhering to the
work surface area.
Step 11
Apply masking tape at the wing joint to hold the wing
halves together securely. Place the wing right side up on
a flat surface. With the wing lying flat on a surface without
any dihedral, apply more masking tape to the wing center
joint and recheck that the wing remains flat. Also make
sure the wing halves are still properly aligned. Allow the
wing joint epoxy to cure completely (overnight).
Step 12
Once the epoxy has cured completely, remove the
masking tape.
Section 3: Aileron/Flap Servo Installation
13
Required Parts
• Assembled wing
• 12" Servo extension (2)
(2 additional 24" for quad-flap configuration
wing)
• Standard size servos with mounting hardware (2)
(4 for quad-flap configuration)
Note: The flap servo must be reversed if using a
Y-harness for flaps.
Required Tools and Adhesives
• Hobby knife • Needle-nose pliers
• Drill • Drill Bit: 1/16"
• Masking tape • Pencil
• String with weight on end
• Phillips screwdriver (medium)
Step 1
Locate the servo openings in the bottom of each of the
wing halves. Use a sharp hobby knife to trim away the
covering over the openings. If you’re building the
conventional wing, you will only cut out the openings
that are closest to the wing root for the aileron servos.
If you build the quad-flap wing, trim away the covering
on all four servo openings in the wing. Use care not to
cut away too much of the covering.
Step 2
Install the recommended servo hardware supplied with
your radio system onto your servos, (grommets and
eyelets). Install 12" servo extensions on the flap servo
lead and 24" extensions on the aileron servo leads.
Secure the connectors with either masking tape or a
commercial connector that prevents the servo lead
connections from becoming disconnected.
Hint: It’s always a good idea to tape or secure
the servo connectors and servo extension
together to prevent the wires from becoming
unplugged inside the wing.
Step 3
Trial fit the servo into the servo opening. Depending upon
the type of servo installed, some trimming may be
required. Note that the servo is orientated so the servo
output shaft is closer to the trailing edge of the wing.
14
Section 3: Aileron/Flap Servo Installation
Step 4
With the servo in place, mark the location of the servo
screws and then remove the servo.
Step 5
Using a 1/16" drill bit, drill the servo screw locations
marked in Step 4.
Step 6
Repeat the procedure for the other servo(s).
Step 7
Before mounting the servos in the wing, it’s suggested
that the servo extensions be run through the wing and
out the opening near the root rib.
Step 8
Locate the two circular servo lead exits near the center
of the wing bottom. Using a sharp hobby knife, trim
away the covering to expose the openings, making sure
to use caution so you don’t cut into the wing sheeting.
Step 9
To thread the ser vo lead extensions/ser vo leads
through the wing, we suggest using a 24” piece of string
with a weight attached (such as one of the wheel collars
in the kit). Thread it from the servo opening down
through the wing structure and out the exit opening
at the center of the wing.
Section 3: Aileron/Flap Servo Installation
15
Step 10
Once the string is threaded though the wing, you can
fish it out with your fingers or let the weight drop out
the opening. Tape each end to the wing to keep it from
falling back into the opening. When you’re ready to
thread the servo extension and servo lead through the
wing, simply tie the string to the extension and carefully
thread them through the wing by pulling the string/lead
through the openings.
Step 11
Tape the lead to the wing to keep it from falling back
into the opening. It may be easier if you thread one
servo lead at a time.
Step 12
Securely fasten the servo in the opening with four of
the servo mounting screws supplied with your radio
system. We suggest you mark which lead is an aileron
lead and which is a flap lead. Apply masking tape to
the appropriate lead and mark either "F" for flap or
"A" for aileron.
Step 13
Repeat the procedure for the other servo(s).
Note: It was intended to have each servo
connected to a specific channel in the receiver,
however you can use a Y-harness to connect
two ailerons to one aileron channel or two
flaps to one flap channel, which will require
one of the flap servos to be a reversed servo.
This will reduce your programming options.
Please refer to Section 19 for computer radio
programming for the Ultra Stick™ Lite.
Installing the linkages and control horns to the
ailerons/flaps will be addressed later in the manual.
16
Section 4: Bolting the Wing to the Fuselage
Required Parts
• Fuselage • Wing
• Wing-bolt plate • Wing bolts
• Leading edge wing dowels
Required Tools and Adhesives
• Hobby knife • File (round)
• Flat screwdriver • Felt-tipped pen/pencil
• 6-minute epoxy • Rubbing alcohol
• Paper towels
• Ruler (36” or tape measure)
Note: Your Hangar 9
®
Ultra Stick™ Lite
comes from the factory with two predrilled
holes in the leading edge of the wing for the
alignment dowels, and two predrilled holes for
the wing hold down bolts. The Ultra Stick Lite
comes with the wing bolt T-nuts preinstalled
in the fuselage.
Step 1
Locate the predrilled leading edge dowel holes located
on both sides of the center joint of the wing.
Step 2
Locate and trial fit the leading edge wing dowels into the
holes in the leading edge. There should be approximately
1/2" of dowel protruding from the leading edge of the
wing, (trim the dowels as necessary). Mark each dowel
where it exits the leading edge of wing.
Step 3
Remove the wing dowels and mix about 1/2 ounce of
6-minute epoxy. Use a generous amount of epoxy in the
leading edge holes and on the portion of the dowels that
will be inserted into the wing. Insert dowels into the wing
and wipe off any excess epoxy. Set the wing aside and
allow epoxy to cure.
Section 4: Bolting the Wing to the Fuselage
17
Step 4
After the epoxy has cured for the leading edge alignment
dowels, trial fit the wing to the fuselage by inserting the
dowels into the former in front of the wing saddle of the
fuselage. If the wing dowel fit is too tight, carefully
enlarge the holes in the former just enough to get the
wing dowels inserted.
Step 5
Locate the wing-bolt hold-down plate. Note the wing-bolt
hold-down plate has the holes already drilled out for the
wing bolts. The holes in the wing bolt plate have the
same spacing as the preinstalled blind nuts in the
fuselage. Carefully remove the covering over the
predrilled openings using a sharp hobby knife.
Step 6
Using a ruler and felt-tipped pen, measure and mark
the center of the fuselage at the tail end just above the
horizontal stabilizer mounting saddle. Insert a T-pin
at the mark you made.
Step 7
Insert the wing bolts through the wing-bolt plate (covered
side up) and insert the bolts through the wing-bolt holes
in the wing. Install the wing onto the fuselage and snug
the wing bolts down finger tight.
18
Section 4: Bolting the Wing to the Fuselage
Step 8
Check the alignment of the wing by measuring the
distance from the wing tip to the T-pin you installed in
Step 6. Make sure to measure from the same spot on
both wing tips. Once satisfied with alignment, tighten
the wing bolts securely.
Step 9
Using a felt-tipped pen or pencil, carefully mark around
the outside of the wing bolt plate.
Step 10
Remove the wing from the fuselage and using a sharp
hobby knife, carefully trim away the covering on the wing
1/8" inside the lines you marked for the wing-bolt plate.
Be sure to avoid cutting into the balsa wood.
Step 11
Mix approximately 1/4 ounce of 6-minute epoxy
and glue the wing hold-down plate onto the wing.
Wipe off any excess epoxy and remove any epoxy
from the wing-bolt holes. Allow the epoxy to
completely cure before proceeding.
Section 5: Horizontal Stabilizer Installation
19
Required Parts
• Horizontal stabilizer • Fuselage
• Assembled wing
Required Tools and Adhesives
• Hobby knife • Ruler
• Felt-tipped pen • Pencil
• 30-minute epoxy • Paper towels
• Rubbing alcohol • Mixing stick
• Epoxy brush • Masking tape
Note: Before assembling the tail, be sure the
elevator and the CA hinges are removed from
the horizontal stabilizer. The hinges and
elevator will be installed later.
Step 1
Measure and mark the center of the horizontal stabilizer
on its trailing edge.
Step 2
On the bottom of the aft end of the fuselage is a saddle
cut out for the horizontal stabilizer to be mounted. Make
a center mark on the back of the saddle and place the
horizontal stabilizer into the horizontal stabilizer saddle.
Align the two marks you made. Tape the leading edge
and trailing edge of the horizontal stabilizer to the
fuselage to secure it for now.
Step 3
Install the wing onto the fuselage.
20
Section 5: Horizontal Stabilizer Installation
Step 4
With the fuselage and horizontal stabilizer resting on a flat
surface, align the horizontal stabilizer by measuring from
fixed points on the wing to the outside of the trailing edge
tip of the horizontal stabilizer. Be sure that the trailing
edge of the horizontal stabilizer stays on its center mark.
Step 5
Adjust the stabilizer until you have an equal distance on
both the right and left sides of the stabilizer to the wing.
Step 6
When you’re satisfied with the alignment of the horizontal
stabilizer to the wing, carefully mark the position with
a pencil at the junction where the horizontal stabilizer
meets the fuselage. The pencil should leave a slight
indentation in the covering.
Step 7
Remove the horizontal stabilizer from the fuselage and
using a sharp hobby knife and a straight edge, carefully
trim away the covering approximately 1/16" inside the
lines you just marked.
Caution: It’s extremely important that you do
not press hard enough to cut into the wood
structure as doing so could weaken the
horizontal stabilizer.
Step 8
Install the wing onto the fuselage. With the fuselage
and horizontal stabilizer together on a flat surface,
check to be sure the wing and horizontal stabilizer are
parallel with each other. If adjustments to the horizontal
stabilizer saddle are necessary because the wing and
stabilizer are not parallel, carefully sand the horizontal
stabilizer saddle to adjust. Be absolutely sure that the
fuse and stabilizer are on a flat surface and the wing
is installed correctly before removing any material
from the saddle area.
Section 5: Horizontal Stabilizer Installation
21
Step 9
Mix approximately 1/2 ounce (minimum) of
30-minute epoxy to install the horizontal stabilizer
to the fuselage. Using an epoxy brush or mixing stick,
spread the epoxy onto the top of the horizontal stabilizer
where it comes into contact with the fuselage. Coat the
stabilizer saddle area of the fuselage.
Note: When joining the horizontal stabilizer to
the fuselage, assemble on a firm, flat surface
to ensure that they are level with each other.
Step 10
Lay the horizontal stabilizer onto a flat surface and
position the fuselage onto it, making sure it is
centered and aligned as in Steps 3 and 4. Reference
the bare wood you just exposed to re-align the stabilizer.
Place a heavy object (one that won’t damage the
fuselage structure) on top of the fuselage to press the
stabilizer and fuselage together.
Step 11
Wipe off any excess epoxy using a paper towel and
rubbing alcohol. Allow the epoxy to cure fully before
proceeding to the next step.
22
Section 6: Vertical Stabilizer (Fin) Installation
Required Parts
• Vertical stabilizer • Fuselage
Required Tools and Adhesives
• Paper towels • 90-degree triangle
• Epoxy brush • Mixing stick
• 30-minute epoxy • Hobby knife
• Pencil • Masking tape
• Rubbing alcohol
Step 1
On the rear of the fuselage a slot is precut in the wood
structure for the vertical stabilizer. Using a sharp hobby
knife cut away the covering on the top rear of the fuselage
where the vertical stabilizer will insert.
Step 2
Remove the rudder and hinges from the vertical stabilizer
if you have not already done so. The rudder will be
hinged to the vertical stabilizer later.
Step 3
Insert the vertical stabilizer into the slot in the top of the
fuselage and make sure it’s firmly seated against the top
of the fuselage. Check that the rear of the vertical
stabilizer (where the hinge slots are located) is aligned
with the rear of the fuselage.
Step 4
Use a pencil to carefully mark the position of the vertical
stabilizer on both sides where it exits the fuselage. Also
mark onto the fuselage where it contacts. The pencil
should leave a slight indentation in the covering.
Section 6: Vertical Stabilizer (Fin) Installation
23
Step 5
Remove the vertical stabilizer. Using a sharp hobby knife
and straightedge, carefully cut away the covering on the
vertical fin and fuselage approximately 1/16" inside the
lines marked in Step 4.
Caution: It’s very important that you do not
press hard enough to cut into the wood
structure, as doing so could weaken the
vertical stabilizer.
Step 6
Mix approximately 1/4 ounce of 30-minute epoxy and
apply it to the vertical stabilizer where it comes into
contact with the fuselage. Also apply epoxy to the
base of the vertical stabilizer where it comes in contact
with the fuselage.
Important: It is essential the vertical
stabilizer base be epoxied to the inside the
fuselage to provide adequate strength. Be
sure to use plenty of epoxy!
Step 7
Insert the fin into the fuselage and wipe away any
excess epoxy using a paper towel and rubbing alcohol.
Step 8
Using a 90-degree triangle, make sure the fin is
perpendicular to the horizontal stabilizer. Use
masking tape to hold the vertical stabilizer in place
until the epoxy cures.
24
Section 7: Rudder and Tail Wheel Assembly
Installation
Required Parts
• Fuselage • Rudder
• Hinges • Tail wheel
• Tail wheel collar
• Tail wheel wire assembly
Required Tools and Adhesives
• Drill • Drill Bits: 3/32", 1/16"
• Hobby knife • Felt-tipped pen
• Thin CA glue • Needle-nose pliers
• Paper towels • 30-minute epoxy
• Rubbing alcohol • Mixing stick
• Threadlock Z-42 • Petroleum jelly or oil
• Masking tape • Keyhole saw blade
• CA remover/debonder
• Toothpicks (optional)
Step 1
Trial fit the rudder on to the vertical fin with the hinges
in place. Locate the tail wheel wire assembly and hold
it up to the fuselage making sure the bottom of the
nylon bushing is flush with the bottom of the horizontal
stabilizer. Note the wire placement in relationship to the
rudder. Using a felt-tipped pen, mark the position where
the hole is to be drilled into the rudder. Also mark the
location for the slot where the bushing tab will be
epoxied into the back of the fuselage. This slot should
be positioned centered on the fuselage tail.
Step 2
Remove the rudder from the vertical fin and use a
3/32” drill bit to drill the hole for the tail wheel wire.
Drill into the exact center of the rudder where you
marked in Step 1. It may be helpful to first drill a
1/16” pilot hole as a guide.
Step 3
Cut a slot and groove in the back of the fuselage where
the tab of the tail wheel bushing will be epoxied. There
are several methods to accomplish this; we used a
Dremel cutting wheel to first cut a slot in the fuselage
as marked in Step 1. Next, use a keyhole saw blade to
enlarge the opening for the tail wheel bushing.
Section 7: Rudder and Tail Wheel Assembly Installation
25
Step 4
Trial fit the rudder and tail wheel assembly to the vertical
fin. Note that the rudder will require trimming to allow
clearance for the tail wheel wire/bushing. Mark the
rudder and using a sharp hobby knife, trim back the
rudder only a small amount and refit the rudder to the
fin. Repeat this process until you achieve a perfect fit
with virtually no gap between the vertical fin and rudder.
Remove the rudder from the vertical fin.
Step 5
Reinstall the hinges in the vertical fin using T-pins to
ensure the hinges are centered. The hinges will be
CA’d in Step 7.
Step 6
Mix approximately 1/2 ounce of 30-minute epoxy and
apply it to both the nylon bushing of the tail wheel
assembly where it goes in the back of the fuselage and
to the hole drilled in the rudder for the wire. A toothpick
applicator may be helpful in getting the epoxy into the
hole. Install the rudder and tail wheel assembly to the
vertical fin and fuselage and remove the T-pins. Make
sure the rudder is positioned properly (up and down).
Wipe away any excess epoxy with alcohol and paper
towels. Allow the epoxy to completely cure before
gluing the hinges in place.
Note: Do not get epoxy on the bushing where
it contacts the rudder. The rudder must move
freely on the bushing.
Step 7
After the epoxy has completely cured, apply thin CA to
the hinges by first deflecting the rudder in one direction,
saturating each hinge, and then repeat the process by
deflecting the rudder in the opposite direction. Wipe
away any excess CA by using a paper towel and CA
remover/debonder. Allow the glue to completely cure.
26
Section 7: Rudder and Tail Wheel Assembly Installation
Step 8
Once the CA has cured, check for security of the
rudder by gently trying to pull the rudder from the fin.
Also move the rudder several times left and right to
"work in" the hinges.
Step 9
Slide the tail wheel onto the tail wheel wire. Next secure
the wheel with the included wheel collar and setscrew.
Use blue Locktite 242 to secure the setscrew in place.
Note: The wheel must rotate freely with only a
small amount of side play. It may be
necessary to drill out the tail wheel slightly so
the wheel can spin freely.
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