Top Flite A0970 INSTRUCTION BOOK

Top Flite Models Champaign, IL

Ph: [phone], Ext. 5

Fax: [phone]

[e-mail]

WARRANTY

Top Flite Models guarantees this kit to be free from defects in both material and workmanship at the date of

SPECIFICATIONS

Wingspan

:

64.5 in [1640mm]

purchase. This warranty does not cover any component parts damaged by use or modification. In no case
shall Top Flite’s liability exceed the original cost of the purchased kit. Further, Top Flite reserves the

Wing Area:

722 sq in [46.6 dm2]

right to change or modify this warranty without notice.

In that Top Flite has no control over the final assembly or material used for final assembly, no liability shall be

Weight:

9.75– 10 lb
[4420– 4530 g]

assumed nor accepted for any damage resulting from the use by the user of the final user-assembled prod­uct. By the act of using the user-assembled product, the user accepts all resulting liability.

Wing

Loading:

31–32 oz/sq ft
[95–98 g/dm

2

]

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.

To make a warranty claim send the
defective part or item to Hobby
Services at this address:

Hobby Services

3002 N. Apollo Dr. Suite 1
Champaign IL 61822 USA

Include a letter stating your name, return shipping address, as much contact information as possible (daytime

Length:

Radio: 5-6 channel with 7-8 servos

Engine: .60–.91 cu in

telephone number, fax number, e-mail address), a detailed description of the problem and a photocopy of the
purchase receipt. Upon receipt of the package the problem will be evaluated as quickly as possible.

READ THROUGH THIS MANUAL BEFORE STARTING CONSTRUCTION. IT CONTAINS IMPORTANT INSTRUCTIONS AND WARNINGS CONCERNING THE ASSEMBLY AND USE OF THIS MODEL.

Entire Contents © 2010 Hobbico®, Inc. TOPA0970 Mnl

55 in
[1395mm]

[10–15cc] two-stroke,
.90–1.20 cu in
[15–20cc] four-stroke

TABLE OF CONTENTS

INTRODUCTION

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

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

SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . 3

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

Building Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Radio Equipment . . . . . . . . . . . . . . . . . . . . . . . . . 3

Engine Recommendations . . . . . . . . . . . . . . . . . . 4

Landing Gear Options . . . . . . . . . . . . . . . . . . . . . 4

Scale Competition . . . . . . . . . . . . . . . . . . . . . . . . 4

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

Hardware and Accessories . . . . . . . . . . . . . . . . . 4

Adhesives and Building Supplies . . . . . . . . . . . . . 4

Optional Supplies and Tools. . . . . . . . . . . . . . . . . 4

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

KIT INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 5

ORDERING REPLACEMENT PARTS. . . . . . . . . . . 5

COMMON ABBREVIATIONS . . . . . . . . . . . . . . . . . 6

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

PREPARATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

ASSEMBLE THE WING . . . . . . . . . . . . . . . . . . . . . . 7

Hinge the Ailerons & Flaps. . . . . . . . . . . . . . . . . . 7

Mount the Servos . . . . . . . . . . . . . . . . . . . . . . . . . 9

Install the Aileron and Flap Pushrods . . . . . . . . 11

Finish the Wing. . . . . . . . . . . . . . . . . . . . . . . . . . 12

Optional Pneumatic Retract Installation . . . . . . . 14

ASSEMBLE THE T AIL SECTION . . . . . . . . . . . . . 16

INSTALL THE ENGINE AND FUEL TANK. . . . . . . 18

INSTALL THE RADIO SYSTEM . . . . . . . . . . . . . . 20

FINISH THE MODEL . . . . . . . . . . . . . . . . . . . . . . . 22

Install the Cowl and Spinner . . . . . . . . . . . . . . . 22

Install the Cockpit Kit and Canopy . . . . . . . . . . . 24

Optional Pneumatic Retract

Hardware Installation . . . . . . . . . . . . . . . . . . . 25

APPL Y THE DECALS . . . . . . . . . . . . . . . . . . . . . . 27

GET THE MODEL READY TO FLY . . . . . . . . . . . . 27

Check the Control Directions . . . . . . . . . . . . . . . 27

Set the Control Throws. . . . . . . . . . . . . . . . . . . . 27

Balance the Model (C.G.). . . . . . . . . . . . . . . . . . 28

Balance the Model Laterally. . . . . . . . . . . . . . . . 28

PREFLIGHT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Identify Your Model . . . . . . . . . . . . . . . . . . . . . . . 28

Charge the Batteries . . . . . . . . . . . . . . . . . . . . . 28

Balance Propellers . . . . . . . . . . . . . . . . . . . . . . . 29

Ground Check . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Range Check . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

ENGINE SAFETY PRECAUTIONS . . . . . . . . . . . . 29

AMA SAFETY CODE (excerpts). . . . . . . . . . . . . . 29

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Radio Control . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

CHECK LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

FLYING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Fuel Mixture Adjustments. . . . . . . . . . . . . . . . . . 30

Takeoff . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Flight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Landing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

TopFlite is well known for the quality and scale detail

provided with our kits. Now you can have that same
quality and detail in an ARF that can be completed in
as little as 15-20 hours! Beautifully covered in TopFlite
MonoKote® with expertly painted fi berglass parts, the
P-40 Warhawk will surely be the focus of attention
at the fl ying fi eld. In addition, the P-40 includes
economical fi xed landing gear, but is designed so that
the optional pneumatic retract set made specifi cally
for TopFlite warbirds is a drop in installation.

For the latest technical updates or manual corrections
to the P-40 Warhawk ARF visit the Top Flite web site
at www.top-fl ite.com. Open the “Airplanes” link, then
select the P-40 Warhawk ARF. If there is new technical
information or changes to this model a “tech notice”
box will appear in the upper left corner of the page.

AMA

We urge you to join the AMA (Academy of Model
Aeronautics) and a local R/C club. The AMA is the
governing body of model aviation and membership is
required to fl y at AMA clubs. Though joining the AMA

provides many benefi ts, one of the primary reasons
to join is liability protection. Coverage is not limited to
fl ying at contests or on the club fi eld. It even applies to
fl ying at public demonstrations and air shows. Failure
to comply with the Safety Code (excerpts printed in the

back of the manual) may endanger insurance coverage.
Additionally, training programs and instructors are
available at AMA club sites to help you get started the
right way. There are over 2,500 AMA chartered clubs
across the country. Contact the AMA at the address or
toll-free phone number below:

Academy of Model Aeronautics

5151 East Memorial Drive
Muncie, IN 47302-9252

Ph. [phone] Or via the Internet at:

Fax [phone] http://www.modelaircraft.org

2

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

PROTECT YOUR MODEL,
YOURSELF & OTHERS…

FOLLOW THESE IMPORT ANT

SAFETY PRECAUTIONS

1. Your P-40 Warhawk ARF should not be considered
a toy, but rather a sophisticated, working model that
functions very much like a full-size airplane. Because of
its performance capabilities, the P-40, if not assembled
and operated correctly, could possibly cause injury to
yourself or spectators and damage to property.

2. You must assemble the model according to the
instructions. Do not alter or modify the model, as

doing so may result in an unsafe or unfl yable model.
In a few cases the instructions may differ slightly from
the photos. In those instances the written instructions
should be considered as correct.

3. You must take time to build straight, true and
strong.

4. You must use an R/C radio system that is in fi rst­class condition, and a correctly sized engine and
components (fuel tank, wheels, etc.) throughout the
building process.

5. You must correctly install all R/C and other
components so that the model operates correctly on
the ground and in the air.

6. You must check the operation of the model before

every fl ight to insure that all equipment is operating

and that the model has remained structurally sound. Be
sure to check clevises or other connectors often and
replace them if they show any signs of wear or fatigue.

7. If you are not an experienced pilot or have not
fl own this type of model before, we recommend that
you get the assistance of an experienced pilot in your

R/C club for your fi rst fl ights. If you’re not a member
of a club, your local hobby shop has information
about clubs in your area whose membership includes
experienced pilots.

8. While this kit has been fl ight tested to exceed
normal use, if the plane will be used for extremely
high stress fl ying, such as racing, or if an engine larger
than one in the recommended range is used, the
modeler is responsible for taking steps to reinforce the
high stress points and/or substituting hardware more
suitable for the increased stress.

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

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

Before starting to build, compare the parts in this model
with the Parts List and note any missing parts. Also
inspect all parts to make sure they are of acceptable
quality. If any parts are missing, broken or defective,
or if you have any questions about building or fl ying
this airplane, please contact Top Flite at the address
or telephone number below. If requesting replacement
parts, please provide the full model name (P-40
Warhawk ARF) and the part numbers as listed in the
Parts List.

Top Flite Product Support

3002 N Apollo Drive, Suite 1 Ph: [phone]
Champaign, IL 61822 Fax: [phone]

E-mail: productsupport@top-fl ite.com

3

DECISIONS YOU MUST MAKE

This is a partial list of items required to fi nish the P-40

Warhawk ARF that may require planning or decision
making before starting to build. Order numbers are

provided in parentheses.

BUILDING STAND

A building stand or cradle comes in very handy

during the build. We use the Robart Super Stand II
(ROBP1402) for most of our projects in R&D, and it
can be seen in pictures throughout this manual.

RADIO EQUIPMENT

A minimum 5-channel radio system with a standard
receiver and seven standard size servos with a
minimum torque of 50 oz-in [3.6 kg-cm] are required
for the control surfaces of the P-40 Warhawk ARF. If

installing optional pneumatic retracts, a standard
torque servo such as a Futaba S3003 will also be
required. One standard torque servo is required for
the throttle. A receiver battery pack with a minimum
capacity of 1000mAh is recommended. Order numbers
are provided below:

❍ Futaba® S9001 Servo Aircraft Coreless BB

(FUTM0075)

❍ Futaba S3003 Servo Standard (FUTM0031)

❍ Futaba NR4RB Receiver NiCd 4.8V

1000mAh J (FUTM1380)

OR

❍ Hobbico® HydriMax™ 4-Cell 4.8V 2000mAh

NiMH Flat AA Rx U (HCAM6321)

If you have a radio system with enough available
channels to mix the fl ap and aileron servos together,
then you will need two 16" [406mm] servo extensions
to connect the aileron servos directly to the receiver
and you will need two 12" [305mm] servo extensions
to connect the fl ap servos directly to the receiver:

❍ Futaba Servo Extension 16" J (FUTM3955)

❍ Hobbico Extension 12" Futaba J (HCAM2100)

If you plan to connect the aileron and fl ap servos
together using Y-harnesses then you will need two 12"
[305mm] servo extensions for the ailerons and two 6"
[152mm] servo extensions for the fl ap servos. You will
also need two Y-harnesses:

❍ Hobbico Extension 12" Futaba J (HCAM2100)

❍ Hobbico Extension 6" Futaba J (HCAM2000)

❍ Futaba 6" Dual Servo Extension J (FUTM4130)

ENGINE RECOMMENDATIONS

A .60-.91 cu in [10-15cc] two-stroke or .90-1.20 [15-

20cc] four-stroke engine is required. An O.S. FS-91
Surpass™ II four-stroke engine installation is shown in
this manual.

❍ O.S.® FS-91 II Surpass (OSMG0896)

An optional 90° header for the O.S. FS-91 engine is

shown in the engine installation section:

❍ O.S. Exhaust Manifold Inside FS-70/FS-91

(OSMG2624)

LANDING GEAR OPTIONS

The P-40 Warhawk ARF includes fi xed wire landing

gear. Optional pneumatic retracts can also be

installed. The part number for the pneumatic retract
set is provided below:

❍ 90° Retract Landing Gear Set (TOPQ7955)

Optional Robart parts:

❍ 615 100 Degree Rotating Mains (2) (ROBQ1815)
❍ 188VR Standard Air Control Kit (ROBQ2302)
❍ 190 Air Line Quick Disconnects (ROBQ2395)
❍ Great Planes Wire Axle 2x3/16" (2) (GPMQ4282)
❍ Optional: 650 Straight RoboStrut (ROBQ1700)

SCALE COMPETITION

Though the Top Flite P-40 Warhawk ARF may not have

the same level of detail as an “all-out” scratch-built
competition model, it is a scale model nonetheless

and is therefore eligible to compete in the Fun Scale

class in AMA competition (we receive many favorable
reports of Top Flite models in scale competition!). To
receive the fi ve points for scale documentation, the
only proof required that a full size aircraft of this type
in your paint/markings scheme did exist is a single
sheet such as a kit box cover from a plastic model,
a photo, or a profi le painting, etc. If the photo is in
black and white other written documentation of color
must be provided. Contact the AMA for a rule book
with full details.

If you would like photos of the full-size P-40 Warhawk
for scale documentation, or if you would like to study
the photos to add more scale details, photo packs are
available from:

Bob’s Aircraft Documentation

3114 Yukon Ave
Costa Mesa, CA 92626

Ph: [phone] Or via the Internet at:

Fax: [phone] www.bobsairdoc.com

ADDITIONAL ITEMS REQUIRED

HARDWARE AND ACCESSORIES

In addition to the items listed in the “Decisions Y ou
Must Make” section, following is the list of hardware

and accessories required to fi nish the P-40 Warhawk
ARF. Order numbers are provided in parentheses.

4

❍ R/C foam rubber (1/4" [6mm] - HCAQ1000, or

1/2" [13mm] - HCAQ1050)

❍ 3' [900mm] standard silicone fuel tubing

(GPMQ4131)

❍ Great Planes Velcro

®

Hook & Loop (GPMQ4480)

ADHESIVES AND BUILDING SUPPLIES

In addition to common household tools (screw drivers,

drill, etc.), this is the “short list” of the most important

items required to build the P-40 Warhawk ARF. We

recommend Great Planes Pro™ CA and Epoxy glue.

❍ 1/2 oz. [15g] Thin Pro CA (GPMR6001)
❍ Pro 30-minute epoxy (GPMR6047)
❍ Drill bits: 1/16" [1.6mm], 5/64" [2mm], 3/32"

[2.4mm]

❍ 8-32 tap and drill set (GPMR8103)
❍ Great Planes Pro Threadlocker (GPMR6060)
❍ #1 Light Duty Aluminum Handle Knife w/Blade

(RMXR6901)

❍ #11 Light Duty Blades (5) (RMXR6930)
❍ Medium T-pins (100, HCAR5150)
❍ Masking tape
❍ Denatured alcohol (for epoxy clean up)
❍ Panel Line Pen (TOPQ2510)
❍ J&Z R/C-56 Glue 4 oz (JOZR5007)
❍ 220-grit sandpaper
❍ Petroleum jelly or oil

OPTIONAL SUPPLIES AND TOOLS

Here is a list of optional tools mentioned in the manual
that will help you build the P-40 Warhawk ARF.

❍ 21st Century® sealing iron (COVR2700)

❍ 21st Century iron cover (COVR2702)

❍ 21st Century trim seal iron (COVR2750)

❍ 1/2 oz. [15g] Medium Pro CA+ (GPMR6007)

❍ 1/2 oz. [15g] Thick Pro CA- (GPMR6013)

❍ Pro 6-minute epoxy (GPMR6045)

❍ Stick-on segmented lead weights (GPMQ4485)

❍ 2 oz. [57g] spray CA activator (GPMR6035)

❍ 4 oz. [113g] aerosol CA activator (GPMR6034)

❍ CA applicator tips (HCAR3780)

❍ CA debonder (GPMR6039)

❍ Epoxy brushes 6, (GPMR8060)

❍ Mixing sticks (GPMR8055)

❍ Mixing cups (GPMR8056)

❍ Pliers with wire cutter (HCAR0630)

❍ Compressed Air 10 oz (TAEC1060)

❍ Microballoons (TOPR1090)

❍ Switch & Charge Jack Mounting Set

(GPMM1000)

❍ Ernst Charge Receptacle Futaba J (ERNM3001)

❍ Rotary tool such as Dremel

❍ Rotary tool reinforced cut-off wheel (GPMR8020)

❍ Servo horn drill (HCAR0698)

❍ Hobby Heat™ micro torch (HCAR0750)

❍ Dead Center™ Engine Mount Hole Locator

(GPMR8130)

❍ AccuThrow™ Defl ection Gauge (GPMR2405)

❍ CG Machine™ (GPMR2400)

❍ Great Planes Heat Shrink Tubing 3/8x3" (3)

(GPMM1060)

❍ Ernst Security Clips Universal (2) (ERNM3035)

❍ Precision Magnetic Prop Balancer (TOPQ5700)

❍ Hobbico Flexible 18" Ruler Stainless Steel

(HCAR0460)

❍ Hobbico Pin Vise 1/16 Collet w/6 Bits

(HCAR0696)

❍ Hobbico 8-Piece Ball Tip Hex L Wrench SAE

(HCAR0520)

❍ Hobbico 7-Piece Ball Tip Hex L Wrench Metric

(HCAR0521)

❍ Great Planes Precision Prop Reamer Standard

(GPMQ5006)

❍ Great Planes Precision Prop Reamer Metric

(GPMQ5007)

❍ Great Planes Clevis Installation Tool

(GPMR8030)

®

❍ X-Acto

❍ Woodland Scenics Low Temp Foam Glue Gun

(WOOU1445)

®

Extra Hands Double Clip (XACR4214)

IMPORTANT BUILDING NOTES

● There are two types of screws used in this kit:

Sheet Metal Screws are designated by a number

and a length. For example #6 x 3/4" [19mm].

This is a number six screw

that is 3/4" [19mm] long.

Machine Screws are designated by a number,
threads per inch, and a length. For example

4-40 x 3/4" [19mm].

This is a number four screw

that is 3/4" [19mm] long
with forty threads per inch.

● When you see the term test fi t in the instructions, it

means that you should fi rst position the part on the

assembly without using any glue, then slightly
modify or custom fi t the part as necessary for the

best fi t.

● Whenever the term glue is written you should rely

upon your experience to decide what type of glue
to use. When a specifi c type of adhesive works
best for that step, the instructions will make a
recommendation.

● Whenever just epoxy is specifi ed you may use

either 30-minute (or 45-minute) epoxy or 6-minute

epoxy. When 30-minute epoxy is specifi ed it is

highly recommended that you use only 30-minute

(or 45-minute) epoxy, because you will need the
working time and/or the additional strength.

● Photos and sketches are placed before the

step they refer to. Frequently you can study
photos in following steps to get another view of
the same parts.

5

KIT INSPECTION

Before starting to build, take an inventory of this kit
to make sure it is complete, and inspect the parts to
make sure they are of acceptable quality. If any parts
are missing or are not of acceptable quality, or if you

need assistance with assembly, contact Product
Support. When reporting defective or missing parts,

use the part names exactly as they are written in the
Kit Contents list.

Top Flite Product Support

3002 N Apollo Drive, Suite 1
Champaign, IL 61822

Ph: [phone], ext. 5
Fax: [phone]
E-mail: airsupport@top-fl ite.com

ORDERING

REPLACEMENT PARTS

Replacement parts for the Top Flite P-40 Warhawk
ARF are available using the order numbers in the

Replacement Parts List that follows. The fastest,

most economical service can be provided by your
hobby dealer or mail-order company. Not all parts
are available separately. Replacement parts are not
available from Product Support, but can be purchased
from hobby shops or mail order/Internet order fi rms.
Hardware items (screws, nuts, bolts) are also available
from these outlets.

To locate a hobby dealer, visit www.top-fl ite.com

and click on “Where to Buy”. Follow the instructions

provided on the page to locate a U.S., Canadian or

International dealer.

Parts may also be ordered directly from Hobby
Services by calling [phone], or via facsimile
at [phone], but full retail prices and shipping
and handling charges will apply. Illinois and Nevada
residents will also be charged sales tax. If ordering
via fax, include a Visa® or MasterCard® number and
expiration date for payment.

Mail parts orders Hobby Services

and payments by 3002 N Apollo Drive, Suite 1
personal check to: Champaign IL 61822

Be certain to specify the order number exactly as

listed in the Replacement Parts List. Payment by

credit card or personal check only; no C.O.D.

If additional assistance is required for any reason
contact Product Support by e-mail at productsupport@
top-fl ite.com, or by telephone at [phone].

KIT CONTENTS

REPLACEMENT PARTS LIST

Order

Number

TOPA1770

TOPA1771

TOPA1772

TOPA1773

TOPA1774

TOPA1775

TOPA1776

TOPA1777

TOPA1778

TOPA1779

TOPA1780

TOPQ7955

Description

Fuselage

Wing

Tail Set

Cowl

Cockpit Kit

Decals

Canopy

Spinner

Dummy Exhaust Set

Landing Gear Wires

Retract Covers

90 Degree Retract Landing Gear

COMMON ABBREVIATIONS

Stab = Horizontal Stabilizer
Fin = Vertical Stabilizer
LE = Leading Edge
TE = Trailing Edge
" = Inches
mm = Millimeters
SHCS = Socket Head Cap Screw
mAh = Milliamp Hours (refers to the

usable capacity of a battery)

To convert inches to millimeters, multiply inches

by 25.4 (25.4mm = 1")

20

5

4

6

2

16

1

19

18

17

15

1. L/R Wing Panels w/ Ailerons & Flaps

2. Horizontal Stabilizer

3. L/R Elevator Halves

4. Rudder

5. Fuselage

6. Canopy

7. Main Wheels

8. L/R Fixed Landing Gear

9. Fixed Landing Gear Blocks

10. L/R Retract Covers

11

21

14

10

8

12

9

13

12. Headrest

13. Instrument Panel

14. L/R Cockpit Side Panels

15. Cockpit Floor

16. Fuel Tank

17. Engine Mount

18. Cowl

19. Spinner

20. Belly Pan

21. Pilot Seat

3

7

11. L/R Landing Gear Mounting Boxes

6

PREPARATIONS

1. If you have not done so already, remove the

❏

major parts of the kit from the box and inspect for
damage. If any parts are damaged or missing, contact
Product Support at the address or telephone number
listed in the “Kit Inspection” section on page 5.

2. Carefully remove the tape and separate all the

❏

control surfaces. Use a covering iron with a covering
sock on medium/high heat to tighten the covering if
necessary. Apply pressure over sheeted areas to

thoroughly bond the covering to the wood.

ASSEMBLE THE WING

HINGE THE AILERONS & FLAPS

You can do the right wing fi rst so your work matches

the photos the fi rst time through, or you can work on
them together.

1. Test fi t the included hinge points into the pre-

❏ ❏

drilled pockets in the fl ap. Press the hinge points into

the pockets with the pins in the hinge points aligned
parallel with the hinge line on the fl ap. Push the hinge
points as far deep as they can fi t into the pockets in
the fl ap. Work the hinge up and down in the pocket. Be
sure that the hinges move freely inside the pocket. If
there is any interference, use a hobby knife to slightly
enlarge the pocket as necessary.

7

2. Fit the fl ap to the wing panel by inserting the

❏ ❏

other ends of the hinge points into the pockets in the
wing trailing edge. Position the fl ap so that there is
a 1/16" [1.6mm] gap between the fl ap trailing edge
and the edge of the recessed area in the wing as
shown. Work the fl ap up and down to ensure smooth
movement.

3. Remove the fl ap from the wing panel and pull

❏ ❏

the hinge points from the pockets. Coat the center of
each hinge point with petroleum jelly or oil. This will
prevent epoxy from sticking to the pivoting portion of
the hinges.

Before performing steps 4 and 5, have denatured
alcohol and some paper towel pieces ready for epoxy
cleanup.

5. Coat one end of each hinge point with epoxy.

❏ ❏

Insert the hinges into the pockets in the fl ap. Use a
clean toothpick to scrape out any excess epoxy that
may have squeezed out the pocket.

edge for excess epoxy. Position the fl ap in the recess
as was done in step #2. When satisfi ed, set the wing
aside and allow the epoxy to cure undisturbed.

1" [25 mm]

3/4" [19mm]

Trim the Corners

7. Cut the included 2" x 9" [51mm x 229mm]

❏ ❏

piece of CA hinge material into 3/4" x 1" [19mm x
25mm] individual hinges. Use a hobby knife or scissors
to trim the corners from each hinge to make them
easier to insert into the hinge slots.

4. Mix up a batch of 30-minute epoxy. Use a

❏ ❏

toothpick or something similar to coat the insides of
the hinge point pockets in the fl ap and the wing panel.
Wipe away any excess epoxy from around the pockets
using a paper towel dampened with alcohol.

6. Coat the other end of each hinge point with

❏ ❏

epoxy. Slowly join the fl ap to the wing while wiping away
any excess epoxy that squeezes out of the pockets.
When the hinge points are all the way inserted into the
wing, defl ect the fl ap downward and check the leading

8

Drill a 3/32" [2.4mm] hole

1/2" [13mm] deep, in the center

of the hinge slot.

Cut the covering

away from the slot.

8. Drill a 3/32" [2.4mm] hole 1/2" [13mm] deep

❏ ❏

in the center of each hinge slot in the wing panel and

aileron. Use a sharp hobby knife to carefully cut away

the covering just around each hinge slot.

Temporary pin

to keep the hinge

centered.

10. Fit the aileron to the hinges and center it in

❏ ❏

the opening. Remove the pins from the hinges and
position the aileron against the TE of the wing panel.

The hinge gap between the aileron and wing should

only be wide enough to allow a small line of light
through. When satisfi ed, apply 6 drops of thin CA glue
to the center of each hinge on both sides. When the
CA has dried, gently pull on the aileron to confi rm that
it is securely glued in place.

2. Attach a 12" [305mm] servo extension to the

❏ ❏

aileron servo and secure the connector using tape,
heat shrink tubing (not included), or clips specifi cally
made for that purpose (Note: If you plan to connect
the aileron extensions directly to the receiver without
using a Y-harness, you will need servo extensions at

least 16" [406mm] in length). Center the servo with
your radio system and install the servo arm to the
servo perpendicular to the servo case as shown. Be
sure to reinstall the servo arm screw into the servo.
Install the grommets and eyelets that came packaged
with the servo.

9. Fit a CA hinge into each hinge slot in the wing

❏ ❏

panel. If the hinges are diffi cult to install, use a hobby
knife to slightly enlarge the slots. Push a pin (T-pins
work well for this) through the middle of each hinge to
keep them centered.

11. Repeat steps 1-10 for the left wing panel.

❏

MOUNT THE SERV OS

Enlarge to

5/64" [2mm]

Cut off

unused arms

1. Cut three arms from a four-armed servo arm

❏ ❏

included with the aileron servo. Enlarge the outer hole
of the remaining arm with a 5/64" [2mm] drill bit.

9

3. Center the aileron servo onto the underside

❏ ❏

of the aileron servo hatch cover. The servo arm should

be centered in the opening. Place a 3/4" x 3/4" x 5/16"
[19mm x 19mm x 8mm] hardwood servo mounting

blocks on each side of the servo against the servo
mounting tabs. Use a pencil to mark the positions of
the blocks onto the cover.

4. Remove the servo from the hatch cover and

❏ ❏

use epoxy to glue the blocks to the hatch cover.

5. When the epoxy is fully cured, position the

❏ ❏

servo against the underside of the aileron servo hatch
cover between the mounting blocks. Place a piece of
paper folded several times between the servo and
the hatch cover to space the servo away from the
hatch cover. Drill 1/16" [1.6mm] holes through the
mounting tabs on the servo case into the blocks.

Thread a servo mounting screw (included with the

servo) into each hole and back it out. Remove the
piece of paper and apply a drop of thin CA to each
hole to harden the wood. When the CA has dried,
install the servo onto the hatch cover using the
hardware supplied with the servo.

6. Use the strings taped inside the aileron servo

❏ ❏

hatches to pull the servo leads through the wing ribs.

7. Drill a hole into the wing through each hole in

❏ ❏

the hatch cover using a 1/16" [1.6mm] drill bit. Thread
a #2 x 3/8" [9.5mm] self-tapping screw into each hatch
mounting hole and back it out. Apply a drop of thin CA
to each hole to harden the wood. Install the aileron
hatch cover to the wing as shown using four #2 x 3/8"
[9.5mm] self-tapping screws and four #2 fl at washers.

8. Mount the fl ap servo and hatch cover in the

❏ ❏

same way. If using a Y-harness, the fl ap servo requires
a 6" [152mm] servo extension. If you plan to connect
the fl ap servo directly to the receiver, install a 12"
[305mm] extension.

10