AeroWorks Carbon Cub SS ARF-QB Assembly Manual Download Page 65

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Fuel Tank Assembly

1. Gather the fuel tank parts as shown below.

Required Parts

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1 - 750cc Smoke Tank

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1 - 1000cc Gas Tank

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2 - Rubber Stoppers

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6 - Brass Tubes

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2 - Aluminum Stopper Front Plates

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2 - Aluminum Stopper Back Plates

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2 - Phillips head bolts

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4 - Brass Barbs for Fuel Line

Required Parts -Not Included

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1 - Aeroworks Fuel Line Installation Kit

Required Tools and Adhesives

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1 - Pencil/felt tip pen

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1 - Phillips Screw Driver

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1 - Wire Cutter

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1 - Soldering Iron

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1 - Silver Solder

“Sta-Brite Recommended”

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1 - 80 Grit Sandpaper

FUEL TANK ASSEMBLY AND INSTALLATION

2. Locate the (2) supplied brass fuel barbs. Solder a

brass fuel barb to the fuel line pick up tube. This
will keep the weight of the fuel clunk from pull-
ing the fuel line off the brass tube.

Note:

No brass barbs are required for the air vent

lines.

3. Assemble the fuel pick up line, rubber stopper

and metal end caps. As shown below.

4. Solder a brass fuel barb to the other end of the

fuel pick up line.

Summary of Contents for Carbon Cub SS ARF-QB

Page 1: ...1 100cc Carbon Cub SS ARF QB Quick Build ASSEMBLY MANUAL AEROWORKS 4903 Nome Street Denver CO 80239 Phone 303 371 4222 Fax 303 371 4320 E mail info aero works net ...

Page 2: ... 41 Main Landing Gear Installation 44 Optional Inflatable Tire Assembly 47 Optional Treaded Tire Assembly 49 Tail Wheel Assembly 52 Engine Installation 55 Throttle Choke Installation 57 Ignition Installation 62 Fuel Tank Assembly and Installation 65 Standard Muffler Installation 71 Cowl Installation For Standard Mufflers 72 Canister Installation 76 Cowl Installation For Canister Mufflers 81 Radio ...

Page 3: ... from defects in both material and workmanship at the date of purchase This warranty does not cover any component parts damaged by use or modification In no case shall Aeroworks liability exceed the original cost of the purchased kit Further Aeroworks reserves the right to change or modify this warranty without notice In that Aeroworks has no control over the final assembly or materials used for f...

Page 4: ...Carbon Cub SS ARF QB Inventory and inspect all parts and hardware for any imperfections or damage Notify Aeroworks immediately if there are missing or dam aged parts INTENDED USE This plane should not be regarded as a toy This is an intermediate to advanced skill level model and is recommended for pilots who are beyond the trainer stage READ WARRANTY READ It is important to notify Aeroworks of any...

Page 5: ...nting 2 Tunnel Hatches front and rear covered and pre installed with 8 T2x10mm PWA screws 1 Top Hatch for engine box pre installed with 4 T2x10mm PWA screws 2 Fuse Rear Side Window tinted color pre glued 2 Fuse Front Side Window can open tinted color pre installed with the below items 4 Nylon Hinges 2 each side 8 M2x8mm bolts 8 M2 hex nuts and 4 Nylon latch 1 Door at the right of fuse covered pre ...

Page 6: ...al fittings mounting 8 4mm flat washers for metal fittings mounting 8 4mm split ring lock washers for metal fittings mounting 4 8 32x25mm hex head bolts for landing gear mounting 4 8 32 lock nuts for landing gear mounting 4 Cooper spacers for landing gear mounting 2 8 32x25mm hex head bolts for landing gear supports mounting 2 8 32 lock nuts for landing gear supports mounting 4 8x3 5mm cooper spac...

Page 7: ...nting 4 Flat washers for stab mounting 4 4mm split ring lock washers for stab mounting 1 8x202mm carbon stab tube 1 8x305mm carbon stab tube 11 4 Tail Flying Wires pre made 3 4 40x25mm hex head bolts 3 4 40 lock nuts 2 T2 6x12mm PWA screws 12 2 Window Latch set 4 T2 6x10 Screws 2 Window Holder 13 1 Engine Mounting Template for DA100 DLE111 1 Universal Engine Mounting Template 2 Canister Mounting B...

Page 8: ...Option 2 DA 100 L 1 DA 100 L 1 Ignition Module 4 1 4 20 x 2 1 4 Mounting Bolts 8 Fender Washers 4 1 4 20 Lock Nuts for engine mounting 3 Large Gas Fuel Line 1 27x10 28x10 2 Blade Propeller Note DA 100 L can be purchased through Aeroworks Engine Option 3 DLE 111 1 DLE 111 1 Ignition Module 4 1 4 20 x 2 1 4 Mounting Bolts 8 Fender Washers 4 1 4 20 Lock Nuts for engine mounting 3 Large Gas Fuel Line ...

Page 9: ...ting bolts 4 Lock Washers 2 Smoke brass inlets 2 Smoke inlet bolt plugs Note Available through Aeroworks Exhaust Option 2 Canister Mufflers 2 MTW TD 75H Rear Exit Canisters 2 70mm Drop Headers Flex Headers Recommended 2 3 Teflon Couplers 2 Header Gaskets 4 Header Clamps 4 Header Mounting Bolts Note Available through Aeroworks ...

Page 10: ...ilable through Aeroworks 8 Hitec 7950TG Servos for flight surfaces 1 Hitec 5625MG Servo for throttle Recommended Spinner 1 4 5 Spinner Carbon Fiber Recommended Note Spinner available from Aeroworks Electronic Accessories Receiver A 12 or 14 channel receiver is recommended using a receiver with 12 14 channels will allow the builder to mix both the aileron and elevator servos together in the radio M...

Page 11: ...ngine the Aeroworks Ignition Power System is recommended 1 Fromeco 2600mah Li Ion Battery w Universal Connector 1 Smart Fly Ignition Regulator 1 MPI charge switch Recommended Extensions 20 22 AWG extensions are recommended through out the 100cc Carbon Cub SS The following sizes will be used 2 6 Extensions for Flaps 1 18 Extension For Throttle Servo 4 24 Extensions For Ailerons Flaps In Fuse 2 48 E...

Page 12: ...ering sock Masking tape Modeling knife Needle nose pliers or crimping tool Paper towels Pen pencil or felt tipped marker Phillips screwdriver Rubbing alcohol Ruler and tape measure Scissors T pins Waxed paper Wire Cutters Adhesives 15 30 Minute epoxy Blue Loctite Epoxy mixing cups mixing sticks brushes CA kicker optional Thick Thin and Medium CA Rubbing alcohol Wipes WARNING Some rubbing alcohols ...

Page 13: ...h thin CA this will ensure your model lasts for many sea sons to come Note Even if you can visibly see glue on all glue joints it is still recommended that the joints be reglued Due to changes in humidity during the life of the aircraft glue joints can separate it is always recommended that the glue joints be checked before each flying session Checking Glue Joints 2 Use thin CA to reglue any acces...

Page 14: ...hile working on the airplane Window Hangars 3 Slide the hook portion of the hangar over the bottom edge of the window 4 The straight portion of the hangar will be placed inside the fuse through the aileron flap extension access hole as shown 2 The window hangar will be placed on the win dow and through the cutout in the fuse side as shown ...

Page 15: ...ed model TIGHTENING AND RE SHRINKING THE COVERING 2 Using your covering iron with a soft sock gently apply pressure and rub in the covering If any bubbles occur your iron may be to hot Reduce heat and work slowly 3 If bubbles persist use a small pin to punch holes in the bubble to relieve trapped air and reheat 4 DO NOT use a heat gun near the side windows Heat applied directly to these surfaces w...

Page 16: ...Go over all hinge gaps ensure there are no wrinkles Excessive wrinkles in the hinge line can cause binding and or damage the covering IMPORTANT It is the responsibility of the purchaser operator to check the covering seams and overlaps for security and a good seal Aeroworks is not responsible for failure of covering seams or overlaps during flight Note If covering continues to lift apply a small a...

Page 17: ... the 100cc Carbon Cub SS True Red 866 White 870 These 300mm X 300mm Pieces can be used for small repairs 1 Your model is covered with Ultracote covering In case of repairs the colors are Blue White Scheme Midnight Blue 885 Black 874 White 870 Blue White Scheme 2 The Following pieces of Ultracote covering have been provided with the 100cc Carbon Cub SS Midnight Blue 885 White 870 These 300mm X 300m...

Page 18: ...om the servo hole to the male plug of the servo extension Aileron Flap Servo Installation 1 The ailerons flaps have been pre hinged and glued to the wing panels and are ready for flight Required Parts 1 Wing panel Required Parts Not Included 1 Aileron servo 1 Flap Servo 8 Servo Mounting Screws Micro Fastener Part number STW0209 recommended 2 1 1 2 servo arms 2 Safety clips 1 48 Servo Extension 1 6...

Page 19: ...wing panel will help to prevent lead from dropping back inside of wing panel during transportation 7 Install servo in servo well with the output arm toward the trailing edge of the wing Drill holes for servo mounting screws 8 Install servo with servo mounting screws Re peat servo installation process for all aileron and flap servos 9 Finished panel shown with servos installed ...

Page 20: ...tle Gap Filling CA Glue 1 34oz Bottle Blue IC Loc Thread Locker 3 Correct installation of ball link to servo arm shown below Note Flat washer will prevent ball link from coming loose from brass ball 2 Assemble the pushrod and control horn assem bly as shown The ball link goes between the left and right sides of the control horn sides and is secured with a nylon lock nut Start with the center hole ...

Page 21: ...im is cen tered Adjust the length of the pushrod so that the servo arm is parallel to the aileron hinge line when it is placed on the servo output shaft Screw servo arm on the servo output shaft 8 Repeat previous steps for all servos Note On metal geared servos use Loctite for all Servo arm mounting screws Builders Tip If using Hitec Servos replace Phillips head servo arm screw with a socket head ...

Page 22: ...s face the wing root as shown Wing Root Strut Assembly and Installation 1 Gather the strut assembly items as shown below Required Parts 2 Struts 2 strut mounts 14 8 32x20mm mounting bolts 2 strut eyelets 12 8 32 lock nuts 4 8 32 flat washers 1 Pushrod adjustment wrench Not Pictured 1 Custom allen wrench Not Pictured 2 Foam transportation pads Required Tools and Adhesives 1 9 64 Ball Driver 1 9mm O...

Page 23: ...ount and eyelet assembly shown below Repeat the same steps for the remaining wing before continuing 6 Install the remaining eyelet in the wing as shown 8 The foam transportation pad can slip over the two eyelets and kept in place using the 8 32 mounting bolts and lock nuts This will prevent the struts from damaging the wing during trans port ...

Page 24: ...ansportation Over tightening of the mount will limit the movement of the strut 11 Secure the center strut support using 8 32x20mm bolt 8 32 Lock nut and Flat Washer 9 Use the 8 32 x 20mm mounting bolts and lock nuts to secure the struts to the strut mounts as shown 12 Center support bolt installation shown below ...

Page 25: ...from the center support to fully col lapse the strut as shown below 13 The remaining 8 32 x 20mm bolts and lock nuts will be used to mount the struts to the fuse It is recommended that these stay in the struts during transport to insure they will not be misplaced ...

Page 26: ...dow Latch Installation 3 Use thick CA on each screw prior to installing to lock screws in place Note CA glues have a fast drying time Remember to work quickly 2 Align window latch with predrilled holes in the bottom of each wing The hook portion of the latch will go towards the wing root 4 Finished window latch installation shown below Repeat previous steps for remaining wing Wing Root Wing Root ...

Page 27: ...on by applying Vase line petroleum jelly or light oil to the hinge joint This ensures no epoxy gets into the hinge during assembly Important Test fit the rudder to the vertical fin before applying epoxy to hinges 3 Mix epoxy in mixing cup and use a tapered stick to apply the epoxy inside the pre drilled holes in the leading edge of the rudder Apply epoxy to trailing edge of each hinge 4 Proper pos...

Page 28: ...y fully cures Rudder Servo Installation 1 Gather the rudder control linkage parts shown below Required Parts 2 3 Double Output Servo Arms 2 Pushrod Couplers 4 4 40 ball link assemblies 2 4 40x16mm Bolts 2 4 40x20mm Bolts 4 4 40 Lock Nuts 2 Brass spacers Not Pictured 4 Flat washer Required Parts Not Included 2 Rudder servos 8 Servo Mounting Screws Micro Fastener Part number STW0209 recommended 2 3 ...

Page 29: ...ushrods and four are for the pull pull system The couplers with the solid base are to be used for the pull pull assembly Rudder Control Linkage Installation 2 Gather the Rudder control linkage parts as shown below Required Parts 2 1x1650mm Pull Pull cable 4 4 40 ball link assemblies 4 4 40 Bolts 2 Brass spacers 2 Flat washer 4 Lock nuts 2 Left control horns 2 Right control horns 12 T2 6 x 7mm Wood...

Page 30: ...e pre installed cable exit tube in the rear of the fuse toward the front of the fuse Repeat for other side Note Loop or tape cable to fuse to prevent cable from being pulled into fuse 9 Pull the rudder cables from rear of fuse to the rudder servo tray Note Cables run parallel down fuse and do not cross each other 10 Thread brass coupler half way into ball link ...

Page 31: ...llow the rudder cable to pass through brass swage easily 12 Thread cable through brass swage tube 13 Thread cable through the threaded coupler hole and back through the brass swage tube as shown 14 Loop the cable back through the brass swage tube 15 Pull cable tight with pliers ...

Page 32: ...e brass swage tube with a crimping tool or pliers 17 Cut off excess cable as shown 18 A drop of thin CA may be applied to the swage tube to help secure the cable 19 Assemble the rudder coupler pushrod as shown below ...

Page 33: ...he top of the servo arm 21 Bottom of servo arm shown below 22 Install remaining ball links on the rear servo arm using 4 40x20mm bolts flat washer and brass spacer Do not install the lock nuts on rear ball links at this time 23 Install ball links attached to pull pull cables onto rear servo arm Secure mounting bolts with lock nuts ...

Page 34: ...r to center rudder servo Ensure servo trim and sub trims are centered Note On metal geared servos use blue Loctite for all Servo arm mounting screws 26 Tape the rudder balance tab to the top leading edge of the vertical fin in the neutral position as shown This ensures the rudder is straight when the cables are attached 27 Attach the ball link to the rudder control horn as shown below Follow the s...

Page 35: ...embly is now complete 29 Once the rear servo has been programmed at tach the front rudder servo arm to the servo as shown below 30 Center the front servo using your radio a servo programmer or matchbox 31 Use the pushrod adjustment wrench to perform final adjustments on coupler pushrod as shown below ...

Page 36: ...ator Servo Installation 1 The elevators have been pre hinged and glued to the stabs and are ready for flight No other steps are necessary for hinging Required Parts 2 Elevator Servos 2 1 1 4 Servo arms 2 48 servo extensions 20awg Recommended 2 12 servo extensions 20awg Recommended 2 Aeroworks safety clips 8 Servo mounting screws Micro Fastener Part number STW0209 recommended Required Tools and Adh...

Page 37: ...Control Linkage Installation 3 Assemble the pushrod and control horn assem bly as shown The ball link goes between the left and right sides of the control horn sides and is secured with a nylon lock nut Start with the center hole in the control horn The ball link may be moved up or down for more or less control throw Brass spacer goes between servo arm and ball link Note Carbon reinforcement sleev...

Page 38: ... as shown below Note On metal geared servos use Loctite for all Servo arm mounting screws Builders Tip If using Hitec Servos replace Phillips head servo arm screw with a socket head screw This will allow for easier removal at a later date These screws can be purchased from Micro Fasteners and are part number SCM2508 1 Gather the stab mounting parts as shown below Required Parts 1 8mm x 202mm Front...

Page 39: ...tab incidence Normal Flight 1 Ensure that the front mounting bracket is all the way against the bottom of the cutout This will set the stab at the correct incidence for normal flight Option 2 1 Stab incidence Towing 1 1 degree of positive incidence can be achieved by pushing the stab to the very top of the mount ing slot This stab location is recommended for towing purposes To help raise the tail ...

Page 40: ...f the stab mount as shown 3 The plywood spacer has been placed in the fuse and may need to be trimmed slightly for re moval 4 Once the spacer has been cut from the fuse it can be removed 5 Once the desired position has been located se curely tighten the mounting bolts Note Set the stab incidence to zero for general flying This can be achieved by setting the front L bracket on the top of the pre in...

Page 41: ...fly ing wires to the top of the fin as shown 1 Gather the following items shown below Required Parts 4 Tail Flying Wires preassembled 3 4 40x25mm Hex Head mounting bolts 3 4 40 lock nuts 2 T2 6x12mm PWA Screws Required Tools and Adhesives 1 5 64 Ball Driver 1 3 32 Ball Driver 1 Thick CA Note Flying wire installation is not optional Please be sure to follow these steps failure to do so may result i...

Page 42: ...llow them to be adjusted without being removed from the airplane 5 Use the 4 40 bolts and lock nuts to mount bot tom flying wires to the stab as shown 6 Adjust the flying wire length until the holes line up with the predrilled holes in the fuse Jam Nut 7 Use wood screws to secure the bottom flying wires to the fuse as shown below Use thick CA to secure the wood screw ...

Page 43: ...r stressing the stabs The flying wires should be adjusted so they are only able to move about 1 2 back and forth or until the stabs have no play in any direc tion Note Ensure flying wire lock nuts are securely tightened after final position has been 9 Stabilizer assembly is now complete ...

Page 44: ...front landing gear mounts 1 Gather the following items shown below for the main landing gear assembly Required Parts 2 Landing gear struts 2 Shock absorbers 1 Shock mount 2 Rear landing gear strut mounts 2 Front landing gear strut mounts 2 Wheel spacers 14 8 32x25mm mounting bolts 4 8 32x20mm mounting bolts 8 Flat washers 8 Lock Washers 4 Brass spacers 10 8 32 lock nuts Required Tools and Adhesive...

Page 45: ...nstall the remaining landing gear strut following the previous mounting instructions 8 Slide the 8 32 mounting bolt through the front landing gear mount Install the brass spacer as shown below 5 Slide the landing gear strut in place as shown the tapered edge of the strut goes towards the tail of the airplane ...

Page 46: ...ow 11 Attach shock to shock mount using a 8 32x20mm bolt and lock nut as shown 12 Secure the shock to the landing gear strut with a 8 32x20mm bolt and lock nut as shown 9 Slide shock mount onto the bolt followed by another brass spacer as shown Secure the mounting bolt with a 8 32 lock nut ...

Page 47: ...nstallation instructions Required Parts 4 Wheel Collars w Set Screw 2 5mm Wheel Spacers Required Parts Not Included 2 6 Inflatable Tires Dubro 600RV Available from Aeroworks 2 Hub Caps Available from Aeroworks 6 Hub Cap mounting Screws Required Tools and Adhesives 1 Phillips head screw driver 1 Pencil 1 Electric Drill 1 1 4 Drill Bit 1 Pin Vice with 1 16 Bit 1 34oz Bottle Blue IC Loc Thread Locker...

Page 48: ... axle Tighten the wheel collar set screw Note Use Blue Loctite on set screw this will prevent it from coming loose due to vibration 2 A 1 4 drill bit will be needed to enlarge the cen ter hole for the axle 5 Place the optional hubcaps onto the wheel as shown Use a pin vice to drill the location of the 3 mounting holes ...

Page 49: ...Parts Not Included 2 8 1 4 Treaded Tires Available from Aeroworks 2 Machined Aluminum Hubs for Aeroworks wheels 2 Hub Caps Available from Aeroworks 6 4 40 Button Head Hub Cap Mounting Screws Required Tools and Adhesives 1 5 64 Ball Driver 1 7 64 Ball Driver 1 34oz Bottle Blue IC Loc Thread Locker 6 Use 3 Phillips head screws to secure the hubcap as shown 7 Repeat all previous steps for remaining w...

Page 50: ...ue to vibration 2 If not using the plastic hubs supplied with the treaded tires remove them at this time Remove the bolts that hold the hubs together and then use two flat head screw drivers to carefully remove the hub from the tire as shown below 5 Slide the wheel collar onto the axle as shown Tighten the set screw at this time Note Use Blue Loctite on set screw this will prevent it from coming l...

Page 51: ...nished wheel installation shown below 6 Slide the wheel followed by the remaining wheel collar onto the axle Tighten the wheel collar set screw Shortening the length of an L wrench may allow easier access to tighten the wheel col lar set screw Note Use Blue Loctite on set screw this will prevent it from coming loose due to vibration 9 Repeat previous steps for the remaining wheel hub assembly ...

Page 52: ...a fast drying time Remember to work quickly 4 Mount the tail wheel steering tiller using two wood screws 1 Gather the tail wheel assembly items as shown below Required Parts 1 Tail wheel assembly 1 Tail wheel leaf spring 3 Tail wheel mounting screws 1 Steering tiller 2 Tiller mounting screws 2 Steering springs Required Tools and Adhesives 1 Phillips Screw Driver 1 1oz Bottle Gap Filling CA Glue 1 ...

Page 53: ...he steering springs 5 Place a drop of thick CA on tail wheel strut mounting screws before inserting in the pre drilled mounting holes on the bottom rear of the fuse Note CA glues have a fast drying time Remember to work quickly 8 Attach the steering spring to the rudder tiller Center the spring between both tail wheel and steering tillers ...

Page 54: ...54 11 Bottom view of completed tail wheel installa tion 9 Twist spring end tight with pliers 10 Repeat spring installation for other side ...

Page 55: ...ne Mounting Bolts 4 1 4x20 Lock Nuts 4 1 4 Diameter Fender Washers 4 1 2 Diameter Fender Washers Required Tools and Adhesives 1 Pencil 1 Masking Tape 1 Electric Drill 1 1 4 Drill Bit 1 Socket Wrench w 7 16 Socket 1 7 16 Open End Box Wrench ENGINE INSTALLATION 2 Locate the laser cut engine mounting template for the DLE111 DA 100 120 If other engines are used the Universal template may be modified f...

Page 56: ...e template are aligned with thrust lines on firewall 6 Mount the motor to the firewall using the sup plied 1 4 engine standoffs as well as 1 4x20 bolts lock nuts and fender washers not sup plied Your motor selection will determine the correct number of 1 4 spacers to use 7 Tighten the mounting bolts evenly using a cross pattern this will prevent the bolts from crushing the firewall ...

Page 57: ...ips Screw Driver 1 5 64 Ball Driver 1 Electric Drill 1 1 16 Drill Bit 1 Rotary Cutting tool with Cutting Disk 1 Wire Cutter 1 Soldering Iron 1 Silver Solder Sta Brite Recommended 1 80 Grit Sandpaper 1 34oz Bottle Blue IC Loc Thread Locker 2 Use a Felt tip pen or a pencil to mark the loca tion of the throttle servo onto the bottom of the motor box Note If using canisters temporarily install the hea...

Page 58: ...coupler install ball link to phenolic arm as shown Note If using stock mufflers it may be necessary to trim the 4 40x16mm bolt so it does not come in contact with the muffler 7 Reinstall phenolic arm to carb at this time Use blue loctite on mounting bolt to ensure it will not loosen from vibration Remove Trim remaining portion of bolt if using standard mufflers ...

Page 59: ...ing final throttle setup 10 Place throttle servo arm onto throttle servo as shown Position the arm so it is parallel to the servo case and open the throttle arm of carbure tor in the center or half throttle position Align the pushrod with the solder coupler and mark its location The pushrod should go all the way into the coupler after it has been cut 11 Remove pushrod from throttle servo and cut t...

Page 60: ...13 Lightly sand end of pushrod for best bond 14 Solder the threaded brass coupler to the end of the throttle pushrod 15 Attach the throttle pushrod with the 4 40 ball links and secure Power up the receiver and throttle servo and adjust pushrod for proper op eration Ensure the servo or rod does not bind or jam at closed or full open positions ...

Page 61: ...nd installing the carburetor choke pushrod as shown Attach ball link to choke arm as shown Use the provided 4 40x300mm pushrod to extend out of the cowling once the proper length has been found cut off excess pushrod and bend at 90 degrees for better grip Note Using a small piece of shrink tubing on the end of the pushrod provides a finished professional look 19 Location of manual choke pushrod sh...

Page 62: ...ng holes IGNITION INSTALLATION 1 Gather the ignition module battery switch regulator and installation parts as shown below Required Parts 2 8x80x300mm Foam Pad 2 8x450mm Nylon Ties Required Parts Not Included 1 Ignition Module 1 Battery 2600mah Li Ion Shown 1 Ignition Regulator Smart Fly Shown 1 Ignition Switch MPI Shown Required Tools and Adhesives 1 Pencil felt tip pen 1 Electric Drill 1 1 16 Dr...

Page 63: ...ire to pass into the motor box as shown 8 Mount ignition battery to motor box side using foam pad and nylon tie as shown 9 Mount switch in accordance with the switch manufacturers instructions and hardware We elected to mount the switch inside the radio compartment as shown below The switch can be easily accessed from the cockpit door If this switch position is used allow plenty of room for the do...

Page 64: ...64 10 Finished switch and installation shown below ...

Page 65: ...Pencil felt tip pen 1 Phillips Screw Driver 1 Wire Cutter 1 Soldering Iron 1 Silver Solder Sta Brite Recommended 1 80 Grit Sandpaper FUEL TANK ASSEMBLY AND INSTALLATION 2 Locate the 2 supplied brass fuel barbs Solder a brass fuel barb to the fuel line pick up tube This will keep the weight of the fuel clunk from pull ing the fuel line off the brass tube Note No brass barbs are required for the air...

Page 66: ...nt tube into rubber stopper and bend upward Note No brass barbs are required for the air vent tube 7 Install the fuel tubing and clunk Secure the fuel tubing with nylon ties to the pick up tube and clunk 8 Insert the rubber stopper assembly into the tank with the vent tube at the top of the tank ...

Page 67: ...supplied but are available through Aeroworks 2 Install a short piece of fuel line and the fuel T to the fuel pick up tube Note Using a heat gun to soften the fuel line will help with the installation of the fuel T 3 Install the fuel pick up and fuel filler lines to the fuel tank Note It is recommended you always use a fuel filter on your gas can filters should not be installed inside the airplane ...

Page 68: ... placement shown below Placing the fuel tank in this location will keep the CG from changing in flight but may also interfere with the dash panel installation and scale looks of the plane 6 Option 2 for fuel tank location shown below This location will cause the CG to change slightly in flight but will improve the scale ap pearance of the airplane 7 Thread nylon ties under tank mounting plate and ...

Page 69: ...s nylon tie as shown 11 We installed the fuel dot inside the radio floor to enhance the scale look of the aircraft Use thick CA to secure fuel dot in fuse 12 Feed filler line through dot and plug line into filler plug as shown 10 Gather the fuel filler dot and drill bits as shown below Note We recommend you start with a smaller size drill bit then increase the bit size to the correct size to fit y...

Page 70: ...rom chaffing 15 Feed vent line tubing through bottom of fuse Cut off excess fuel line Note Place a zip tie around the vent line as shown Be careful not to tighten the zip tie to the point of closing the vent line This will pre vent the vent line from falling back inside the fuse and flooding the airplane with gas during fueling ...

Page 71: ...installation 4 Install mufflers using the supplied gasket or high temp silicon gasket material and securely bolt to cylinder heads as shown 2 Install the smoke inlet plugs in the threaded hole on the side of each muffler If using smoke in stall the smoke inlets at this time Note Use blue loctite on the threads of either the smoke inlets or inlet plugs This will prevent them from coming loose over ...

Page 72: ...fuse as shown 4 Remove the cowling and install the standard mufflers as shown on page 71 1 Gather the following items for the cowling in stallation Note If using canister mufflers please skip to page 81 Required Parts 1 100cc Carbon Cub Cowling 1 16 3 4 x 11 1 2 Cowl Cutting Template Required Tools and Adhesives 1 Pencil felt tip pen 1 5 64 Ball Driver 1 Ruler Straight Edge 1 Masking Tape 1 Rotary...

Page 73: ...the muffler holes will not need to be elongated By separating the top and bottom cowl pieces the bottom cowl can be slid over the muffler stacks 7 Use a hobby knife to cut out the muffler exit as shown 8 Check the fit of the template at this time It may be necessary to make small adjustments to the cutout to get it to fit properly 9 Align template to cowl using the air scoop as a guide Once the te...

Page 74: ...use a rotary cutting tool and sanding drum to cut out the openings in the cowl Note Take care not to remove too much material or scratch the cowl Install the cowling to double check your cuts and make any changes as necessary 13 Slide the bottom half of the cowling over the exhaust and onto the fuse as shown Ensure that the exhaust stingers do not come in contact with the cowl at this time 12 Remo...

Page 75: ...l drop of blue loctite will prevent the cowling bolts from loosening due to vibration 17 It is recommended that the canister vents be cut open to help cool the motor regardless of ex haust used 16 Install the final 4 40x16mm bolt in the rear hole of the top cowl half This bolt will pass through both the upper and lower portion of the cowl ...

Page 76: ... CANISTER INSTALLATION Canister Installation 1 Gather the canister muffler parts as shown Required Parts 2 Canister Mounting Bracket w Silicone Tubing Flex or Non Flex Required Parts Not Included 2 MTW TD 75H Rear Exit Canisters 2 70mm Drop Flex Headers 2 3 Teflon Couplers 2 Header Gaskets 4 Header Clamps 4 Header Mounting Bolts 2 6 Silicon Stinger Extensions Required Tools and Adhesives 1 9 64 Ba...

Page 77: ...ter mount viewed from front as shown be low 5 Canister mount will be glued inside fuse in the location shown below Note Two canister mounts have been supplied One for mounting flex headers and one for mounting headers without flex adjustment Be sure to select the correct mount for your needs See pages 79 80 for more information on the non flex canister mount Flex Non Flex ...

Page 78: ...Secure the header in place using the mounting bolts and gasket provided with your engine Use blue Loctite to secure the bolts 13 Position canister stingers so they are pointing towards the bottom of the fuse 9 Assemble the canister to the header with the Tef lon coupler and clamps in accordance with manufactures instructions ...

Page 79: ...nal Non Flex Header installation 1 If non flex headers are used follow these steps for the canister installation Many of the previ ous steps will be used for the mounting of the non flex header 2 The non flex headers will use a different mount both of these mounts have been supplied The canister mount with the stinger cutouts towards the bottom of the fuse will be used for non flex headers the mou...

Page 80: ... The non flex mount is shown above the fuse this mount will require the use of longer stinger extensions 3 Install the mount using the same method de scribed in the standard canister mounting in structions ...

Page 81: ...of the cowling onto the fuse as shown Ensure that the headers do not come in contact with the cowl at this time 4 Bolt the bottom half of the cowl to the fuse using 4 4 40 16mm bolts 5 Place the top half of the cowling in place using the 16 4 40x10mm bolts fasten the top half of the cowl to the lower half Note A small drop of blue loctite will prevent the cowling bolts from loosening due to vibrat...

Page 82: ...be left open to help cool the motor regardless of ex haust used 8 Cowling installation is now complete 6 Install the final 4 40x16mm bolt in the rear hole of the top cowl half This bolt will pass through both the upper and lower portion of the cowl ...

Page 83: ...teries 5200mah Li Ion Shown 2 Regulators Fromeco Sahara Shown 2 Receiver Switch Smart Fly Shown 1 Adhesive backed Velcro 4 Large Nylon Ties Required Tools and Adhesives 1 Pencil felt tip pen 1 Wire Cutter RADIO INSTALLATION 2 Roll the supplied foam rubber to make a 4 layer pad as shown Make the pad slightly larger than the battery 3 Install battery using Velcro or Nylon ties as shown below ...

Page 84: ... inside fuse as shown A nylon tie can also be used to secure the regulator 6 Repeat battery and regulator installation for re maining battery and regulator 7 Mount the receiver switches inside door on the right hand side of the fuse This will maintain the scale looks of your 100cc Carbon Cub SS ...

Page 85: ... below 10 Ensure all wires are secured inside the fuse If using canister mufflers it is extremely important that all wires are located on the top side of the radio tray as shown 11 Run aileron and flap extensions from the re ceiver behind the rear window and out the top of the fuse as shown This will help maintain the scale appearance of airplane ...

Page 86: ...hillips Mounting Screws Required Tools and Adhesives 1 Phillips Screw Driver 2 Remove decals from sheet and carefully apply to the correct location on the dash panel 3 Apply decals carefully ensuring they are straight Once the decal has been applied it can not be removed 4 Final decal installation shown below Optional Dash Panel Installation ...

Page 87: ...ith the panel Reinstalling Windshield 2 Reinstall the windshield using the 23 T2x8mm Mounting Screws 1 Gather the windshield and mounting screws as shown below Required Parts 1 Front Windshield 23 T2x8mm Canopy Mounting Screws Required Tools and Adhesives 1 Phillips Screw Driver ...

Page 88: ...t card Windex or Application fluid like Rapid Tac Also a solu tion of 1 drop of dish detergent to a cup of water sprayed on the model will assist in proper posi tioning Note Clean surface and tighten all covering before any decals are applied OPTIONAL DECAL INSTALLATION 2 Placement of optional decal package shown 3 Placement of optional decal package shown 4 Placement of optional decal package sho...

Page 89: ...pport for the struts using the 8 32 bolts and lock nuts as shown 3 Slide the wing tube in the fuse wing tube sleeve Slide the wings on the wing tube 4 Secure the aileron and flap connectors with Aeroworks Safety Clip Ensure the connectors will not come apart from vibration or light ten sion 5 Bolt the struts to the fuse using 2 8 32 bolts and lock nuts as shown below ...

Page 90: ...the wings 7 Slide the rubber backed washers on the wing mounting bolts and insert bolts through the fuse side and into the wing root blind nuts Tighten snugly but do not over tighten and crack the fuse or wing root wood Note Use the window latch to hold the window in place while tightening the wing bolts ...

Page 91: ...del by moving the batteries and receiver before adding any bal last 3 Start at recommended CG until you are com fortable with the flight characteristics of the aircraft You may find this a bit nose heavy at first but that is fine to start with After you are comfortable adjust the CG to suit your flying style in small steps especially when shifting the CG toward the tail Move the battery or add sma...

Page 92: ...nd high rates 2 Use the supplied flight control deflection meter to measure the throws in degrees Prop up the tail of the aircraft until the fuselage is parallel to the table top 3 Use the widest part of the aileron flap to measure the aileron flap throw in degrees or inches 4 Use the widest part of the elevator to measure the elevator throw in degrees or inches 5 Gather the Rudder Deflection Mete...

Page 93: ...down 30 down High Rate Aileron 2 1 4 or 40 up 2 1 4 or 40 down Rudder N A or 50 left N A or 50 right Elevator 3 1 2 or 45 up 3 1 2 or 45 down Flap 45 down Recommended Exponential 15 Exponential on low rates 30 Exponential on medium rates 60 Exponential on high rates Use the given rates as a starting point You can adjust from there to suit your own flying style 7 Secure the tabs to the fin using sc...

Page 94: ...ced fly ers have lost airplanes due to reversed ailer ons Right roll is right up left down Left roll is left up right down Batteries Transmitter ignition and receiver bat teries are fully charged Fasteners Check all engine bolts wing bolts hatch bolts servo screws control horn bolts wheel collars and clevis keepers are tight and secure Covering Check all covering and seams are sealed and secure Ra...

Page 95: ..._____ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ______________...

Page 96: ...irplane at your flying field Fuel Line Installation Kit The fuel line installation kit includes everything needed to plumb your gasoline powered aircraft 3 feet of 1 8 I D Dubro tygon tubing is pro vided Simple turn fuel dot provides a nice finished look to any model Aluminum fuel T with 1 8 I D will provide superior fuel flow Rubber Grommets For more information or to order accessories visit our ...

Page 97: ... off rough fields and the occasional rough take off These are highly recommended if using the 8 1 4 treaded tires Carbon Cub SS Dash Panel The optional 3 dimensional dash panel from Aeroworks adds that finished look to any cockpit This dash panel is specifically designed to fit the 100cc Carbon Cub SS For more information or to order accessories visit our website WWW AERO WORKS NET or call Aerowor...

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AeroWorks Carbon Cub SS ARF-QB, Assembly Manual

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