GREAT PLANES Ultra Sport 40 Plus Page 26 Instruction Manual Download | Manualshive

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9. Now that both fuselage sides are completed, align

them and clamp them together. Lightly sand the fuselage
edges until they are identical. Also, sand the end of the
fuselage side (where the stab doubler (SD) is) at a slight
bevel as shown.

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10. Locate the die-cut 1/16" [1.6mm] balsa forward

fuselage top (FFT) and aft fuselage top (AFT). Align them
over the plans and glue them as shown. After the glue has
cured, sand the joint smooth. Pin the assembled top
fuselage on the plans.

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11. Locate the die-cut 1/8" [3.2mm] lite-ply fuselage former

F3 and the die-cut 3/32" [2.4mm] balsa fuselage formers
F4, F5 and F6. Glue them in position on the fuselage top as
indicated on the plans. Make sure that all formers are glued
90 degrees to the building board.

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12. Glue the right side of the fuselage to the fuselage top.

When completed, glue the left side in place.

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13. Locate the two die-cut 1/8" [3.2mm] lite-ply fuselage

formers F1. Glue them together with epoxy. Wipe excess
epoxy with a paper towel dampened with alcohol. Sand the
edges so they match after the glue has cured.

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Summary of Contents for Ultra Sport 40 Plus

Page 1: ...ser assembled product the user accepts all resulting liability 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 imme...

Page 2: ...Ultra Sport 40 Plus tracks straight no matter what flying attitude the pilot tries to hold This is a fly where you point airplane The Great Planes Ultra Sport 40 Plus has an extremely wide CG range to...

Page 3: ...are available at AMA club sites to help you get started the right way Contact the AMA at the address or toll free phone number below The Great Planes Ultra Sport 40 Plus can use either a 4 channel ra...

Page 4: ...Q3870 In addition to common household tools screw drivers drill etc this is the short list of the most important items required to build the Great Planes Ultra Sport 40 Plus We recommend Great Planes...

Page 5: ...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 Not all die cut parts h...

Page 6: ...LE Leading Edge TE Trailing Edge LG Landing Gear Ply Plywood Inches mm Millimeters SHCS Socket Head Cap Screw TYPES OF WOOD COMMON ABBREVIATIONS 6 0 1 2 3 4 5 6 7 0 10 20 30 40 50 60 70 80 90 100 110...

Page 7: ...7 DIE PATTERNS...

Page 8: ...8 DIE PATTERNS RETRACT WIRE TEMPLATE...

Page 9: ...ure 6 Locate the 1 8 x 1 8 x 30 3 2mm x 3 2mm x 760mm balsa sticks Cut them to size as shown on the plans to complete the stab s inner structure Glue them in place with thin CA Remove the stab from th...

Page 10: ...e the stabilizer and elevators to check the fit Shape the leading edge of the stab and the leading edge of the elevator counter balance to obtain the shape shown in the plan s cross section Do not sha...

Page 11: ...6mm the holes for the control horns on both elevators as indicated on the elevators plan Wick some thin CA into the holes 1 Unroll the wing plan Pin the die cut 1 8 3 2mm balsa fin base FB onto the p...

Page 12: ...ure Glue them in place with thin CA 5 Remove the fin and rudder from the plan and sand them smooth Locate two 1 16 x 3 x 36 1 6mm x 76mm x 914mm balsa sheets Sheet both sides of the fin and the rudder...

Page 13: ...ind it helpful to cut the plan in half making them a more manageable size to pin to your building board 3 Position the right wing panel plan flat on the building board Cover the plan with Great Planes...

Page 14: ...ut 3 32 2 4mm wing rib W1 Place the rib in the notches in MSW at the root of the wing Use the die cut dihedral gauge DG to set the correct amount of dihedral for the root rib W1 Insert the trailing ed...

Page 15: ...nd one of the servo tray supports STS to make it fit as shown in the above image Once you are satisfied with the fit glue the assembly in place with medium CA 16 Fixed Tricycle Locate the die cut 1 8...

Page 16: ...on the ribs After the epoxy has cured sand the ribs smooth with the top and bottom surfaces of the wing 22 Fixed Mains and Tailwheel Locate one of the 1 2 x 3 4 x 5 1 2 13mm x 19mm x 140mm hardwood la...

Page 17: ...they fit between the ribs at the trailing edge of the wing and glue them in place with medium CA 27 Cut another piece from the leftover 1 4 x 1 2 x 30 6 4mm x 13mm x 760mm sticks in the above steps an...

Page 18: ...g The other part will be used to sheet part of the center section of the wing and for cap stripping the wing 32 Sand the top of the wing smooth with a long sanding bar Glue the sheeting to the main wi...

Page 19: ...are the sheeting for the bottom wing surface Glue the sheeting in place using the same procedure as was used for the top sheeting Cut the ends of the sheeting that extend out from the wing root and ti...

Page 20: ...ron at the trailing edge of the wing against the piece you just glued Draw a line at the tip rib on the aileron Cut the aileron stock to length 43 Use the same method described on step 14 page 10 to d...

Page 21: ...edge at the root to hold the aileron in a neutral position Sand the block to shape as shown on the plans 47 Use a high speed rotary tool to drill a 1 2 13mm hole in the top sheeting of the center sec...

Page 22: ...ment and on the edges of the sheeting to reinforce it 51 Retractable Mains FixedTailwheel Drill a 1 4 6 4mm hole through W1 and W2 as shown at the die cut mark 52 Fixed Mains and Tailwheel Locate the...

Page 23: ...Do this for both wing panels Lightly sand the wing root ribs to achieve the 1 5 8 41mm dihedral Note that you will need to bend the joiner back slightly to make the wing root ribs meet because of the...

Page 24: ...hat there is enough epoxy in all the holes After the dowels are installed use a brush to apply some more epoxy around the holes and the dowels inside the wing 1 Unroll the plan sheet Roll it inside ou...

Page 25: ...n the above image The aft edge of SD should be aligned with the aft edge of the aft fuselage side AFS 6 Glue the right FSD on the assembled right forward fuselage side as shown with epoxy The top and...

Page 26: ...Pin the assembled top fuselage on the plans 11 Locate the die cut 1 8 3 2mm lite ply fuselage former F3 and the die cut 3 32 2 4mm balsa fuselage formers F4 F5 and F6 Glue them in position on the fuse...

Page 27: ...th sandpaper at the marks you have made Reinstall the outer pushrod tubes back into the fuselage and glue them in place with thin CA The tubes should extend about 2 52mm into the radio compartment 17...

Page 28: ...uselage sides 21 Flip the fuselage over and mark the location of the screw hatch support Remove the screw and the hatch cover Wick some thin CA into the hatch s hole and the hatch support hole 22 Cut...

Page 29: ...the outer pushrods Note that one of the pushrods is for the throttle and the other one is for the steering if you are using a tricycle gear setup Also use a high speed rotary tool to drill the large h...

Page 30: ...ot to get any in the threads 31 Locate the two die cut 1 16 1 6mm balsa tank floor parts TF Glue them side by side using CA as shown above 32 Cut a 1 4 x 1 2 6 4mm x 12mm piece of balsa stick to lengt...

Page 31: ...er than the other end The wider ends must be on the same end 39 Insert the cockpit floor in the space between F3 A and F4 A The wider end of the cockpit floor must be towards the front of the fuselage...

Page 32: ...hrough the large hole in the firewall F1 Locate the two die cut 1 16 1 6mm balsa fuel tank holders TH and glue them as shown to hold the fuel tank in place Once both tank holders are glued in place wi...

Page 33: ...flush with the formers 46 Follow the same procedure to glue the sheeting on the other side of the aft turtle deck 47 Locate a 1 16 x 3 x 18 1 6mm x 76mm x 457mm balsa sheet Use the preceding sketch to...

Page 34: ...el Temporarily install the tail wheel assembly into the rudder and fit the rudder to the fin and fuse Mark where the slot for the tail wheel assembly nylon bushing needs to be cut out in the aft fusel...

Page 35: ...d another at 22 1 4 565mm from the threaded end and the last one at 23 3 4 603mm from the threaded end Bend the wires as indicated in the above image 5 Center the servos and position the servo arms as...

Page 36: ...arm and install a FasLink Cut the excess wire 1 16 1 6mm away from the FasLink Note In the installation shown the engine installed is an O S 70 4 Stroke A 2 stroke engine can be installed the same wa...

Page 37: ...6 32 x 3 4 19mm SHCS and four 6 lock washers Use Great Planes Pro Threadlocker on the SHCS and tighten them 5 Locate a 1 16 x 36 914mm music wire and cut it in half Insert the 18 457mm music wire int...

Page 38: ...elage Use Great Planes Pro Threadlocker on the SHCS and tighten it 9 Fixed Tricycle Locate the leftover piece of music wire used in step 5 Insert the music wire into the steering plastic outer pushrod...

Page 39: ...of the wing Also draw a line at the center of the die cut 1 8 3 2mm lite ply wing bolt plate WBP 4 Align the aft edge of the wing bolt plate WBP with the line on the wing remember you are working on...

Page 40: ...lsa belly pan BP sides to the bottom center section of the wing between formers F4 B and the wing dowel plate 9 Make a mark on the edges of the belly pan sides where the wing bolts are located 10 Loca...

Page 41: ...nd 14 Locate the 3 8 x 2 x 6 9 5mm x 51mm x 152mm balsa block and cut it in two 3 76mm pieces Glue a block to each side of rib W2 as shown above 15 Sand the blocks flush with the wing skins Also test...

Page 42: ...es 3 Retractable Mains Fixed Tailwheel Install the retract servo in place with the hardware supplied by the manufacturer Remove the servo s output shaft 4 Retractable Mains Fixed Tailwheel The retract...

Page 43: ...l the retracts The control pushrod should slide into the hole previously drilled in W2 8 Retractable Mains Fixed Tailwheel Cut up a servo arm as shown in the above image and install two screw lock pus...

Page 44: ...Mains and Tailwheel Fixed Tricycle Use a small file to bevel the hole in the landing gear mounting blocks Locate the left main gear wire and slide it in place in the landing gear mounting block Do the...

Page 45: ...n the spinner backplate against the engine s drive washer Position the cowl so that it is 3 32 2 4mm behind the spinner backplate Draw a line parallel to the cowl edge 1 4 6 4mm away from it Make a ma...

Page 46: ...covering in the middle and work outward pushing out air as you proceed Do not move the iron in a circular motion but move it span wise with the grain of the wood 4 When you cover smaller parts with sq...

Page 47: ...fuselage When cutting the covering away be careful not to cut the balsa wood Cutting the balsa wood can weaken the structure Use the Expert Tip on page 46 for cutting the MonoKote 3 Stand five to ten...

Page 48: ...omponents you may not already have in place such as the fuel valve fuel lines servos on off switch etc Make sure you install silicone clevis retainers on all nylon clevises 1 Use scissors or a sharp h...

Page 49: ...one of its sides glued to the fuselage s bottom balsa sheeting and the other wrapping the battery to secure it in place In any case you should always use some kind of rubber padding to protect the ba...

Page 50: ...many flights DO NOT OVERLOOK THIS IMPORTANT PROCEDURE A model that is not properly balanced will be unstable and possibly unflyable Balance the Model C G IMPORTANT The Great Planes Ultra Sport 40 Plus...

Page 51: ...RTV silicone or epoxy to permanently hold the weight in place 4 IMPORTANT If you found it necessary to add any weight recheck the C G after the weight has been installed 1 With the wing level have an...

Page 52: ...appening If the control surfaces do not respond correctly do not fly Locate and correct the problem first Look for loose servo connections or broken wires corroded wires on old servo connectors poor s...

Page 53: ...ical fasteners such as the set screws that hold the wheel axles to the struts screws that hold the carburetor arm if applicable screw lock pushrod connectors etc 7 Add a drop of oil to the axles so th...

Page 54: ...ntinue to fly around executing various maneuvers and making mental notes or having your assistant write them down of what trim or C G changes may be required to fine tune the model so it flies the way...

Page 55: ...for optional flaps GPMA0180 Great Planes Extra 300S 40 Ideal for MiniMAC Great Planes sport scale Extra 300S kit requires no more experience expense or assembly work than the average mid size sport mo...

Page 56: ...the output shaft Length 1 59 in Width 0 78 in Height 1 42 in Weight 1 6 oz Torque 33 3 oz in 4 8V 41 7 oz in 6V Transit time 0 28 sec 60 4 8V 0 22 sec 60 6V One year warranty FUTM0029 Futaba S9001 Ai...

Page 57: ...57 ENGINE MOUNT TEMPLATE...

Page 58: ...0 10 20 20 30 30 40 40 50 50 60 60 70 70 0 20 20 40 40 60 60 80 80 100 100 10 10 8 6 4 2 0 0 7 8 9 3 2 1 4 5 6 0 7 8 9 3 2 1 4 5 6 4 2 12 12 15 15 4 2 6 1 1 0 10 10 20 20 30 30 40 40 50 50 60 60 70 70...

Page 59: ...59 Note Make a copy of the Two View Drawing that appears on the back cover page before cutting out this template...

Page 60: ...TWO VIEW DRAWING Use copies of this page to plan your trim scheme...

Page 61: ...C B...

Page 62: ...D A...

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