GREAT PLANES Ultra Sport 40 Plus, Instruction Manual

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14. Using 30-minute epoxy, glue the firewall (F1) in place
to the fuselage sides and the fuselage top. When gluing,
push the firewall (F1) against the fuselage sides and top.
Make sure the firewall (F1) is glued in with 3 degrees of right
thrust (check the plans) and 0.5 degrees of down thrust.
Hold in place with clamps until the glue has cured. Note:
Because the fuselage is being built upside down, the built-in
right thrust will appear to be left thrust and the down thrust
will appear to be up thrust.
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15. Locate three 36" [914mm] plastic flexible outer
pushrod tubes. Using the plans as your guide, install the
outer pushrods into the holes in the fuselage formers,
exiting the slots in the rear of the fuselage. Note that there
are two elevator pushrod tubes and only one rudder
pushrod tube.
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16. Make a mark on the tubes where they contact the
fuselage formers and sides. Remove the tubes. Then
roughen the tubes with 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.
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17. Cut the tubes at an angle about 1/4" [6.4mm] away
from where they exit the fuselage. Fill the slots where the
tubes exit the fuselage with a 50/50 mix of 6-minute epoxy
and microballoons. The addition of the microballoons
thickens the epoxy, preventing it from running and making it
sand easier. Be careful not to get epoxy in the tubes. Do this
for both the right and left side of the fuselage. After the
epoxy is fully cured, use a sanding bar to sand the pushrod
exits flush with the fuselage on both sides of the fuselage.
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18. Make a mark on the bottom fuselage 3" [76mm] in
front of former F5. Make another mark 3" [76mm] in front of
the first one. Locate the 3/32" x 4" x 30" [2.4mm x 102mm x
760mm] balsa sheeting and sheet the bottom of the aft
fuselage, leaving the portion between the marks unsheeted.
Sand the sheeting flush with the fuselage sides. Note that
the sheeting is done across the fuse for strength.
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