Hangar 9 Cap232 Page 4 Instruction Manual Download | Manualshive

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Zenoah G-62

Zenoah GT-80

Additional Required Equipment

Radio Equipment with Computer Radio

1000mAh receiver battery pack or larger
(4) Servos with 80 oz/in of torque minimum for elevator and rudder

(JR8101, 4721, 2721, or 8411 or equivalent)

(4) Servos with 60 oz/in of torque (aileron)
(1) Servo for throttle
(6) 24" Servo Extension (JRPA102)
(1) 18" Servo Extension (JRPA101)
(2) 3" Servo Extension (JRPA093)

Radio Equipment (Non-Computer Radio)

(1) 1000mAh receiver battery pack or larger
(4) Servos with 80 oz/in of torque minimum for elevator and rudder

(JR8101, 4721, 2721, or 8411 or equivalent)

(4) Servos with 60 oz/in of torque (aileron)
(1) Servo for throttle
(3) Y-Harnesses (JRP133)
(4) 18" Servo Extension (JRPA101)
(2) 12" Servo Extension (JRPA099)
(2) 6" Servo Extension (JRPA095)

Note:

Requires one reversed servo for elevator

Recommended JR

®

Systems

JR XP652
JR XP783
JR XP8103
JR PCM10X

Engine Requirements

62-80cc Gasoline Engine

Recommended Gasoline Engines:

Zenoah

®

G-62 Gasoline Engine

Zenoah GT-80 Gasoline Engine

JR 8103

JR 10X

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Summary of Contents for Cap232

Page 1: ...0 4 11 8 kg Recommended Engines 60 to 80 cc gasoline 90 Custom built Designed by 8 time TOC competitor Mike McConville Specifically designed for excellence in precision and 3 D aerobatics Prepainted fiberglass cowl and wheelpants Plug in wing and stab Precovered with genuine Hangar 9 UltraCote IMAC and Giant Scale legal Instructions include 3 D flying tips from Mike McConville ...

Page 2: ...g the Aileron Linkages 15 Section 6 Installing the Rudder and Elevator Servos 17 Section 7 Installing the Elevator Control Horns and Linkages 19 Section 8 Installing the Rudder Control Horns and Linkages 22 Section 9 Installing the Landing Gear and Wheel Pants 24 Section 10 Attaching the Tail Wheel 27 Section 11 Installing the Receiver Battery and Fuel Tank 28 Section 12 Mounting the Engine and Co...

Page 3: ...d to a crash The 1 3 Scale CAP 232 does not include hardware Many experienced giant scale pilots have specific hardware preferences and can individually choose the components they prefer Hangar 9 offers an optional Hardware Package HAN1220 JR HAN1221 FUT that includes the hardware that our staff regularly uses and recommends Throughout the manual the above hardware will be used during the assembly...

Page 4: ...quipment Non Computer Radio 1 1000mAh receiver battery pack or larger 4 Servos with 80 oz in of torque minimum for elevator and rudder JR8101 4721 2721 or 8411 or equivalent 4 Servos with 60 oz in of torque aileron 1 Servo for throttle 3 Y Harnesses JRP133 4 18 Servo Extension JRPA101 2 12 Servo Extension JRPA099 2 6 Servo Extension JRPA095 Note Requires one reversed servo for elevator Recommended...

Page 5: ...ron Measuring device e g ruler tape measure Additional Needed Items Zenoah 2 Prop Drive ZEN20004 GT 80 only 41 4 Spinner Tru turn TRU4252M Propeller refer to recommendations listed in your engine s operating instructions 2 gas compatible tubing Cup engine mount B B 6202 G 62 only Coarse sandpaper Radio packing foam Antenna tube Canopy glue Blue Locktite Electrical tape Masking tape Scissors Moto t...

Page 6: ...ing Gear HAN1263 Decal Set HAN1264 True Red UltraCote HANU866 White UltraCote HANU870 Pearl Blue UltraCote HANU845 31 2 Wheels 2 DUB350L 41 2 4 40 Threaded Pro Links 4 HAN3556 5 4 40 Thread Pro Links 4 HAN3557 32 oz Fuel Tank DUB690 Tail Wheel Assembly with Hardware OHI130 4 40 Ball Links 9 ROC87 8 32 Swivel Control Horns 8 ROC01B 3 16 Main Axles DUB249 Super Hinge Points 24 ROB309 4 40 3 D Arm 11...

Page 7: ...icult to insert into the internal hardwood blocks located inside the fuselage take a small round file or carefully use your hobby knife and adjust the opening in the block so that the alignment tubes fit properly but snugly Step 3 Carefully slide the other wing panel onto the wing tube that projects from the other side of the fuselage The fit may be tight use caution when inserting the wing panels...

Page 8: ...vos do not fight each other If this is not done correctly battery consumption will be greatly increased and in the case of a high torque digital servo the servos may be damaged When setting up the ailerons with two servos there are some special steps that need to be taken Step 1 Select two sets of servos and Hangar 9 1 arms that have the same neutral All servos will have a slightly different neutr...

Page 9: ...radio s instructions If a non computer radio is used then three Y harnesses and two 12 extensions are required In this case each of the two servos should be plugged directly into a Y harness and a 12 extension connected to the Y harness This lead will exit the root of the wing Step 5 Using the screws included with the servos fasten the servos in place You may find it helpful to drill a 1 16 pilot ...

Page 10: ...and make another mark using a pen These will be the positions for the control horns Step 3 Remove the ailerons from the wing Use rubbing alcohol to remove any tape residue Notice that the hinge pockets are already cut into place Step 4 Using a 5 32 drill bit and hand drill carefully drill a 5 32 hole through the aileron at the marked positions Drill perpendicular 90 to the aileron cross section ra...

Page 11: ...and securely tighten Wipe away any excess epoxy with rubbing alcohol and a paper towel Screw the A nuts in place as shown Allow the epoxy to fully cure Step 7 Screw the molded swivel links onto the inboard 8 32 screw until the distance from the aileron surface to the bottom of the link is 5 8 The outboard swivel link will be installed later Step 8 Install the control horns in the opposite aileron ...

Page 12: ...232 control surfaces are predrilled to use Robart s Super Hinge Points Step 1 Sand each end of the hinge point hinge using coarse sandpaper This will improve the bond of the epoxy to the hinge Step 2 Mix 1 ounce of 30 minute epoxy Using a glue syringe or toothpick place a sufficient amount of 30 minute epoxy into one of the hinge pockets on the wing s trailing edge Install one of the hinge points ...

Page 13: ...rtually touch Using a paper towel and rubbing alcohol wipe away any visible epoxy around the hinges Step 6 Double check the hinge gap and allow the epoxy to fully cure for at least six hours Repeat the process for the other wing half Step 7 When the epoxy has fully cured move each control surface throughout its travel range several times to break away any epoxy in the hinge Be sure to deflect the ...

Page 14: ... the hinge bevel on the bottom of the ailerons Step 12 Remove the backing from one piece of the UltraCote Place the folded crease side to the center of the hinge line on the bottom of one wing half Using a straight edge as shown hold one side of the covering in place while ironing down the opposite side with a sealing iron We recommend setting the iron temperature to 320 for this operation Step 13...

Page 15: ... for easy accurate adjustment without discon necting the linkages Consistently putting the right hand threads toward the servo arms on all servos will prevent you from getting confused as to which way to turn the linkage to lengthen or shorten the link Hangar 9 also offers a Pro Link Wrench HAN3558 to make adjustments easier Step 2 Using the 4 40 screws don t substitute a standard screw and nuts i...

Page 16: ...hold full left aileron and again note how the holes align The holes have to line up nearly perfectly If they don t line up perfectly adjust the horn length distance out from the aileron in or out a few turns and recheck Repeat this process until it is nearly perfect at full deflection in both stick directions and at neutral Step 6 Attach the swivel clevis to the horn with the supplied screw Sectio...

Page 17: ...ded The rudder and elevators require a minimum of 80 in oz of servo torque In the prototype 1 3 Scale CAP 232 we used JR8101 and JR8411 servos with excellent results Using servos with less torque could cause a crash Computer Radio Step 1 If using a 7 channel or greater computer radio with mixing highly recommended install four 24 servo extensions one on each servo Tie a knot at each connector and ...

Page 18: ...ng sure to connect the servo to the other open connector of the respective Y harnesses Don t forget to knot and tape the connectors Note One of the elevator servos must be a reversed servo Step 3a Using the screws included with the servos fasten the servos in place You may find it helpful to drill a 1 16 pilot hole before installing the screws Note With some servos such as the JR 8411 it is necess...

Page 19: ...osition of the control horn on the bottom of the elevator measure inward 11 8 from the root and rearward 1 4 from the top of the bevel Mark this position on both elevators Step 2 Using a 5 32 drill bit and hand drill carefully drill a 5 32 hole through the elevators at the above marked position It s important to drill 90 to the elevator s centerline to the elevator s surface Be especially careful ...

Page 20: ... will have to make sure this is done so the stabilizers can be securely attached to the fuselage Check the tube opening sockets on both sides of the fuselage and remove any covering or debris with a sharp 11 blade Step 7 Locate the holes in each of the stabilizer s top surface The holes have been drilled for the 4 40 cap screw and split washer These screws are used to secure each stabilizer to the...

Page 21: ...rews before each flight Step 11 Remove the servo arms from the elevator servos and replace them with Hangar 9 heavy duty 1 arms The arms need to face up as shown in the photo below Be sure to use a drop of blue Locktite on the servo arm screw if using metal geared servos Step 12 Screw a 4 40 ball link five to six turns onto a 41 2 long 4 40 linkage Screw the opposite end of the linkage into the sw...

Page 22: ...om the edge of the rudder bevel Step 2 Using a 5 32 drill bit and hand drill carefully drill a 5 32 hole through the rudder perpendicular 90 to the rudder centerline at the marked position Be especially careful when penetrating through the backside of the rudder Step 3 Using an 8 32 tap thread the hole you just drilled in the rudder Step 4 Mix a small amount of 30 minute epoxy and lightly coat the...

Page 23: ...be positioned as shown below Step 10 Screw a 4 40 ball link five to six turns onto a 41 2 long 4 40 linkage Screw the opposite end of the linkage into the swivel control horn that was installed in Section 7 Adjust the length until the hole in the ball link lines up with the outer hole in the servo arm when the rudder is in neutral and the arm is centered Step 11 Using the 4 40 screws and nuts incl...

Page 24: ...ble wrench Felt tipped pen Blue Locktite Step 1 Install the axles in the landing gear as shown and secure in place using an adjustable wrench Note A plywood mounting plate is glued in place inside the wheelpants for mounting the wheel pant to the landing gear Step 2 Mark the position on the wheel pant where the axle will pass through on the plywood side It s helpful to hold the wheel in place over...

Page 25: ...s and carefully drill a 1 8 hole through the pants at the marked hole Step 6 Install the 4 40 blind nut from inside the wheel pants as shown Later we will fully seat the blind nut into the plywood when installing the wheel pants onto the landing gear Step 7 Install onto the axle in the following order wheel pant 3 16 collar wheel then another 3 16 collar It will be necessary to fit the parts insid...

Page 26: ...the collars against the wheels so that they are held in place Use blue Locktite on the collar set screws Step 10 Mount the landing gear to the fuselage using four 10 32 x 1 screws and locking nuts Section 9 Installing the Landing Gear and Wheel Pants CONTINUED ...

Page 27: ...f the fuselage Using a felt tipped pen accurately mark the two hole positions through the tail wheel bracket Step 3 Remove the bracket and drill 1 8 pilot holes at the previously marked positions Step 4 Using two 6 x 3 4 sheet metal screws fasten the tail wheel bracket in place Note that the hardwood plate is positioned in the rear of the fuselage allowing these screws to be firmly tightened Hint ...

Page 28: ... to the interior of the fuselage Using the included templates on the back cover of the manual cut out the battery tray from 1 8 light plywood Step 2 If using the Zenoah GT 80 it will be necessary to mount the battery pack slightly behind the wings trailing edge to properly balance the model The lighter Zenoah G 62 requires the battery be mounted in the nose Using 5 minute epoxy attach the battery ...

Page 29: ... by wrapping rubber bands or Velcro straps around the tank and tank floor Cup hooks can be used to hook the rubber bands to the tank floor Later we will run the fuel lines Step 6 Using 5 minute epoxy fasten the receiver mount in place as shown below Step 7 Using foam and rubber bands or Velcro straps fasten the receiver in place as shown An antenna tube not included can be used to route the antenn...

Page 30: ... 62s and GT 80s The G 62 offers good sport performance and is a good choice for doing all IMAC basic and sportsman maneuvers While the G 62 equipped CAP doesn t quite provide unlimited vertical performance most experienced sport flyers find that the G 62 offers plenty of power for all but the most aggressive types of aerobatics If you re a 3 D fanatic or an Advanced or Unlimited IMAC class competi...

Page 31: ...ace and attach the 4 40 ball link to the pushrod and the servo arm Step 5 If using a Zenoah GT 80 attach a 4 40 x 6 threaded rod to the choke lever using a 4 40 ball link The 4 40 rod runs down through the engine mount and exits the bottom of the cowl Step 6 Run the fuel lines from the pick up in the tank to the carburetor and run the vent line out the bottom of the fire wall We recommend using a ...

Page 32: ...nd nuts Step 4 Mount the Zenoah throttle linkage to the engine as per the instructions included with the engine Cut out the servo hole in the bottom plate as shown and mount the servo Using a 4 40 threaded rod a solder link and a 4 40 ball link make up the throttle pushrod to the appropriate length Securely solder the solder link in place and attach the 4 40 ball link to the pushrod and the servo ...

Page 33: ...pit area silicon glue works good here and attach the instrument panel Hangar 9 offers a sharp looking Instrument Panel HAN187 that replaces the decals for a more scale look Step 2 When satisfied with the cockpit detail fit the canopy in place It may be necessary to trim the edges for a perfect fit When satisfied glue the canopy in place using canopy glue like Pacer Formula 560 Use masking tape to ...

Page 34: ...o with flapperon mix the aileron servos are each plugged into their own channels The right aileron servo plug into the aileron socket in the receiver while the left aileron servo plug into channel 6 With flapperon activated in the programming this allows for independent travel adjustment of each aileron in each direction and electronic aileron differential Consult your manual for more programming ...

Page 35: ... transmitter with the antenna collapsed Turn on the receiver in your airplane With your airplane on the ground and the engine running you should be able to walk 30 paces approximately 100 feet away from your airplane and still have complete control of all functions If not don t attempt to fly Have your radio equipment checked out by the manufacturer Step 2 Double check that all controls aileron el...

Page 36: ... is absolutely necessary If the nose is down the throttle comes back CHECK The Prototype Model Setup All of the recommended settings in this manual are a result of the flight testing on the prototype CAPs There are no secrets If you follow the instructions and these tips your CAP 232 will be set up just like mine Although a computer radio is not mandatory it is preferable in this model I use Expon...

Page 37: ...a bit The goal on 3 D rates is to get the model to feel the same around neutral as it does on low rates I use low rate settings for all flying except for 3 D aerobatics For precision flying or general sport hot dogging the low rate throws are perfect even for snap rolls The only exception is rudder rates I go to 3 D rate when doing stall turns and rolling circles since the more rudder the better f...

Page 38: ...toward the aft location will help but I have had great results even at the forward CG location This is a wing tester and can be extremely violent but will always generate gasps of excitement Done correctly the CAP 232 can handle the challenge How to do it Start from about 400 500 feet straight and level chop throttle and push the nose straight down As soon as the model is diving straight down at l...

Page 39: ... hundred feet down to 20 feet or less and power up into a Torque Roll Ooh Worst way to mess up Let your direction control rudder get away from you after starting too low you could snap it right into the ground Ouch The Harrier What it is It is very slow forward flight in a very nose high about 45 attitude Setup Same as the Elevator and the raised ailerons help in this maneuver even more How to do ...

Page 40: ... vertically in place rotating left around its roll axis Setup Full 3 D throws in elevator and rudder are a must An aft CG helps a little Also gyros provide the best aid to stabilize the aircraft They won t do the maneuver for you but they ll help I found them a fantastic tool in learning to torque roll kind of like training wheels A few years ago gyros made a big difference for me now I don t use ...

Page 41: ...t over stresses the wing Watch the speed The Wall What it is The Wall is a Parachute turned on end The model starts in normal level flight and suddenly corners nose up 90 as if it hit a wall Setup Same as the Elevator and the raised ailerons help in this maneuver too How to do it Start from about 100 feet straight and level chop throttle and as the model begins to slow down quickly pull full up el...

Page 42: ...heir internal combustion engine s nor will I operate models with extremely hazardous fuels such as those containing tetranitromethane or hydrazine 9 I will not operate models with pyrotechnics any device that explodes burns or propels a projectile of any kind including but not limited to rockets explosive bombs dropped from models smoke bombs all explosive gases such as hydrogen filled balloons or...

Page 43: ... 2 All officials must be off the course except for the starter and his her assistant 3 On the course is defined as any area beyond the pilot staging area where actual flying takes place B I will not fly my model aircraft in any organized racing event which does not comply with paragraph A above or which allows models over 20 pounds unless that competition event is AMA sanctioned Note Refer to AMA ...

Page 44: ... 2001 Horizon Hobby Inc 4105 Fieldstone Road Champaign IL 61822 www horizonhobby com HAN1250 46 ...

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