Hangar 9 Easy Fly 40 Instruction Manual Download

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❑

1. Carefully remove the aileron from the right wing panel.

Note where the hinges and the aileron torque rod fit into
the aileron.

❑

2. Mix a small amount of 30-minute epoxy, carefully

following the instructions included with the epoxy.

❑

3. Using a toothpick, apply epoxy into the ailerons’ torque

rod hole. Fill the hole 1/2 full.

❑

4. Replace the aileron on the right wing half. Make sure

the hinges slide in place and the aileron torque rod
inserts into its respective hole in the aileron. The gap
between aileron and wing should be a constant 1/16”.

❑

5. Wipe off any excess epoxy using a paper towel and

rubbing alcohol.

❑

6. Deflect the aileron and apply a small amount of thin CA

glue to each hinge. Make sure that the CA glue
penetrates into the aileron and wing while maintaining a
1/16” aileron gap.

❑

7. Wipe off any excess CA glue using CA remover and a

paper towel.

❑

8. Repeat this process for the left wing (Steps 1-7).

Note:

After the CA has dried completely, check to ensure that
the hinges are secure by pulling firmly on the ailerons.

Important:

The ailerons are fitted in place but not glued in. They
must be correctly glued prior to flying.

Left Wing Panel with Aileron and Hinges
Right Wing Panel with Aileron and Hinges

CA Remover
30-Minute Epoxy
Thin Instant CA Glue

Paper Towels
Rubbing Alcohol
Toothpicks

Section 1: Assembling The Wings

Parts Needed

Tools Needed

Summary of Contents for Easy Fly 40

Page 1: ...True UltraCote covering Positive self righting flight characteristics 90 pre built Extensive hardware kit included Break away motor mount prevents engine damage during minor nose overs Specifications Raising the Standard of Quality in Almost Ready To Fly Aircraft ALMOST READY TO FLY PRE BUILT 90 9 HANGAR TM INSTRUCTION MANUAL ...

Page 2: ...setup trimming the plane and breaking in and tuning your engine It covers the basic flight concepts you need to know like takeoffs landings and most importantly how to find and work with a qualified instructor You ll find out just what to expect when you arrive at the flying field before you even get there When you use the video in conjunction with the complete photo illustrated instruction manual...

Page 3: ...uselage 16 Section 6 Installing The Nose Gear 17 Section 7 Installing The Wing Dowels 18 Section 8 Assembling The Fuel Tank 19 Section 9 Installing The Fuel Tank 21 Section 10 Installing The Control Horns 22 Section 11 Installing The Horizontal Vertical Stabilizers 24 Section 12 Installing The Engine 26 Section 13 Installing The Radio 29 Section 14 Installing The Linkages 32 Section 15 Setting Up ...

Page 4: ...shop will be able to put you in touch with qualified pilots and a local club Note Due to temperature changes during shipping the covering on your Easy Fly may be slightly wrinkled The careful use of a heat gun or iron is recommended to shrink the UltraCote until its taut Warning An R C aircraft is not a toy If misused it can cause serious bodily harm and damage to property Fly only in open areas p...

Page 5: ...Vertical stabilizer with rudder HAN1403 E Horizontal stabilizer with elevator HAN1404 1 Pushrods 2 Aileron servo mounts 2 3 Main landing gear 4 Nose landing gear 5 Spinner 6 Motor mounts and hardware 7 Wheels 3 8 Fuel tank and hardware 9 Rubber bands 8 10 Control horns 11 Wing joiner A B C E D 1 11 9 8 7 6 5 4 3 2 10 ...

Page 6: ... Required Adhesives CA cyanoacrylate Glue instant thin and medium viscosity CA Remover dissolve 5 Minute Epoxy 30 Minute Epoxy Tools Clips e g clothespins binder clips Cloth Drill and Assorted Drill Bits Heat Gun Heat Iron Hobby Knife Masking Tape Needle Nose Pliers Paper Towels Pencil 1 and 2 Phillips Screwdrivers Rubbing Alcohol Ruler straight edge Sandpaper Scissors Straight Screwdriver Thread ...

Page 7: ...quipment Required HAN3000 2 cycle Performance Plug MDC101 Glow Driver Model Airplane Fuel HAN 3005 Extra Life Sport Plug HAN104 12V Super Starter HAN102 12V Battery HAN118 Fuel Pump HAN2510 Glow Plug Wrench 7 ...

Page 8: ...Optional Field Equipment Extra Propellers Flight Box Power Panel Prop Wrench Miscellaneous Tools Paper Towels 64 Rubber Bands After Run Oil Extra Glow Plugs 8 ...

Page 9: ...aper towel and rubbing alcohol 6 Deflect the aileron and apply a small amount of thin CA glue to each hinge Make sure that the CA glue penetrates into the aileron and wing while maintaining a 1 16 aileron gap 7 Wipe off any excess CA glue using CA remover and a paper towel 8 Repeat this process for the left wing Steps 1 7 Note After the CA has dried completely check to ensure that the hinges are s...

Page 10: ...ed section Important Do not cut into hard wood wing joiner section 10 Aileron Servo Mounts 2 Dihedral Brace Left Wing Half from Section 1 Right Wing Half from Section 1 Standard Servo 1 30 Minute Epoxy Hobby Knife Masking Tape Paper Towels Pencil Rubbing Alcohol Ruler Wax Paper Section 2 Joining The Wing Halves Parts Needed Tools Needed ...

Page 11: ... scrap piece of wood smear the epoxy into the wing joiner cavity of both wings Remember use plenty of epoxy 5 Coat one half of the dihedral brace with epoxy up to the line Note the orientation of the V of the dihedral brace Install the epoxy coated side of the dihedral brace into a wing half up to the line making sure the V of the dihedral brace is positioned correctly as shown 11 Section 2 Joinin...

Page 12: ...r section Be sure that the leading and trailing edges line up properly Use masking tape as necessary to hold the wing halves in position 8 Place a 12 x 12 sheet of wax paper on the edge of a flat table Place the center section of the wing on the wax paper with the aileron torque rod hanging off the edge of the table Prop up each wing tip 2 1 2 inches off the table as shown Books work well for this...

Page 13: ...tant 1 16 gap between the two and the edges are lined up correctly 2 Deflect the elevator and apply thin CA glue at the hinges so that it absorbs both into the stabilizer and the elevator 4 places 3 Using the same technique hinge the rudder to the vertical stabilizer 4 Wipe off any excess CA using CA remover and a paper towel Set these assemblies aside for now Note After CA has dried completely ch...

Page 14: ...ays are properly aligned Wipe off any excess epoxy with a paper towel and set aside to dry for 15 minutes 4 Using a ruler measure the distance on the bottom of the wing at the center line 5 1 2 inches from the trailing edge and mark with a pencil 5 Next measure 3 3 4 inches from the leading edge back to the center line and mark with a pencil Aileron Servo Trays 2 Wing Center Section Tape Clips e g...

Page 15: ... tray Using a sharp hobby knife carefully cut through the plastic covering Be careful not to cut into the wood on the line you just made in Step 7 9 Carefully remove the covering in the aileron tray area This is necessary so that the tray will properly adhere to the wing 10 Mix a small amount of 5 minute epoxy and spread it over the entire area of one side of the servo tray Section 4 Installing Th...

Page 16: ...te adhesive backed tape and remove the adhesive backing Starting at the edge of the aileron tray apply the tape around the wing at the center section ending at the other side of the tray Use a hobby knife to trim the excess length of tape Your wing is now complete 14 Locate the small blue decal square in shape on the decal sheet included with your kit Apply this decal to the leading edge of the wi...

Page 17: ...s fit into the holes in the edges of the slot 3 Reposition the landing gear straps over the 1 16 hole you drilled in Step 1 Screw into position with the four sheet metal screws provided 4 Place the wheels on the ends of the struts and secure them with the supplied wheel collars Use thread lock on the collar screws Fuselage Main Landing Gear 2 pcs Main Landing Gear Hardware Wheels 2 pcs Wheel Colla...

Page 18: ...de the spring into position 2 Insert the nose gear assembly from Step 1 into the nose gear mount attached to the front of the fuselage Be sure the spring stays in position and rests against the nose gear mount Install the collar on the top end of the landing gear flush with the landing gear and secure it into position with a screw and the thread lock 3 Attach the nose wheel and hold it in place us...

Page 19: ...equal amount of dowel extends from each side of the fuselage Using thin CA glue apply five drops around each side of the wing dowel 4 places where the dowel touches the fuselage 3 If necessary use a paper towel and CA remover to wipe off any excess CA glue Fuselage Wing Dowels 2 CA Remover Hobby Knife Paper Towel Thin Instant CA Glue Section 7 Installing The Wing Dowels Parts Needed Tools Needed ...

Page 20: ...stopper so that an equal amount of tube extends from each side This tube will be the fuel tank pickup tube 2 Locate the long copper tube and bend it using your fingers as shown This tube will be the fuel tank vent tube 3 Slide this tube into the other open hole of the stopper as shown 4 Slide the two white plastic caps over the copper tubes as shown Note the orientation of the caps The small insid...

Page 21: ... fuel tubing 6 Install the open tube end of the clunk and tubing assembly on the short copper tubing 7 Press the 3mm locknut between the three pegs on the inside white plastic cap as shown 8 Carefully insert the assembly into the fuel tank Note the position of the vent tube It must be at the top of the fuel tank to function properly Section 8 Assembling The Fuel Tank CONTINUED ...

Page 22: ...m Section 8 Fuselage None Section 9 Installing The Fuel Tank Parts Needed Tools Needed 1 Note that the fuel stopper is mounted closer to one edge of the tank than the other This closer edge is the top of the tank Slide the tank into the fuselage stopper first Make sure that the top of the tank is positioned towards the top of the fuselage 2 Press the tank into position until the stopper inserts in...

Page 23: ...elevator Next drill two 1 16 holes through the elevator where marked 3 Install the control horn using the two screws and the back plate and tighten the screws with a 1 Phillips screwdriver 4 Using a pencil measure up 1 2 from the bottom of the rudder and mark Control Horn with Backplate 2 Horizontal Stabilizer with Elevator Small Phillips Screw 4 Vertical Stabilizer with Rudder Drill with 1 16 Dri...

Page 24: ... the rudder control horn as shown with the mark just below the edge of the control horn 6 Now mark drill and install the horn as you did previously for the elevator Section 10 Installing The Control Horns CONTINUED ...

Page 25: ...fit the forward cutout is for the rudder pushrod exit 3 Position the horizontal stabilizer in place on the fuselage and trial fit the vertical stabilizer in place Using a pencil mark where the horizontal stabilizer and vertical stabilizer meet on the vertical fin on both sides 4 Remove the vertical stabilizer and cut away the covering below the marked section Be careful not to cut into the wood A ...

Page 26: ...lly align the horizontal stabilizer to the fuselage 7 Apply 30 minute epoxy to the area on the vertical stabilizer wood section from which you cut the covering in Step 4 8 Carefully insert the vertical stabilizer into the horizontal stabilizer as shown Be sure that it fully seats Wipe away the excess epoxy with rubbing alcohol and a paper towel 9 Using a 90 degree triangle align the vertical stabi...

Page 27: ...thrust Trial fit the engine in place Using a pencil mark the position of the four holes that secure the mounts to the fuselage as shown 3 Remove the mounts and drill four 1 8 holes at the points you marked 4 Reposition the engine mounts and engine on the fuselage making sure right thrust is achieved and mark through the holes in the engine mount with a pencil Note Motor mount in fuselage is design...

Page 28: ... Place the engine and the motor mounts in the desired position It is helpful to have the prop and spinner installed at this time to check the clearance Using a pencil carefully mark the engine mount through the holes in the engine mount flange Remove the engine and drill four 1 8 holes where marked 8 Secure the engine in place using the four remaining screws nuts and washers Section 12 Installing ...

Page 29: ...to the carburetor nipple Special Instructions for Installing a 4 Cycle Engine The Easy Fly 40 is designed to also accept 40 65 4 cycle engines The installation is similar to the 2 cycle engine installation except that it may be necessary to trim away some of the plywood in the nose of the fuselage in order to allow the wider 4 cycle engine ease of clearance Section 12 Installing The Engine CONTINU...

Page 30: ...2 Remove the aileron servo and drill four 1 16 holes where marked 3 Place the aileron servo back in its mount and secure it in place with the four screws included with the servo 4 Channel Radio System with 4 Standard Servos and Hardware not included Fuselage Radio Packing Foam not included Wing Drill with 1 16 Drill Bit Hobby Knife Pencil 1 Phillips Screwdriver Section 13 Installing The Radio Part...

Page 31: ... included with the servos Installing the Receiver and Battery 1 Radio packing foam available at your local hobby shop should be used to install the receiver and battery With a sharp hobby knife cut a layer of foam the size of the compartment in front of the servo tray and place it in the bottom of the fuselage Then cut out another layer of foam and cut out the center section to match your battery ...

Page 32: ...ust gases Place the switch plate against the side of the fuselage as shown and mark the position of the holes and square 2 Using a sharp hobby knife cut out the marked area and drill holes to allow the switch to be mounted Mount the switch using the hardware provided Section 13 Installing The Radio CONTINUED ...

Page 33: ...horn and trim the long arms off as shown 4 Install the servo horn on the aileron servo as shown Install the z bends in the second outermost hole from the center of the servo horn as shown Aileron Horn 2 Balsa Dowel 2 Fuselage and Wing Heat Shrink Tubing 1 16 Plain Rod Long 2 1 16 Plain Rod Short 2 Plastic Clevis 4 1 16 Threaded Rod 4 Drill with 1 16 Drill Bit Heat Gun Hobby Knife or Scissors Needl...

Page 34: ...the neutral position when the servo is centered and the clevis is in the aileron horn Adjust both sides Assembling the Pushrods 1 Locate the two balsa dowels the two remaining threaded rods two short plain rods and the black heat shrink tubing Cut the heat shrink tubing into four equal pieces with a knife or scissors 2 Using a pencil make a mark two inches from each end of both balsa dowels Sectio...

Page 35: ...rt plain rods Using needle nose pliers bend a 90 degree angle 1 4 from one end of the rods Repeat this procedure for the other rod 5 Locate one balsa dowel and insert the 90 degree end of one threaded rod into the previously drilled 1 16 hole Cover the portion of the rod that touches the dowel with thick CA glue 6 Slide a piece of the heat shrink tubing over the end of the balsa dowel and shrink i...

Page 36: ...eat Steps 5 7 to complete the other pushrod Installing the Pushrods 1 Insert one of the pushrods threaded rod first into the tail of the fuselage so that the threaded rod exits the rudder pushrod exit hole 2 Screw on a clevis for 20 full turns Fasten the clevis in the third hold from the inside of the rudder control horn Section 14 Installing The Linkages CONTINUED ...

Page 37: ...hat the horn is exactly perpendicular to the fuselage and adjust the clevis on the rudder horn by screwing it in or out until the rudder is exactly neutral when the servo is centered 5 Use the same procedure to install the elevator pushrod noting that the elevator pushrod exits the rear opening of the fuselage 6 The two remaining long plain rods are for the throttle and nose wheel linkage Using a ...

Page 38: ... centered adjust the nose wheel so it s straight Tighten the Phillips screw in the steering arm 8 A 1 16 hole is pre drilled through the fire wall This is for the throttle linkage Insert the remaining plain rod through the fire wall and make a z bend at both ends as before being especially careful that the length is correct so that when the servo is centered the throttle is half open Section 14 In...

Page 39: ...Adjust the linkage until this is achieved If you need a longer stroke move the push rod one hole out on the screw If less stroke is needed move the push rod in one hole Important It may be necessary to reverse the throttle reversing switch if the carburetor works in reverse e g full throttle closes the carburetor 4 Cut out the control throw gauges in the back of this manual Then place the elevator...

Page 40: ...all the wing with rubber bands and place your two index fingers on the marks on the bottom of the wing The model should balance level If not add weight to the tail or nose as necessary until the model balances perfectly level Stick on weights are available at your local hobby shop and work well for this purpose Rubber Bands Pencil Ruler Section 16 Balancing The Model Parts Needed Tools Needed ...

Page 41: ... snapped into position 3 Check that all servo horn screws are tight 4 Charge the transmitter and receiver battery per the instructions included with the radio system 5 Read and follow all the instructions included with the engine and follow the recommended break in procedure Pre Flight Check ELEVATOR ELEVATOR AILERON AILERON AILERON THROTTLE 1 16 CARBURETOR RUDDER RUDDER ...

Page 42: ...e check that all controls aileron elevator throttle rudder move in the correct direction See page 40 3 Be sure that your batteries are fully charged per the instructions included with your radio Adjusting the Engine 1 Completely read the instructions included with your engine and follow the recommended break in procedure At the field adjust the engine to a slightly rich setting at full throttle an...

Page 43: ...d trim your Easy Fly 40 and then give you your first chance on the sticks with very little risk of damage to the airplane We cannot overemphasize the importance of having a qualified instructor to help you through your first flight Don t try it alone Experienced pilots will find the Easy Fly 40 to be a confidence inspiring airplane Super stable and slow flight characteristics make pinpoint landing...

Page 44: ...t operate models with metal bladed propellers or with gaseous boosts in which gases other than air enter their 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 rocke...

Page 45: ... an elevator which you adjust to control the airplane s pitch axis Pulling the transmitter s control stick toward the bottom of the transmitter adjusts the elevator upward and the airplane begins to climb Push the control stick forward and the airplane begins to dive Expanded Scale Voltmeter ESV This device is used to check the voltage of the battery pack Flight Box The box in which you store and ...

Page 46: ...ects the servo to the pushrod Single Stick A special kind of transmitter that has only one stick with special movements to control the airplane s flight Not common Spinner Term describing the nose cone that covers the propeller hub Switch Harness This switch is commonly located on the fuselage and governs the on off mechanism for the flight pace Tachometer A device the measures the engine s RPM ro...

Page 47: ...47 ...

Page 48: ...Neutral 1 4 1 4 HINGE LINE ELEVATOR THROW GAUGE EASY FLY 40 Neutral 1 4 1 4 HINGE LINE AILERON THROW GAUGE EASY FLY 40 Neutral 1 4 1 4 HINGE LINE RUDDER THROW GAUGE EASY FLY 40 ...

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Hangar 9 Easy Fly 40, Instruction Manual

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