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Hangar 9 J-3 Piper Cub, Assembly Manual

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Hangar 9 J-3 Piper Cub Assembly Manual Download Page 2

2

Table of Contents

Introduction

3

Additional Equipment Required

4

Tools and Supplies Required

4

Section 1: Hinging The Aileron

5

Section 2: Joining the Wing Halves

6

Section 3: Installing the Aileron Servos

8

Section 4: Installing the Aileron Linkage

12

Section 5: Mounting The Wing

14

Section 6: Installing The Tail

17

Section 7: Hinging The Rudder

20

Section 8: Installing The Engine

22

Section 9: Landing Gear Assembly and Installation

25

Section 10: Assembling and Installing the Fuel Tank

26

Section 11: Installing The Radio

28

Section 12: Installing The Linkages

29

Section 13: Attaching The Cowl

34

Section 14: Installing The Windows

35

Section 15: Scale Detailing

35

Section 16: Balancing the J-3 Piper Cub

38

Section 17: Control Throw Recommendation

39

Section 18: Flying the J-3 Piper Cub

39

Pre-Flight Check

40

Pre-Flight at the Field

41

AMA Safety Code

42

Cowl Template (for Saito .50 or .56)

43

Summary of Contents for J-3 Piper Cub

Page 1: ... Engines 40 46 2 Cycle 45 60 4 Cycle WE GET PEOPLE FLYING TM TM Raising the Standard of Quality in Almost Ready To Fly Aircraft Ultra Covering Pre finished Fiberglass Cowl Highest Quality Craftsmanship 90 Pre Built IMAA Legal 80 1 8 Wingspan ALMOST READY TO FLY PRE BUILT 90 ASSEMBLY MANUAL ...

Page 2: ...r 20 Section 8 Installing The Engine 22 Section 9 Landing Gear Assembly and Installation 25 Section 10 Assembling and Installing the Fuel Tank 26 Section 11 Installing The Radio 28 Section 12 Installing The Linkages 29 Section 13 Attaching The Cowl 34 Section 14 Installing The Windows 35 Section 15 Scale Detailing 35 Section 16 Balancing the J 3 Piper Cub 38 Section 17 Control Throw Recommendation...

Page 3: ... engine Or for enhanced scale realism a 45 55 4 cycle engine can be used to power this Cub Hangar 9 s J 3 Piper Cub comes 90 pre built to a high level of craftsmanship and is pre covered and trimmed in Ultra covering This means you can have a large 80 1 8 span high quality scale J 3 Piper Cub showing it to your friends at the field in 20 hours or less Best of all they ll never know it s an ARF and...

Page 4: ...s Small round file Adjustable wrench Razor saw Heat gun Moto Tool with sanding drum Hobby knife with 11 blade Mixing stick Epoxy brush 4 Additional Equipment Required Tools and Supplies Required Saito 50GK Recommended JR Systems JR F400 FM JR XF642FM PCM JR XP783 JR XP8103 FM PCM Recommended 2 Cycle Engines Thunder Tiger Pro 40 Thunder Tiger Pro 46 Webra Speed 40 Sport Recommended 4 Cycle Engines ...

Page 5: ...ace should lightly contact the wing during this procedure Ideally when the hinge is glued in place a 1 32 gap or less will be maintained throughout the length of the aileron The hinge is constructed of a special material that allows the CA to wick or penetrate and distribute throughout the hinge securely bonding it to the wood structure 3 Turn the wing panel over and deflect the aileron in the opp...

Page 6: ... into one of the wing panels It should insert smoothly up to the center line marked in Step 1 Now slide the other wing half onto the dihedral brace until the wing panels meet If the fit is overly tight it may be necessary to lightly sand the dihedral brace 6 Section 1 Hinging The Ailerons Right wing panel from Section One Left wing panel from Section One Dihedral brace Trim Tape 30 minute epoxy Ma...

Page 7: ...vity of one wing half A scrap piece of wood or mixing stick is handy here 6 Coat one half of the dihedral brace with epoxy up to the pencil line drawn in Step 1 Note the orientation of the V side of the dihedral brace the V must face up Install the epoxy coated side of the dihedral brace into the wing joiner cavity of the wing half up to the center line making sure the V of the dihedral brace is p...

Page 8: ... center joint so any excess epoxy doesn t adhere to the surface of the work area 11 When the wing center joint is completely dry remove the masking tape and apply the included trim tape to cover the center joint 1 Hold the assembled wing up to a strong light Note the aileron servo cut outs on the bottom side of each wing Using a very sharp hobby knife carefully trim away the covering material wher...

Page 9: ...vos 5 Using scissors cut out the aileron cover Also using a hobby knife cut out the opening where the linkage exits the aileron cover 6 Temporarily install a servo arm with a hole located between 10 12mm out from the center on the servo as shown Now trial fit the servo on the aileron servo cover as shown with the servo arm aligned in the middle of the linkage opening in the aileron cover 7 Using a...

Page 10: ...he servo in place drill four 1 16 pilot holes into the wood servo blocks 11 Using 30 minute epoxy glue the servo blocks in place then screw them into position with 4 sheet metal screws 12 Center the aileron cover over the aileron cut out in the wing and drill four 1 16 holes at each corner of the aileron cover through the wing s bottom surface 13 Screw the aileron cover in place with four sheet me...

Page 11: ...rvo aileron opening It may be helpful to slightly bend the music wire Using masking tape tape the aileron s servo connector to the end of the music wire closest to the aileron opening Pull the music wire or equivalent and the servo connector through the wing until it comes out the servo lead opening Note With most servos it will be necessary to use an extension 18 Repeat this procedure for the opp...

Page 12: ...ls of the J 3 Piper Cub exhibit these flight tendencies 3 Place a piece of masking tape on the top of the aileron cover so the edge of the tape lines up with the output hole on the servo arm See the photo below 4 Reinstall the aileron cover on the wing Place an aileron linkage perpendicular to the aileron hinge so it passes directly in line with the servo arm under the aileron cover With a felt ti...

Page 13: ...the control horn in place 9 Thread a clevis onto one of the aileron linkages 16 turns 10 Install the clevis in the outermost hole With the aileron in the neutral position and the servo arm 30 offset from Step 2 mark the position where the linkage will attach to the servo arm a small piece of masking tape works well for this 11 Using Z bend pliers make a Z bend at the marked location Cut off any ex...

Page 14: ...oth are the same 14 Section 4 Installing the Aileron Linkage Section 5 Mounting The Wing Completed wing assembly Wing dowel rods 2 Fuselage Wing hold down plate Wing hold down screws Blind nuts 2 Drill 1 4 drill bit Medium Phillips screwdriver Small round file 12 minute epoxy Measuring device e g 36 ruler or tape measure Masking tape Pliers Parts Needed Tools And Adhesives Needed Adjust the length...

Page 15: ...ition below the rear wing hold down plate in the fuselage Use pliers to squeeze the blind nuts so the teeth penetrate the wood and stay in place Note It may be helpful to place a piece of wood on the top side of the hold down plate before squeezing the pliers This will keep the pliers from crushing the rear wing hold down plate Additionally a small amount of epoxy or thick CA will permanently atta...

Page 16: ...e drill bit doesn t tear the covering when it exits through the top surface of the wing 9 Trial fit the wing into position on the fuselage Thread the wing hold down bolts into the wing and loosely tighten Check the alignment of the wing by measuring from a fixed point on each wing tip to the narrow strip of tape on the fuselage as you did in Step 2 It may be necessary to slightly enlarge the holes...

Page 17: ... stabilizer 3 Using a razor saw carefully cut out the area rearward of the horizontal stabilizer slots in the fuselage and extend the slots to the rear of the fuselage 4 Hold up the horizontal stabilizer to a strong light and note the cut out notch on the leading edge of the stabilizer The vertical fin keys into this notch when the tail is assembled Using a hobby knife carefully trim the covering ...

Page 18: ...e horizontal fin Then carefully check the fin to be sure it is aligned 90 to the horizontal stabilizer Note The back of the vertical fin and the back of the horizontal stabilizer must be even with the back of the fuselage 8 Double check the horizontal stabilizer and vertical fin alignment It may be necessary to slightly trim the balsa wood on the fuselage with a sharp hobby knife to achieve exact ...

Page 19: ...o the fuselage and position it in the approximate location Wipe away any excess epoxy with a paper towel and rubbing alcohol 13 Apply 30 minute epoxy to the vertical fin where the fuselage contacts the fin Also apply epoxy to the base of the fin where it keys into the horizontal stabilizer Insert the fin into the fuselage in approximately the correct position and wipe away any excess epoxy 14 Prec...

Page 20: ...e position of the slot where the pivot bushing will fit into the back of the fuselage 4 Remove the rudder Using a 3 32 drill bit drill into the exact center of the rudder to accept the tail wheel wire as shown 5 Using a hobby knife cut a slot in the back of the fuselage as marked to accept the tail wheel pivot bushing 6 Trial fit the tail wheel assembly and rudder in place Deflect the rudder makin...

Page 21: ...arned in Section 1 Hinging The Ailerons After the hinges are dry check to be sure they are securely in place by trying to pull the rudder from the vertical stabilizer There should be a minimal gap between the rudder and the fin Wipe away any excess CA with CA remover 9 Work the rudder right and left Check for free movement and ensure that the tail wheel wire tracks accordingly 10 Once you are sati...

Page 22: ...he motor mount into position on the firewall Be sure the motor mount is firmly pressed against the firewall Set this assembly aside to dry 2 Locate the six balsa triangle stock pieces These are used to reinforce the motor mount and firewall Using 30 minute epoxy glue these triangular pieces in place as shown in the photo 3 Mix approximately 1 2 ounce of 30 minute epoxy Using an epoxy brush coat th...

Page 23: ...all distance at 4 1 4 mark the location for the mount holes 4 places Four holes one in each corner of the engine plates will attach the plates to the engine mount while the other four holes attach the engine to the engine plates A sharp pencil is recommended to mark the correct position 8 Remove the engine and mount plates Now drill four 1 8 diameter holes at the points on the engine mounting plat...

Page 24: ...Assembly and Installation Aluminum landing gear Wheels Landing gear hardware Yellow covering for landing gear Medium Phillips screwdriver Small adjustable wrench Heat gun or Iron Hobby knife Blue Locktite 242 Items Needed Tools And Adhesives Needed 11 Using a pencil mark the engine mounting plate where the four holes are to be drilled Mark through the engine mount flanges 12 Remove the engine and ...

Page 25: ...he landing gear so that the front edge of the gear is even with the alignment guide drawn previously Once you are satisfied with the alignment of the landing gear mark the mounting hole locations through the landing gear onto the fuselage and remove the gear from the fuselage Note It is imperative to the ground handling characteristics of the aircraft that the landing gear is straight 6 Using a 1 ...

Page 26: ...the orientation of the caps The small inside cap and the three pegs face away from the black rubber stopper The large outside cap and the raised center face away from the black rubber stopper 5 Locate the small diameter fuel tubing and cut it to 3 in length This tubing will be used for the fuel pickup inside the fuel tank Insert the brass clunk into one end of the fuel tubing 26 Section 10 Assembl...

Page 27: ...can properly connect the fuel tank to the engine 10 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 toward the top of the fuselage 11 Press the tank into position until the stopper inserts into the hole in the firewall 12 Plumb ...

Page 28: ... servo tray Cut out another layer of foam that is the same size only this time cut out an open area in the center to accept a battery pack Place another solid layer of foam on top Cut an open area in the next layer of foam to accept the receiver Top off with a final solid layer of foam that holds everything in place 4 Place the pre cut layers of foam with the battery and receiver in place in the f...

Page 29: ...he rudder and make a mark on the elevator with a felt tipped pen as shown Mark the other elevator half in the same way 3 4 from the rudder This marks the center position of the elevator control horn 2 Place the control horn on the elevator at the mark from Step 1 exactly in the center of the control horn Mark the hole positions of the control horn with a pencil and drill two 1 16 holes in each ele...

Page 30: ...de as shown This mark represents where the center of the control horn will be located 6 Center the control horn over the mark you just made and using a pencil mark the mounting hole locations through both holes onto the rudder 7 Drill these holes with a 1 16 drill bit and install the rudder control horn using the two screws and back plate provided 8 Locate the two balsa dowel pushrods and cut them...

Page 31: ...s rod will be used in the hole you drilled in Step 12 It is cut so that it will match the length of the other threaded rod when it is installed in the balsa pushrod 14 Using needle nose pliers bend a 90 angle 1 4 from the unthreaded end of each of the threaded rods Also bend a 90 angle in one end of each of the two unthreaded rods 15 Locate the end of the pushrod that has two holes drilled in it F...

Page 32: ...lly cut away the covering at the tail of the fuselage where the pushrods exit Note there are two cut outs on the left side top cut out for elevator bottom cut out for rudder and one cut out on the right side elevator 21 Spread the two threaded pushrods apart about 2 Insert the elevator pushrod into the fuselage so that each threaded rod comes out the elevator pushrod exit Thread a clevis onto each...

Page 33: ... they pass the respective servo arms 24 Using Z bend pliers make a Z bend at the marked locations on both the elevator and rudder pushrods Cut off the excess rod 25 Insert the Z bend into the servo arm as shown It may be necessary to enlarge the holes in the servo arm slightly to accept the Z bend 26 Install the throttle pushrod using the same method Note It will be necessary to drill a 1 8 hole i...

Page 34: ... position and check that it fits correctly There should be ample clearance 1 8 around the engine and muffler Also check that the prop hub is centered in the opening in the cowl and that the prop hub extends 3 16 forward of the cowl Drill four 1 16 holes as shown 6 Remove the tape and attach the cowl to the fuselage using the four sheet metal screws provided Note On some engines where the carbureto...

Page 35: ... include wing struts shock absorbing landing gear detail wheel inserts vacuum formed engine and decals Installing the Wing Struts Four pre covered wing struts are included with your J 3 Piper Cub The struts are for aesthetics only They are not a structural member of the airframe You can choose to fly with them attached for a more true scale appearance or you can choose to fly without them for conv...

Page 36: ...o the straps Landing Gear Scale Detailing 3 Scale landing gear detail is included to reproduce the shock absorbing system found on the full scale J 3 Piper Cub It will be necessary to bend a hook in each end of the shock absorbing wires to attach the straps 4 Scale wheel inserts are included When the CUB decal is attached they provide an authentic final touch Trim the wheel inserts slightly oversi...

Page 37: ... epoxy Wipe away any excess epoxy with a paper towel and rubbing alcohol 6 Fuel proof self adhesive decals are included The following photos and the box top can be used to identify their location Additional Scale Detailing Added scale detailing can easily be accomplished with a little imagination 1 16 black stripe tape can be used to outline the door A door handle can be made from a short piece of...

Page 38: ...ecommended C G Center of Gravity location for the first flights with the J 3 Cub is 3 1 4 from the leading edge With the Saito 50 installed very little if any additional weight will be needed to balance the model If you re using a lighter 2 cycle engine expect to add weight Stick on weights are available at your local hobby shop and work well for this purpose 38 Section 16 Balancing the J 3 Piper ...

Page 39: ...at scale speeds If you re a first time pilot it s imperative that you seek out an experienced flier to help you with your first flights you should do this with any R C aircraft Your local hobby shop should be able to suggest pilots who can assist you When set up as per the instructions control response gives a gentle roll and pitch control while the Cub s large size offers excellent visibility and...

Page 40: ... clevis is securely 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 40 Pre Flight Check ELEVATOR ELEVATOR AILERON AILERON AILERON THROTTLE 1 16 CARBURETOR RUDDER RUDDER ...

Page 41: ...ols 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 and adjust the idle and ...

Page 42: ... indoors 8 I will not 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 ...

Page 43: ...ne up with edges of cowl Cowl Template For Saito 50 Cut out for engine COWL TEMPLATE For Saito 50 and 56 This is the minimum size of cut out required enlargement may be necessary to meet your specific needs ...

Page 44: ...HAN1501 ...

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